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FIELD OF THE INVENTION
The present invention relates to a soil release composition and a method for imparting a soil release property to a substrate.
BACKGROUND OF THE INVENTION
Plastics, fabrics, paper and the like are often treated with a soil release composition to increase their values including durability of a substrate.
Conventional soil release compositions contain silicone, hydrocarbon polymer or fluorocarbon polymer (cf. Japanese Patent Publication No. 18346/1978 and Japanese Patent Kokai Publication (unexamined) Nos. 134786/1978, 163269/1980, 129281/1981, 164181/1982, 171762/1982 and 171790/1982).
The conventional soil release composition containing silicone or the hydrocarbon polymer, however, imparts only a water absorption property and a soil release property to the substrate or alternatively only a water repellent property to the substrate. The conventional soil release composition containing the fluorine polymer only imparts a water- and oil-repellent property or an undurable soil release property to the substrate.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a soil release composition which can impart a durable water absorption property and oil-repellency as well as the soil release property to a substrate.
Another object of the present invention is to provide a soil release composition which can impart durable water- and oil-repellency as well as the soil release property to a substrate.
Further object of the present invention is to provide a method for imparting a soil release property to a substrate with the soil release composition.
These and other objects are accomplished by a soil release composition according to the present invention which comprises:
(A) a polymer comprising 10 to 100% by weight of constituting units of the formula: ##STR2## wherein R f is a C 3 -C 21 fluoroalkyl group; R 1 is a hydrogen atom or a C 2 -C 4 acyl group; R 2 , R 3 , R 4 and R 5 are, the same or different, each a hydrogen atom, a methyl group or an ethyl group; A is a group of the formula: --CH 2 CH(OR 1 )CH 2 --OCO-- in which R 1 is the same as defined in the above, --CO--, --(CH 2 ) k N(R 2 )CO-- in which R 2 is the same as defined in the above and k is an integer of 1 to 10, or --(CH 2 ) k -- in which k is the same as defined in the above; h is an integer of 0 to 5; p is an integer of 1 to 40; q and r are, the same or different, each an integer of 0 to 40,
(B) a hydrophilic resin, and
(C) optionally a water- and oil-repellent, a weight ratio of (A):(B):(C) being 5-95:95-5:0 or 1-95:5-95:1-50.
In the case where the soil release composition of the present invention comprises the polymer (A) and the hydrophilic resin (B) but not the water- and oil-repellent (C), it can impart the water absorption property and oil repellency as well as the soil release property to the substrate. In the case where the soil release composition of the present invention comprises the polymer (A), the hydrophilic resin (B) and the water- and oil-repellent (C), it can impart water- and oil-repellency as well as the soil release property to the substrate.
DETAILED DESCRIPTION OF THE INVENTION
The polymer (A) comprising the constituting unit (I) may be prepared by homopolymerizing an unsaturated monomeric compound of the formula:
R.sub.f --(CF.sub.2).sub.h CH(OR.sup.1)CH.sub.2 --O--(CHR.sup.2 CH.sub.2 O).sub.p --(CHR.sup.3 CH.sub.2 O).sub.q --(CHR.sup.4 CH.sub.2 O).sub.r --A--CR.sup.5 ═CH.sub.2 (II)
wherein R f , R 1 to R 5 , A, h, p, q and r are the same as defined in the above, or copolymerizing the monomer (II) with at least one of other ethylenically unsaturated monomers.
The fluoroalkyl group R f in the formulae may be a straight or branched one, and preferably the number of the fluorine atoms in the group is larger than that of the carbon atoms, more preferable the former is twice as large as the latter. The carbon chain in R f may have at least one oxygen atom between the carbon atoms.
Specific examples of the monomer (I) are
C 5 F 11 CH 2 CH(OH)CH 2 O(CH 2 CH 2 O) 4 COCH═CH 2 ,
C 7 F 15 CH 2 CH(OH)CH 2 O(CH 2 CH 2 O) 8 COC(CH 3 )═CH 2 ,
C 8 F 17 CH 2 CH(OH)CH 2 O(CH 2 CH 2 O) 5 CH 2 NHCOCH═CH 2 ,
C 8 F 17 CH 2 CH(OH)CH 2 O(CH 2 CH 2 O) 8 COC(CH 3 )═CH 2 ,
C 8 F 17 CH 2 CH(OCOCH 3 )CH 2 O(CH 2 CH 2 O) 9 COCH═CH 2 ,
C 9 HF 18 CH 2 CH(OH)CH 2 O(CH 2 CH 2 O) 10 COC(CH 3 )═CH 2 ,
C 9 F 19 CH 2 CH(OH)CH 2 O(CH 2 CH 2 O) 13 CH 2 CH═CH 2 ,
C 10 F 21 CH 2 CH(OH)CH 2 O(CH 2 CH 2 O) 16 CH 2 CH(OH)CH 2 OCOC(CH 3 )═CH 2 ,
C 12 F 21 CH 2 CH(OCOCH 3 )CH 2 O(CH 2 CH 2 O) 22 COC(CH 3 )═CH 2 ,
C 8 F 17 CH 2 CH(OCOCH 3 )CH 2 O(CH 2 CH 2 O) 10 COCH═CH 2 ,
C 9 F 19 (CH 2 ) 3 CH(OH)CH 2 O(CH 2 CH 2 O) 5 (CH(CH 3 )CH 2 O) 5 COCH═CH 2 ,
C 15 F 31 CH 2 CH(OCOCH 2 CH 3 )CH 2 O(CH 2 CH 2 O) 13 CH 2 CH═CH 2 ,
C 11 F 23 CH 2 CH(OH)CH 2 O(CH 2 CH 2 O) 8 CH 2 CH 2 NHCOCH═CH 2 .
Specific examples of the ethylenically unsaturated monomer to be copolymerized with the monomer (II) are vinyl chloride, vinyl acetate, styrene, α-methylstyrene, methyl vinyl ketone, acrylic or methacrylic acid or its derivative of the formula:
CH.sub.2 ═CR.sup.6 COOR.sup.7 (III)
wherein R 6 is a hydrogen atom or a methyl group; R 7 is a hydrogen atom, a sodium atom, a potassium atom, an ammonium group, a C 1 -C 18 alkyl group, a glycidyl group or a group of the formula: --(CH 2 CH 2 O) p R 8 in which R 8 is a hydrogen atom, a C 1 -C 18 alkyl group or a C 2 -C 18 acyl group and p is the same as defined in the above, --(CH 2 CH 2 O) p --(CH 2 CH(CH 3 )O) q --(CH 2 CH 2 O) r --R 8 in which R 8 , p, q and r are the same as defined in the above or --R 9 --OH in which R 9 is a C 2 -C 6 alkylene group; and acryl- or methacryl-amide or its derivative of the formula:
CH.sub.2 ═CR.sup.6 CONHR.sup.10 (IV)
wherein R 6 is the same as defined in the above, R 10 is a hydrogen atom or a group of the formula: --CH 2 OH or --(CH 2 ) p --N(CH 3 ) 2 in which p is the same as defined in the above.
The monomer(s) can be homo- or co-polymerized by a known method described in, for example, Japanese Patent Kokai Publication (unexamined) No. 134786/1978 and the Journal of the Japanese Association of Adhesives, Vol. 17, No. 9 (1981) 371.
The hydrophilic resin includes glyoxal resin, melamine resin, polyamide resin, urethane resin, acrylic resin, triazine resin and the like. Some of the hydrophilic resins are commercially available under trade names of HW-100 (Dainippon Ink and Chemicals), Sumitex resin 901, 1000, M-3, NR-2, NS-2, W-2, AR-2 and AMH-3000 (Sumitomo Chemical), Blencope PWB-4021, PEB-4001 and PEB-4002 (Nippon Oil & Fats), Teisan urethane SL-1780 and SL-4780 (Teikoku Chemical Industries) and SR-1000 (Takamatsu Oil & Fats).
The water- and oil-repellent may be a conventionally used one and preferably a copolymer of an acrylic acid derivative of the formula:
R.sub.f CH.sub.2 CH.sub.2 XCOCH═CH.sub.2 (V)
wherein R f is the same as defined in the above and X is an oxygen atom or a sulphur atom, and an acrylic or methacrylic acid or its derivative of the formula:
CH.sub.2 ═CR.sup.6 COOR.sup.11 (VI)
wherein R 6 is the same as defined in the above and R 11 is a hydrogen atom, a sodium atom, a potassium atom, an ammonium group or a C 1 -C 18 alkyl group. The preparation of the copolymer of the compounds (V) and (VI) is described in, for example, Japanese Patent Publication Nos. 851/1969, 31202/1971, 42880/1972, 3438/1975, 4800/1975, 2998/1978, 11324/1982 and 9666/1984 and Japanese Patent Kokai Publication (unexamined) Nos. 132694/1979 and 11888/1983.
In the case where the soil release composition of the invention comprises the polymer (A) and the hydrophilic resin but not the water- and oil-repellent (C), the copolymer (A) comprises 10 to 100% by weight, preferably 20 to 80% by weight of the constituting unit (I) to impart sufficient oil repellency and the soil release property to the substrate. For the same reason as above, 5 to 95 parts by weight, preferably 20 to 80 parts by weight of the polymer (A) is contained in the composition. 5 to 95 parts by weight, preferably 10 to 80 parts by weight of the hydrophilic resin (B) is contained in the composition to impart the durable water absorption property and oil repellency as well as the soil release property to the substrate.
In the case where the soil release composition of the present invention comprises the polymer (A), the hydrophilic resin (B) and the water- and oil-repellent (C), the polymer (A) comprises 10 to 100% by weight, preferably 20 to 90% by weight of the constituting unit (I) to impart sufficient oil-repellency and the soil release property to the substrate. For the same reason as above, 1 to 95 parts by weight, preferably 5 to 90 parts by weight of the polymer (A) is contained in the composition. 5 to 95 parts by weight, preferably 10 to 80 parts by weight of the hydrophilic resin (B) is contained in the composition to improve the durability of water- and oil-repellency as well as of the soil release property. 1 to 50 parts by weight, preferably 20 to 40 parts by weight of the water- and oil-repellent (C) is contained in the composition to impart sufficient water- and oil-repellency as well as the soil release property to the substrate.
The soil release composition of the invention may further contain at least one additive used in the conventional soil release composition. The additive includes a catalyst which cures the hydrophilic resin (B) (e.g. zinc nitrate, magnesium chloride and the like) One of the commercially available catalyst is Sumitex accelerator (trade mark of Sumitomo Chemical).
The soil release composition of the invention may be applied to the substrate in the form of a solution, a dispersion, a suspension or an emulsion by a conventional method, for example, dip coating, spray coating, flow coating and the like. A medium in which said components are mixed includes water, acetone, ethyl acetate, tetrahydrofuran, trichlorotrifluoroethane, benzotrifluoride, hexafluoro-m-xylene, and mixtures thereof. The components of the invention are usually mixed in the medium in an amount of 0.5 to 1.0 parts by weight per 100 parts by weight of the medium.
Now, the present invention will be explained further in detail by following examples. In the examples, the soil release composition comprising the polymer (A) and the hydrophilic resin (B) but not the water- and oil-repellent (C) is examined for the properties of water absorption, oil repellency and soil release as well as their durability. The soil release composition comprising the the polymer (A), the hydrophilic resin (B) and the water- and oil-repellent (C) is examined for the properties of water-repellent, oil-repellent and soil release as well as their durability. In the examples, parts and % are by weight unless otherwise indicated.
Copolymers (A1) to (A5) and Polymers (i) to (iii) for comparison to be used in Examples and Comparative Examples were prepared in following Preparation Examples.
PREPARATION EXAMPLE 1
Preparation of Copolymer (A1)
In a four-necked 200 ml flask equipped with a thermometer, a condenser, a stirrer and an inlet for introducing nitrogen, there were added a fluorine-containing monomer mixture (14 g) of the formula:
CF.sub.3 CF.sub.2 (CF.sub.2 CF.sub.2).sub.n CH.sub.2 CH(OH)CH.sub.2 --O--Z--COC(CH.sub.3)═CH.sub.2
in which Z is a polyethyleneoxide residue having an average molecular weight of 400 and which contains the compounds wherein n is 2, 3, 4, 5 and 6 in amounts of 3%, 55%, 28%, 12% and 3%, a methacrylate derivative (14 g) of the formula:
HO--Z--COC(CH.sub.3)═CH.sub.2
wherein Z is the same as defined in the above, isopropanol (112 g) and dodecylmercaptan (0.4 g), and stirred at 67° C. for 30 minutes with introducing nitrogen. Thereafter, perbutyl pivalate (0.17 g) was added to initiate the reaction and the polymerization was carried out at the same temperature for 6 hour with stirring. After removing isopropanol from the reaction mixture, the residue was washed with benzene and dried under reduced pressure to obtain Copolymer (A1).
PREPARATION EXAMPLES 2-5 AND COMPARATIVE PREPARATION EXAMPLES 1-3
Preparation of Copolymers (A2) to (A5) and
Polymers (i)-(iii)
In the same manner as in Preparation Example 1 but using the following monomers, the polymerization was carried out to obtain the polymer:
Preparation Example 2 (Copolymer (A2))
The fluorine-containing monomer mixture as used in Preparation Example 1 (100 parts), the methacrylate derivative as used in Preparation Example 1 (100 parts) and HOCH 2 --NHCOCH═CH 2 (20 parts).
Preparation Example 3 (Copolymer (A3))
The fluorine-containing monomer mixture as used in Preparation Example 1 (100 parts), styrene (300 parts) and glycidyl methacrylates (100 parts).
Preparation Example 4 (Copolymer (A4))
The fluorine-containing monomer mixture as used in Preparation Example 1 (100 parts) and H--Y--SCH 2 COOCH 2 CH(OH)--CH 2 OCOC(CH 3 )═CH 2 wherein Y is a polystyrene residue having an average molecular weight of 1,500 (100 parts).
Preparation Example 5
The fluorine-containing monomer mixture as used in Preparation Example 1 (100 parts), the methacrylate derivative as used in Preparation Example 1 (80 parts) and butyl acrylate (20).
COMPARATIVE PREPARATION EXAMPLE 1 (Polymer (i))
CF 3 CF 2 (CF 2 CF 2 ) 3 CH 2 CH 2 OCOCH═CH 2 (100 parts), CH 3 O--W--COC(CH 3 )═CH 2 wherein W is a polyethyleneoxide residue having an average molecular weight of 660 (80 parts) and HOCH 2 NHCOCH═CH 2 (20 parts).
COMPARATIVE PREPARATION EXAMPLE 2 (Polymer (ii))
H[SCH 2 CH(CH 3 )COO(CH 2 CH 2 O) 4 COC(CH 3 )CH 2 ] 10 SH (10 parts) and C 8 H 17 SO 2 N(C 3 H 7 )CH 2 CH 2 OCOC(CH 3 )═CH 2 (60 parts).
COMPARATIVE PREPARATION EXAMPLE 3 (Polymer (iii))
C 8 H 17 SO 2 N(C 3 H 7 )--W--COC(CH 3 )═CH 2 (100 parts) and CH 3 O--W--COCH═CH 2 (100 parts) wherein W is the same as defined in the above.
EXAMPLES 1-5 AND COMPARATIVE EXAMPLES 1-2
Preparation of a soil release composition
The copolymer (A) or the comparative polymer, a hydrophilic resin and other additives were added according to the following composition to 100 parts of water and stirred to prepare a soil release composition with water-absorption property and oil-repellency:
Composition
Examples 1 and 2
Copolymer (A1) (0.5 part),
Sumitex resin 901 (0.5 part) and Sumitex resin W-2 (0.5 part) (hydrophilic resins), and
zinc nitrate (0.5 part).
Example 3
Copolymer (A2) (0.5 part), and
Blencope PEB-4201 (0.5 part) (a hydrophilic resin)
Example 4
Copolymer (A3) (0.5 part), and
Sumitex resin AR-2 (0.5 part) (a hydrophilic resin).
Example 5
Copolymer (A4) (0.5 part), and
Sumitex resin AR-2 (0.5 part).
Comparative Example 1
Polymer (ii) (0.5 part),
Sumitex resin 901 (0.5 part) and Sumitex resin W-2 (0.5 part), and
zinc nitrate (0.5 part).
Comparative Example 2
Polymer (ii) (0.5 part), and
Sumitex resin AR-2 (0.5 part).
Each composition prepared in Examples 1-5 and Comparative Examples 1-2 was applied to various substrates and its water-absorption property, oil-repellency property and soil release ability as well as their durability were examined.
When the substrate was cloth, it was dipped in the composition for 5 minutes, squeezed with rollers, dried at 80° C. for 10 minutes and heated at 150° C. for 5 minutes. When the substrate was in the form of a plate, it was dipped in the composition for 5 minutes, dried at 80° C. for 10 minutes with leaning it against a wall, and then heated at 150° C. for 5 minutes.
The properties of the treated substrate were evaluated as follows:
Water-absorption property
A drop of water is dropped on the surface of the treated substrate and a time (seconds) till complete disappearance of water is confirmed by naked eyes is measured.
Oil-repellency
A drop of 4 mm in diameter of a following solvent mixture is dropped on the substrate and a critical composition of the mixture with which the drop maintains its form for three minutes is determined by naked eyes, and following point is assigned to express the oil-repellency. The larger the point, the better the oil-repellency.
______________________________________Point Nujol (vol. %) n-Hexane (vol. %)______________________________________100 50 5090 60 4080 70 3070 80 2050 100 0 0 (100% Nujol not retained)______________________________________
Stainproofing test
The treated substrate was dipped in a waste motor oil for 10 hours and the surface condition was observed by naked eyes. The criteria are as follows:
1: Very bad stain remains.
2: Bad stain remains.
3: Slight stain remains.
4: Little stain remains.
5: No stain remains.
Durability
The treated substrate is washed ten times according to JIS H 103 with a detergent concentration of 2 g/l (detergent: "Super Zabu" manufactured by Kao) at 40° C. with a bath ratio of 1:40 and then subjected to the water-absorption test, the oil-repellency test and the soil release tests as described in the above.
The results are shown in Tables 1-1 to 1-3.
TABLE 1__________________________________________________________________________Water absorption (sec.) (Before washing/after washing)ExampleNylon PET.sup.1 PET/cotton Cotton Wool PET ABS.sup.2 PMMA.sup.3 AlNo. cloth cloth cloth cloth cloth plate plate plate plate__________________________________________________________________________1 30/30 35/35 30/30 10/10 30/30 40/40 40/40 40/40 40/402 30/30 35/35 30/30 10/10 30/30 40/40 40/40 40/40 40/403 20/20 25/25 20/20 10/10 20/20 30/30 30/30 30/30 30/304 35/35 40/40 30/30 20/20 35/35 50/50 50/50 50/50 50/505 35/35 40/40 30/30 20/20 35/35 50/50 45/45 45/45 45/45Comp. 1Both Both Both Both Both Both Both Both Both>60 >60 >60 >60 >60 >60 >60 >60 >60Comp. 2Both Both Both Both Both Both Both Both Both>60 >60 >60 >60 >60 >60 >60 >60 >60__________________________________________________________________________ Oil-repellency (Before washing/after washing)Example PET PET/cotton Cotton PET AlNo. cloth cloth cloth plate plate__________________________________________________________________________1 90/70 90/70 90/50 90/70 90/702 90/70 90/70 90/70 90/70 90/703 90/70 -- 90/50 -- --4 -- -- -- -- 90/705 -- -- -- -- 90/70Comp. 1 80/70 80/70 80/70 90/70 90/70Comp. 2 90/50 60/50 60/50 -- --__________________________________________________________________________Stainproofing (Before washing)ExampleNylon PET PET/cotton Cotton Wool PET ABS PMMA AlNo. cloth cloth cloth cloth cloth plate plate plate plate__________________________________________________________________________1 -- 5/5 5/4 5/4 -- 5/5 -- -- 5/52 -- 5/5 5/4 5/4 -- 5/5 -- -- 5/53 -- 5/4 -- -- -- -- -- 5/5 --4 5/5 -- -- -- 5/4 -- 5/4 -- 5/55 5/5 -- -- -- -- -- -- -- --Comp. 13/1 3/1 4/1 4/1 -- 4/1 4/1 4/1 4/1Comp. 22/1 2/1 2/1 2/1 -- -- -- -- --__________________________________________________________________________ Note: .sup.1 Polyethylene terephthalate. .sup.2 Acrylonitrile/butadiene/styrene copolymer. .sup.3 Polymethyl methacrylate.
EXAMPLES 6-15 AND COMPARATIVE EXAMPLES 3-6
The copolymer (A) or the comparative polymer, a hydrophilic resin, a water- and oil-repellent and other additives in the following amounts were added according to the following composition to 100 parts of water and stirred to prepare a soil release composition with water-absorption property and oil-repellency:
Composition
Example 6
Copolymer (A1) (0.5 part),
Sumitex resin 901 (0.5 part) and Sumitex resin W-2 (0.5 part),
a water- and oil-repellent (A) 1 ) (0.1 part), and
zinc nitrate (0.5 part).
Example 7
Copolymer (A2) (0.5 part),
Sumitex resin M-3 (0.5 part),
a water- and oil-repellent (A) (0.1 part), and
Sumitex accelerator (0.5 part).
Example 8
Copolymer (A2) (0.5 part),
Teisan urethane SL-4780 (0.5 part), and
a water- and oil-repellent (A) (0.1 part).
Example 9
Copolymer (A3) (0.5 part),
Sumitex resin M-3 (0.5 part),
a water- and oil-repellent (A) (0.1 part), and
Sumitex accelerator (0.5 part).
Example 10
Copolymer (A3) (0.5 part),
Serbifan MKP1 (0.5 part)
a water- and oil-repellent (A) (0.05 part) and a water- and oil-repellent (B) 2 ) (0.2 part), and
Serbifan KP2 (0.2 part).
Example 11
Copolymer (A4) (0.5 part),
Sumitex resin M-3 (0.5 part)
a water- and oil-repellent (A) (0.1 part), and
Sumitex accelerator (0.5 part).
Example 12
Copolymer (A4) (0.5 part),
Sumitex resin NR-2 (0.5 part),
a water- and oil-repellent (A) (0.1 part), and
zinc nitrate (0.5 part).
Example 13
Copolymer (A5) (0.5 part),
Sumitex resin (0.5 part),
a water- and oil-repellent (A) (0.2 part), and
Sumitex accelerator (0.5 part).
Example 14
Copolymer (A5) (0.5 part),
Blencope 4001 (0.5 part), and
a water- and oil-repellent (A) (0.2 part).
Example 15
Copolymer (A5) (0.5 part),
Serbifan MKP1 (0.5 part),
a water- and oil-repellent (A) (0.2 part), and
Serbifan KP2 (0.2 part).
Comparative Example 3
Polymer (i) (1.0 part),
Sumitex resin M-3 (0.5 part),
a water- and oil-repellent (A) (0.2 part), and
Sumitex accelerator (0.5 part).
Comparative Example 4
Polymer (i) (0.5 part),
Serbifan MKP1 (0.5 part)
a water- and oil-repellent (A) (0.05 part) and a water- and oil-repellent (B) (0.2 part), and
Serbifan KP2 (0.2 part).
Comparative Example 5
Polymer (iii) (0.5 part),
Sumitex resin 901 (0.5 part) and Sumitex resin W-2 (0.5 part),
a water- and oil-repellent (A) (0.1 part), and
zinc nitrate (0.5 part).
Comparative Example 6
Polymer (iii) (0.5 part),
Teisan urethane SL-4780 (0.5 part), and
a water- and oil-repellent (A) (0.1 part). Note: A water- and oil-repellent (A): A copolymer of C 8 F 17 --CH 2 CH 2 OCOCH═CH 2 and stearyl methacrylate having an average molecular weight of 25,000.
A water- and oil-repellent (B): A copolymer of C 8 F 17 --CH 2 CH 2 SCOCH═CH 2 and stearyl methacrylate having an average molecular weight of 25,000.
Each composition prepared in Examples 6-15 and Comparative Examples 3-6 was applied to various substrates and its water-repellency, oil-repellency and soil release ability as well as their durability were examined.
The composition was applied to the substrate in the same manner as in Examples 1-5.
The water-repellency was evaluated according to JIS L-1005. The oil-repellency and the soil release ability were evaluated in the same ways as in Examples 1-5. The durability of these properties was also evaluated in the same way as in Examples 1-5.
The results are shown in Tables 2-1, 2-2 and 2-3.
TABLE 2__________________________________________________________________________ExampleNylon PET PET/cotton Cotton Wool PET ABS PMMA AlNo. cloth cloth cloth cloth cloth plate plate plate plate__________________________________________________________________________Water-repellancy (Before washing/after washing) 6 -- 100/100 90/80 90/80 -- 100/100 -- -- 100/90 7 100/100 100/100 100/100 100/90 -- -- 100/100 -- -- 8 100/100 -- -- -- 100/100 -- 100/100 -- 100/100 9 100/100 100/100 -- -- -- -- -- -- --10 90/80 90/80 -- -- -- -- -- -- 90/8011 100/100 100/100 -- -- -- -- -- -- --12 -- -- 100/80 100/90 -- -- -- -- --13 -- 100/100 100/100 100/100 -- -- -- -- --14 -- -- -- -- -- 100/100 -- 100/100 100/10015 -- -- -- -- -- 100/100 100/100 -- 100/100Comp. 390/80 90/80 90/80 90/80 -- 100/90 -- -- 100/90Comp. 4100/100 100/100 -- -- -- 100/100 100/100 100/100 100/100Comp. 580/60 80/60 80/60 70/60 80/60 -- -- -- 100/100Comp. 680/60 80/60 80/60 70/60 80/60 -- -- -- 100/100Oil-repellency (Before washing/after washing) 6 -- 100/90 100/80 100/70 -- 100/90 -- -- 100/90 7 100/90 100/90 100/90 100/90 -- -- 100/80 -- -- 8 100/90 -- -- -- 100/90 -- 90/80 -- 100/90 9 100/100 100/90 -- -- -- -- -- -- --10 90/80 90/80 -- -- -- -- -- -- 90/8011 100/100 100/100 -- -- -- -- -- -- --12 -- -- 100/80 100/90 -- -- -- -- --13 -- 100/90 100/90 100/90 -- -- -- -- --14 -- -- -- -- -- 100/100 -- 100/100 100/10015 -- -- -- -- -- -- 100/100 -- 100/100Comp. 3100/90 100/90 100/90 100/80 -- 100/90 -- -- 100/90Comp. 490/70 90/70 -- -- -- 90/80 90/80 90/80 90/80Comp. 590/70 90/70 80/50 80/50 80/50 -- -- -- --Comp. 690/70 90/70 80/50 80/50 80/50 -- -- -- --Stainproofing (Before washing/after washing) 6 -- 5/5 5/4 5/3 -- 5/5 -- -- 5/5 7 5/5 5/5 5/5 5/5 -- -- 5/5 -- -- 8 5/5 -- -- -- 5/5 -- 5/4 -- 5/5 9 5/5 5/5 -- -- -- -- -- -- --10 5/4 5/4 -- -- -- -- -- -- 5/411 5/5 5/5 -- -- -- -- -- -- --12 -- -- 5/5 5/5 -- -- -- -- --13 -- 5/5 5/5 5/5 -- -- -- -- --14 -- -- -- -- -- 5/5 -- 5/5 5/515 -- -- -- -- -- -- 5/5 -- 5/5Comp. 32/1 2/1 2/1 2/1 -- 2/1 -- -- 2/1Comp. 42/2 2/2 -- -- -- 2/2 2/2 2/2 2/2Comp. 54/1 4/1 4/1 4/1 4/1 -- -- -- --Comp. 64/2 4/2 4/2 4/2 4/2 -- -- -- --__________________________________________________________________________
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A soil release composition comprising:
(A) a polymer comprising 10 to 100% by weight of constituting units of the formula: ##STR1## wherein R f is a C 3 --C 21 fluoroalkyl group; R 1 is a hydrogen atom or a C 2 --C 4 acyl group; R 2 , R 3 , R 4 and R 5 are, the same or different, each a hydrogen atom, a methyl group or an ethyl group; A is a group of the formula: --CH 2 CH(OR 1 )CH 2 --OCO-- which R 1 is the same as defined in the above, --CO--, --(CH 2 ) k N(R 2 )CO-- in which R 2 is the same as defined in the above and k is an integer of 1 to 10, or --(CH 2 ) k -- in which k is the same as defined in the above; h is an integer of 0 to 5; p is an integer of 1 to 40; q and r are, the same or different, each an integer of 0 to 40,
(B) a hydrophilic resin, and
(C) optionally a water- and oil-repellent, a weight ratio of (A):(B):(C) being 5-95:95-5:0 or 1-95:5-95:1-50, which can impart stainproofing property with good durability to a substrate such as plastics, fabrics and paper.
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PRIORITY CLAIM
[0001] This application is a continuation application claiming priority from U.S. patent application Ser. No. 11/388,847, filed on Mar. 24, 2006.
FIELD OF THE INVENTION
[0002] The field of the invention is completion techniques and more particularly those involving sequential procedures in a zone which need periodic obstruction of the flow bore to conduct the operation and need the flow bore cleared thereafter for production.
BACKGROUND OF THE INVENTION
[0003] Some completion methods require sequential isolation of adjacent zones in an interval to perform treatments such as fracing. Typically the zones are isolated with packers and in between them there are sliding sleeves that can be selectively opened to provide access. Typically, this assembly is run in to position, and then a ball or plug is pumped down to the bottom which closes off the flow path through the bottom end of the liner. Pressure is applied and the packers are set, creating multiple isolated zones. The tubular string is pressurized and the lowermost sliding sleeve is opened. After the lowermost zone is treated a ball is dropped on a lowermost seat to close off the zone just treated and the pressure is built up on this first dropped ball to open the next sliding sleeve up. After that treatment an even bigger ball lands on an even bigger seat to close off the second zone just treated. The process is repeated until all zones are treated using a progression of bigger and bigger seats as the treatment moves toward the surface. At the end, the balls on all the seats are either floated to the surface when the flow commences from the treated formation or the assembly of all the seats and the balls that are respectively on them are milled out so as not to impede subsequent production from the treated zone. This technique is shown in U.S. Pat. No. 6,907,936. The problem with it is that different sized seats are required at specific locations to make the isolation system work and in the end there are some rather small passages through the smallest of the seats even if the balls are floated out that then requires a discrete step of milling out the seat and ball near all but one sliding sleeve.
[0004] Techniques have been developed to temporarily block wellbores using dissolving or other wise disappearing plugs. Such devices are illustrated in U.S. Pat. Nos. 6,220,350, 6,712,153 and 6,896,063. Some packers are built to be disposable involving the use of degradable polymers as illustrated in US Publication No. 2005/0205264; 2005/0205265 and 2005/0205266. Some assemblies involve landing collars that can be changed from a go to a no go orientation with a shifting tool that also doubles as a tool to operate sliding sleeves. This is illustrated in US Publication No. 2004/0238173. Yet other designs that create selective access into a formation by using perforating charges that blow out plugs in casing or pressure actuated pistons with internal rupture discs are illustrated in U.S. Pat. Nos. 5,660,232 and 5,425,424. U.S. Pat. No. 6,769,491 illustrates a typical anchor assembly for a downhole tool.
[0005] The present invention seeks to streamline certain downhole operations by matching profiles on plugs to those on sliding sleeves or nipple profiles. This allows a specific plug to be located at a certain location and bypass other potential landing locations. The flow path can be identical in size for the duration of the zone and yet different portions can be addressed in a particular sequence. Apart from that, the plugs, after having served their purpose, reopen the flow path for further operations. These and other benefits of the present invention will be more readily understood by those skilled in the art from a review of the description of the preferred embodiment that appears below, as well as the drawings and the claims, which define the full scope of the invention.
SUMMARY OF THE INVENTION
[0006] A system allows for sequential treatment of sections of a zone. Access to each portion can be with a sliding sleeve that has a specific internal profile. Pump down plugs can be used that have a specific profile that will make a plug latch to a specific sleeve. Pressure on the plug when latched allows a sequential opening of sleeves while zones already affected that are below are isolated. The pump down plugs have a passage that is initially obstructed by a material that eventually disappears under anticipated well conditions. As a result, when all portions of a zone are handled a flow path is reestablished through the various latched plugs. The plugs can also be blown clear of a sliding sleeve after operating it and can feature a key that subsequently prevents rotation of the plug on its axis in the event it later needs milling out.
DETAILED DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a section view of a pump down plug before it is pumped downhole;
[0008] FIG. 2 is the plug of FIG. 1 with the passage through the plug open after the nose plug has disappeared;
[0009] FIG. 3 is a section view of a typical sliding sleeve in the closed position;
[0010] FIG. 4 is a section view of the pump down plug landed on the sliding sleeve;
[0011] FIG. 5 is the view of FIG. 4 with pressure applied and the sleeve shifted to an open position;
[0012] FIG. 6 is a section view of an alternative embodiment showing the sliding sleeve closed and the profile to receive the pump down plug;
[0013] FIG. 7 is the view of FIG. 6 with the pump down plug landed creating a piston around the sliding sleeve;
[0014] FIG. 8 is the view of FIG. 7 with pressure applied that results in shifting the sliding sleeve;
[0015] FIG. 9 is a section of a pump down plug showing the disappearing portion in the nose;
[0016] FIG. 10 is a closer view of FIG. 9 showing how the disappearing portion is attached to the pump down plug;
[0017] FIG. 11 is a section of an alternative design of the disappearing component;
[0018] FIGS. 12 a - c are a section view of an alternative pump down plug design showing the plug landed in the sliding sleeve;
[0019] FIGS. 13 a - c are the view of FIGS. 12 a - c with the sliding sleeve shifted;
[0020] FIGS. 14 a - c are the view of FIGS. 13 a - c with the plug released from the sliding sleeve and captured on a landing collar;
[0021] FIG. 15 is a part section perspective view showing the sliding sleeve and a groove that holds the pump down plug against turning if the plug is milled out;
[0022] FIG. 16 is the pump down plug in perspective showing the lug that resists turning if the plug is milled out.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] FIG. 1 shows a typical pump down plug 10 that has wiper seals 12 and 14 to make contact with the surrounding tubular so that it can be pumped down. Although cup seals are shown, other types and quantities of seals can be used. The plug 10 has a tubular body 16 with a through passage 18 . Near end 20 is a fishing neck 22 to be used if the plug 10 is to be fished out for any reason. A series of longitudinal grooves 22 define flexible collet fingers 24 that are attached at opposed ends to body 16 . Cantilevered fingers can be alternatively used or any other structure that can maintain a cylindrical shape with sufficient strength and still allow flexing. The flexing feature allows the protrusions 26 and 28 to move radially as the plug 10 is pumped downhole. While the preferred plug 10 has seals 12 and 14 the invention envisions a plug 10 that simply is dropped making the use of seals 12 and 14 optional. Looking at FIG. 3 , there is a sliding sleeve 30 that has depressions 32 and 34 that are designed to match the shape of protrusions 26 and 28 on the plug 10 . As the plug 10 approaches the sliding sleeve 30 the fingers 24 flex to let the protrusions 26 and 28 jump up on the sleeve 30 and then spring out into depressions 32 and 34 as radial surface 36 on projection 28 registers with radial surface 38 on depression 32 .
[0024] Those skilled in the art will appreciate that while 2 protrusions 26 and 28 are shown on the plug 10 to match similarly shaped depressions on the sliding sleeve 30 there are many different ways to execute the inventive concept. The concept is to create a unique match between a given plug 10 and a given downhole location which happens to be a sliding sleeve such as 30 . For example, when treating a long zone there will be a plurality of sliding sleeves such as 30 that have packers such as 40 and 42 to isolate a surrounding annulus (not shown). The idea is to progressively isolate parts of a zone working uphole so that the next sliding sleeve between a pair of packers can be opened for treating the formation between those two packers while the portions below already treated are isolated.
[0025] To better understand how this happens reference is again made to FIG. 1 where the passage 18 is shown to be blocked by what will generically be referred to as a disappearing material 44 . In this application, the phrase disappearing material is intended to encompass a wide variety of materials used alone or in combination that can retain structural integrity during the pump down procedure but over time when subjected to well conditions whether existing or artificially created will lose that integrity and no longer block the passage 18 , as shown in FIG. 2 . Threads 46 are visible in FIG. 2 after the disappearing material 44 has gone away. They are used to initially retain the material 44 in position as shown in FIG. 1 . The preferred material 44 is a biopolymer that responds to well temperature. Generally when a plug is pumped down from the surface, the fluids used and the flow keeps the material 44 in a plug 10 strong enough to withstand that applied pumping pressures. After a particular portion of a zone is treated through an open sleeve such as 30 , another plug lands in the next sleeve. That cuts off all the lower plugs from flow and allows them to come to equilibrium with well temperatures. Over time the material 44 in the lower plugs disappears opening a path 18 through the lower plugs as plugs land above them in another sliding sleeve.
[0026] FIGS. 4 and 5 show how a plug 10 with projections 26 and 28 registered with depressions 34 and 32 respectively can be used to shift sleeve 30 from the closed position with ports 48 closed in FIG. 4 and where they are open in FIG. 5 . By design, the material 44 continues to block passage 18 with ports 48 open so that a frac job for example can be accomplished through ports 48 with a zone isolated between two external packers 40 and 42 .
[0027] One aspect of the invention is that a given plug has a profile on the fingers 24 that registers with a specific sliding sleeve profile in the embodiment of FIGS. 1-5 . The concept is related to a key in a lock cylinder. Combinations of protrusions and depressions can be used with either one being on the plug or the sleeve and the mating profile on the other member. The registration can be determined by having a protrusion and mating depression have similar longitudinal lengths to make them register. There can be more than one pair of protrusions and matching depressions and their spacing from each other can be unique to a given sliding sleeve and a plug that will match.
[0028] If fracing is to be done for example, using sliding sleeves A, B and C where A is furthest from the surface, the procedure would be to run the assembly into position and set packers between A, B and C and another above C. All sleeves would be run in closed. To frac the zone adjacent sliding sleeve A the string is simply pressurized to open sleeve A to treat the furthest zone from the surface. Sleeve A can be a pressure to open design. When that zone is done a plug is pumped down into sleeve B and that effectively isolates the zone just treated through sliding sleeve A. This plug has a pattern on its fingers to register only with sleeve B. Pressure is built up again and sleeve B opens and treatment of the zone through open sleeve B takes place. When that treatment is done, another plug specially configured to register only with sleeve C is pumped down. Pressure is again built up and the zone is treated through open sliding sleeve C. While that is going on the plug in sleeve B is isolated by virtue of the plug above it and it starts to warm to well temperature and the material 44 in that plug disappears. When pumping is stopped against the plug in sliding sleeve C, it too warms up and the material 44 in it disappears. What are then left are the open passages in the two plugs 18 with all sleeves open and the need to go in and drill out is not there. The treated formation can simply be produced. Should it be desired, the plugs could be fished out using necks 20 .
[0029] While a procedure with 3 sleeves A, B and C has been described those skilled in the art will understand any number of sleeves that have external isolation devices can be used. The only difference among the sleeves is the profile on them is unique to each and the plugs pumped down have matching profiles to properly land in the sleeves in the desired sequence. In the preferred bottom up sequence each successive plug isolates an already treated zone while the material 44 in that now isolated plug just disappears. What's left is a fully treated interval and a fully open passage to the entire treated interval with no need to drill or mill ball seats as in the past. In the preferred embodiment the sleeves that span the zone can all have similar internal diameters and the unique patterns that register between a plug and a sleeve will ensure that similarly dimensioned plugs wind up at the right sleeve. After it is all done each plug now with its material 44 disappeared presents a consistent flow path 18 to the entire treated interval.
[0030] In an optional variation, instead of using the material 44 an easily milled disc can be provided. While this way will require subsequent intervention after all the plugs are in place, the milling should go quickly if only the discs themselves are milled out and not the plugs that retain them. Thereafter, with the passage in each plug open, production can flow through them all. Any remnants from milling can be brought to the surface with this production.
[0031] While the embodiment in FIGS. 1-5 registered with a given sleeve, the embodiment in FIGS. 6-8 registers with grooves 50 and 52 in the housing 54 . The sliding sleeve 56 initially covers ports 58 as seals 60 and 62 straddle the ports 58 . Projection 68 initially registers with depression 64 to hold the sleeve 56 in the FIG. 6 closed position. Eventually when lower end 70 of sleeve 56 hits shoulder 72 , the projection 68 will register with depression 66 as shown in FIG. 8 . FIG. 7 shows a plug 74 that has projections 76 and 78 to match depressions 50 and 52 fully registered. Since material 80 is intact and closes passage 82 , and seal 84 contacts sleeve 56 any applied pressure on plug 74 now moves sleeve 56 because sleeve 56 is now turned into a piston. The final position of sleeve 56 is shown in FIG. 8 with ports 58 open.
[0032] In this embodiment a given plug has a unique profile or pattern than is matched in the housing adjacent to a sleeve as opposed to literally on the sleeve in the case of FIGS. 1-5 to be sure a plug lands adjacent a desired sleeve to turn it into a piston so that pressure above it can force it to shift to open the associated ports. Again the plug uses a disappearing material 80 that goes away after it is isolated by another plug latched above it. As in the case of the procedure described above for FIGS. 1-5 the FIGS. 6-8 procedure is similar with the main difference being that in FIGS. 1-5 the plug literally moves the sleeve and in FIGS. 6-8 the latched plug allows pressure to force the sleeve open in a piston effect. In other respects the procedure is similar.
[0033] FIGS. 9 and 10 illustrate an embodiment for the disappearing material plug 44 or 80 illustrated in use in FIGS. 1-8 . Since the material needs some structural strength to withstand differential pressure during pumping procedures like a frac job, the design features alternating layers of a biopolymer 86 alternating with water soluble metal discs 88 . In the assembly, the discs 88 are all internal. The biopolymer 86 has a relatively slow dissolving rate coupled with poor creep resistance. The discs 88 are fast dissolving but add strength and creep resistance. A retaining sleeve 90 engages thread 92 on housing 94 to compress the assembly within passage 96 for run in. Longitudinal compression creates a better peripheral seal in housing 94 .
[0034] FIG. 11 represents another construction for such a plug as an alternative to the one illustrated in FIGS. 9 and 10 . Here the end components 98 and 100 are preferably a biopolymer with a relatively slow dissolving rate and poor creep resistance. Sandwiched in between is a granular substance such as, for example, sand, frac proppant or glass micro spheres 102 . When a directional load is placed on either end component 98 or 100 the applied stress is transferred to the layer 102 and due to shifting of the granular material the load is shifted outward against ring 104 that is secured to the housing 106 at thread 108 before it can migrate to the opposite end component. This helps to retain the sealing integrity of the assembly. As before in FIGS. 9 and 10 , the ring 104 is used to initially longitudinally squeeze the assembly for better sealing. After exposure to well temperatures for a long enough period, the end components dissolve and production can be used to deliver the granular substance to the surface.
[0035] While two specific embodiments have been described as a unique way to block a passage in a plug that disappears, those skilled in the art will appreciate that independent of the specific execution of the disappearing member the invention encompasses the use of other assemblies that disappear by a variety of mechanisms apart from dissolving when used in the contexts that here described in the application and covered in the claims.
[0036] Referring now to FIG. 16 another optional feature of a plug 110 is illustrated. Here there is a leading section 112 that has one or more projections 114 that are designed to enter a matching depression 116 seen in section in FIG. 15 . Although not shown, those skilled in the art will appreciate that alignment ramps to interact between a plug 110 and the surrounding housing 118 to get the projection 114 to properly align with a depression 116 can be used. However, since the projection is on a flexible finger 120 and the purpose of the registration of parts is to prevent rotation if the plug is to be milled out for any reason, alignment device will not be necessary because some rotation induced from milling will result in registration of 114 with 116 as long as they are supported at the same elevation from the registration of projections 122 and 124 above.
[0037] FIGS. 12-14 show the plug illustrated in FIG. 16 (where the disappearing material is not shown in passage 126 ) used to shift a sleeve and then get off the sleeve and latch to a body just below the sleeve. In FIG. 12 b projection 128 is just below the bottom of sleeve 130 while projection 132 has engaged a radial surface 134 on the sleeve 130 . FIG. 12 c shows the offset at this time between the torque resisting projection 114 ′ and the receiving recess 116 ′. In FIG. 12 the sleeve 130 has not been shifted. Moving on to FIG. 13 b the sleeve 130 is now shifted to travel stop 136 with plug 138 still engaged at radial surface 134 of sleeve 130 . In FIG. 14 b the fully shifted sleeve 130 is no longer engaged by the pumped plug 138 . Instead, projections 128 and 132 are now registered with recesses 140 and 142 while torque resisting projection 114 ′ is registered with recess 116 ′. Those skilled in the art will realize that the torque resistance feature is optional and that it can be used regardless of whether the pumped plug 138 remains connected to the sleeve 130 after shifting it or, as shown in FIGS. 12-14 leaves the sleeve 130 to register with housing 144 .
[0038] It is worthy of mention again that all types of ways to obtain a unique registering location between a given plug and a given sleeve or a given downhole location are part of the invention. While projections and depressions have been used as an example with either member capable of having one or the other, other combinations that result in registrations of selected pump down plugs at different locations are within the scope of the invention. The sleeves or landing locations can be all the same diameter but what makes them unique is the ability to register with a specific plug that has a profile that registers with it.
[0039] Yet another aspect of the present invention is to use progressively larger seats as described in U.S. Pat. No. 6,907,936 except to make the obstructing members of a disappearing material so that when all zones are treated, all the seats are reopened. While this embodiment has the disadvantage that without milling there are well obstructions that vary in size, it does retain an advantage over the method in the aforementioned patent in that production can begin without milling out balls on seats.
[0040] In another technique, a plurality of nipple profiles that are unique can be placed in a casing string. A pump down plug that supports a perforating gun can be delivered to register with a particular nipple profile whereupon registering at the proper location pressure above the now supported plug can fire the gun. In that manner an interval can be perforated in a specific order and intervals already perforated can be isolated as other portions of the interval are perforated.
[0041] In another embodiment the sliding sleeves that have explosive charges to open access to the formation as described in U.S. Pat. No. 5,660,232 can be selectively operated with the pump down plugs described above that register with a discrete sleeve to open access to the formation in a desired order. The technique can also be grafted to the sliding sleeves used in combination with telescoping pistons as described in U.S. Pat. No. 5,425,424 to selectively shift them in a desired order using the techniques described above.
[0042] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below.
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A system allows for sequential treatment of sections of a zone. Access to each portion can be with a sliding sleeve that has a specific internal profile. Pump down plugs can be used that have a specific profile that will make a plug latch to a specific sleeve. Pressure on the plug when latched allows a sequential opening of sleeves while zones already affected that are below are isolated. The pump down plugs have a passage that is initially obstructed by a material that eventually disappears under anticipated well conditions. As a result, when all portions of a zone are handled a flow path is reestablished through the various latched plugs. The plugs can also be blown clear of a sliding sleeve after operating it and can feature a key that subsequently prevents rotation of the plug on its axis in the event is later needs milling out.
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BACKGROUND OF THE INVENTION
Methods are currently available for providing non-removable and optically readable security devices in paper during the paper making process. U.S. Pat. No. 4,437,935 discloses a method for incorporating one such security device by using a carrier paper which becomes dispersed upon contact with the wet paper stock during the paper making process. U.S. patent application (Crane-4) discloses a method of introducing a security device within the paper stock during the paper making process by employing a carrier paper to which the device is adhered. The carrier paper intermeshes with the base paper fibers forming a composite paper facilitating permanent attachment of the device. Both the aforementioned Application and Patent are incorporated herein for purposes of reference.
In both the aforementioned patent and patent application the carrier paper used to transport the security device remains an integral part of the finished paper and can be discerned from the base paper only by close examination. When it is desired to provide a micro-code integrally formed within the substance of the paper for optical reading by means of transmitted light, the carrier paper is an inappropriate substrate for fine line codes or microprint. U.S. Pat. No. 3,880,706 discribes a method for imparting security fibers manufactured from a thermoplastic material which is fused within the paper fibers during the paper making process. One such material being a thermoplastic material which becomes fused at the final stages of the paper making process by subjecting the paper to a pre-determined temperature. Once the thermoplastic material has become fused within the paper, its presence may be detected by transmitted light.
When micro-coded information is to be deployed within paper, it is first microprinted on a thin strip or transparent material such as a polyester plastic film. The polyester film is then introduced from a continuous spool to the paper stock on a Fourdrenier or a cylinder mold machine during the sheet forming process. Once the paper fibers are pressed and dried to form the finished paper, the polyester film remains intact and the microprinted material can be viewed by transmitted light. Such a film, is removable from the paper by tearing the paper to expose the film and then lifting the film from the paper as a continuous strip. The authenticity of a banknote or security document can be brought into question if part or all of the encoded thin film strip has been removed. If the micro-code contains machine-readable information for both verifying the authenticity of currency, for example, as well as identifying the denomination of the currency, this could present a serious problem. The identifying micro-code for a higher denomination currency could be reinserted.
The purpose of this invention is to provide a method for incorporating micro-coded information within security paper without leaving any indication of a carrier paper or of a carrier film.
SUMMARY OF THE INVENTION
The invention comprises the incorporation of micro-coded information on a substrate which is later dissolved during the stages of the paper making process to leave the micro-coded imformation within the paper web. The micro-cded information may be machine-read by transmitted light or detected by the emittance of unique radiation when exposed either in reflectance or transmittance to a specific source of excitation energy. This information cannot be removed from the paper without destroying both the paper and the micro-coded information. In one embodiment, the micro-coded information is provided by micro-printing on a thin strip of polyvinyl alcohol film. The polyvinyl alcohol polymer may be modified by acetylation or heat treatment to produce a film strip with specifically controlled solubility properties.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of the substrate micro printed with various security codes;
FIG. 2 is a side view in partial section of a Fourdrenier paper making machine with a funnel tube for introducing the soluble substrate strip into the paper fibers;
FIG. 3 is a side view in partial section of a cylinder-type paper making machine with a tube for inserting the soluble substrate film within the paper fibers;
FIG. 4 is a cross section of the PVA substrate with printed indicia applied to the surface;
FIG. 5 is a sectional view of the PVA strip after it is formed within the wet paper web prior to dissolution;
FIG. 6 is a sectional view of the PVA strip while the film is dissolving and the paper web is becoming more dense;
FIG. 7 is a sectional view of the finished paper with only indicia;
FIG. 8 is plan view of a currency bill containing the micro-code inserted therein by the soluble substrate strip according to the invention; and
FIG. 9 is a an end view of a PVA strip with the micro-code impressed directly on the strip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 contains a soluble carrier substrate which consists of a film or strip 10 of a polyvinyl alcohol (PVA) such as is manufactured by Meno-sol Co. of Gary, Ind. The micro-code consists of microprint indicia 11, bar graph code indicia 12 as well as phosphorescent indicia 13 which is applied by means of a microprinting or coating process. The PVA strip 10 has a thickness of 1.5 thousandths of an inch and a width of approximately 1/32 of an inch. The PVA is treated by heating the polymer in air in order to render the polymer insoluble in water up to a temperature of 160° F. This allows the PVA strip 10 to be inserted within the slice 15 of a Fourdronier paper making machine 16 by inserting within the fiber slurry 17 through a tube 14. The slurry 17 contains a mixture of cellulosic fibers 24 which are dewatered along the Fourdrenier wire 18 to form the finished paper as best seen in FIG. 2. The slurry temperature is maintained less than 160° F. allowing the soluble PVA strip 10 to become incorporated within the nascent web which is later formed during dewatering of the fibrous slurry and then the web is pressed and dried to completely remove all the water. During the drying process the web temperature exceeds 160° F., the PVA strip dissolves and leaves the micro-code indicia intact within the web. PVA is selected as the soluble carrier substrate for the obvious reason that the PVA polymer is soluble in water and the stage at which the PVA dissolves can be controlled by the temperature usually between 100° F. and 200° F. When other water soluble materials such as gelatin, for example, are employed, the water temperature is adjusted in accordance with the preferred solubility of gelatin in water. When non-water soluble carrier substrates are used, a post processing exposure to the solvent can be made by immersing the paper in a solvent bath. Should aqueous insoluble resins be employed, the wet paper fiber containing these resin substrates can be exposed to alcohols, ketones, esters as well as specific hydrocarbons depending upon the composition of the particular resin.
FIG. 3 shows a cylinder machine 20 wherein the PVA strip 10 is introduced through a tube 14 inserted within the slurry 17 consisting of a plurality of mixed cellulosic fibers 24 in water. A paper cylinder mold 21 in combination with a couch roll 22 is employed for forming the fibers into the finished paper.
The method in which the microprinted indicia is retained intact within the paper web is not clearly understood at this time. One explanation being that the microprinted ink material 23, best seen in FIG. 4, being non-water soluble retains its integrity after the water soluble PVA strip 10 dissolves and migrates under capillary forces within the pores and interstices of the paper web. Other materials that have been applied to the surface of PVA strip 10 include fluorescent pigments and dyes, and metalized and metal oxide coated films. All these materials remain intact and in position upon the dissolving of the PVA strip.
An enlarged crossection of a portion of the strip 10 shown in FIG. 1 is depicted in FIG. 4 to show the relative thickness of the ink 23 to the strip 10.
The enlarged strip 10 is shown submerged within the slurry 17 with the individual paper fibers 24 on both sides of the strip and before the strip becomes dissolved by the water contained within the slurry.
The partial dissolution of the strip 10 is shown in FIG. 6 with the strip material being displaced by the paper fibers during the dissolution process.
In FIG. 7 the strip material has completely dissolved and the individual fibers 24 have set the ink within a predetermined position within the slurry as determined by the original placement of the strip.
FIG. 8 shows a currency bill 25 manufactured containing the dissolving strip according to the invention and detailing the placement of the indicia 11 at a particular position as viewed by high-intensity transmitted light projected from the back surface.
In lieu of providing non-water soluble indicia to the strip surface as depicted in FIG. 1, an alternative method for providing authentication features within the paper involves the properties of the strip material itself.
FIG. 9 depicts an end view of the strip 10 as viewed by means of polarized light within a pair of crossed polarizers. The information is impressed upon the surface of the strip 10 by an instrument similar to a typewriter with the ribbon removed. The bar code or symbols are pressed onto the surface of the strip to form an indentation 27 below the surface 26. When PVA material is used for the dissolving or "disappearing" strip 10 it was determined that the stress imposed upon the PVA material drastically changed its solubility characteristics. The polarized strain lines 28 which represent the densification of PVA material comprising strip 10 indicates that the material under the depression 27 is much denser than that under the un-stressed surface 26. When the water temperature is adjusted such that the unstressed PVA material dissolves during the dewatering and drying stage the stressed PVA remains within the interstices of the paper fibers. The result is strikingly similar to a high quality water mark wherein the paper fibers are displaced from the region occupied by the undissolved PVA material and the indicia comprising the undissolved PVA material is readily readable by transmitted light. Other methods for selectively stressing the PVA material include treatment by ultraviolet light or high energy electrons wherein the material to be dissolved is masked. This is similar to the photoresist process used in making semi-conductor devices where acids are used to dissolve the undesired material. Besides its use as a means for authentification purposes, the impressment of indicia on the dissolving PVA strip 10 can also be used for other purposes for which watermarks are employed. The size of the watermark would determine the thickness as well as the width of the dissolving strip o be employed in the process.
Applicant has described herein methods and materials for imparting authentification indicia within paper during the paper making process such that the substrate for such indicia is dissolved in the process and is not removable from the paper material. Applicant has also described a method for providing high quality simulated watermarks having detailed features within the paper that are not otherwise attainable by standard wet screen watermark techniques.
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Security features for authentification of currency paper are incorporated within the paper during the paper making process. Various codes are incorporated within the paper for viewing by means of transmitted light. In one embodiment the identifying indicia is microprinted on thin strips of a carrier material which dissolves during the dewatering and drying stage of the paper making process. The microprinted indicia remains intact and is readable by means of transmitted light yet is neither legible nor reproductible with reflected light.
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BACKGROUND
The invention concerns a textile machine with a multiplicity of workstations, a central machine control and a machine bus for communication between the machine control and each, or possibly a group of electronic devices associated with each workstation, wherein a sensor device is located at each workstation.
A textile machine made known by EP 0 832 997 A2 possesses a multiplicity of workstations and respectively, a workstation electronic device is placed at each said workstation. The workstation electronic devices are respectively grouped with a section controller by a connection through a data interface. Section controllers are, in turn, interconnected by a data line to a machine bus. The machine bus is further connected to a machine center in such a manner, that the machine center controls the sectional controllers which are connected in parallel along the machine bus. This arrangement accordingly provides control for the workstation electronic devices. At each workstation electronic device a thread-monitor is located, which detects the presence of a thread at its assigned workstation and in a case of absence of a thread, transmits a corresponding signal to the workstation electronic device. The body of information transmitted from the thread-monitor, that is, the data throughput demanded for this purpose, is very small, since the information provided, i.e. “Thread Lacking”, for example, is only given out by a break in the running thread. This is an event which occurs but seldom.
In the case of a disclosed communication structure, namely from WO 85/01073, the workstations of a textile machine are monitored by respective warning instruments. In this way, the sensors are placed at each workstation and accordingly transmit analog thread-signals to a processor. Analog thread-signals from a group of monitoring sensors can be evaluated by one processor and subsequently transmitted in digital form through a communication channel to a communication processor. Several processors are connected in parallel onto the said communication channel. The data, which are transmitted from the processors to the communication channel, are received by a centralized unit of the thread monitoring system and are there evaluated.
From this centralized unit, in turn, alarm signals and commands for intervention are sent over a communication connection to a control center of the textile machine. Because of the thread-signal, the monitoring at the workstations requires a stand-alone communication structure.
SUMMARY
It is the purpose of the invention to create an economical communication structure for the monitoring of the workstations of a textile machine. Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
The textile machine in accord with one embodiment of the invention encompasses a multiplicity of workstations and respectively one electronic device per workstation. A workstation is usually a spinning station of an open end spinning machine, a winding point, or the like. The textile machine is monitored and regulated by a machine control center in order, for example, to detect failure at a workstation, to take individual workstations out of production, or to shut down or to start up an entire machine. By means of a machine bus, the machine control remains in communication with the electronic devices of the workstations or in some cases with a group of such electronic devices. The communication, in this arrangement, is bidirectional, so that commands are transmitted from the machine control to the electronic device or, conversely, error conditions captured by the electronic device at the workstation are sent to the machine control.
Besides the electronic device, at each workstation a sensor apparatus is installed, which carries out a supervisory function. With its high scanning frequency of a plurality of values per second the sensor apparatus picks up a characteristic values at the workstation. Extremely advantageously in this case, a sensor is included in the apparatus for the monitoring of the thread quality of the thread produced or processed at the individual workstation.
Besides the centralized machine control, a central evaluation unit is assigned to the textile machine for the evaluation of sensor data and/or the data which are therefrom derived. To obtain a substantially reduced data throughput, the sensor data capture, in this arrangement, primary data, which are generated at each sensor, or, conversely, the quality or signal data derived therefrom.
The central evaluation unit, with this two-way circuit, makes decisions overriding the sensors in regard to the textile machine. When, the thread quality is monitored by the sensor apparatus, then the advantage of this override is that from the thread quality values of any one of the individual sensors, the central evaluation unit can make one evaluation which governs all workstations on the textile machine. The central evaluation unit weighs, in this manner, the primary sensor data, the data corresponding to the measured values, and advantageously the secondary quality or signal data derived therefrom. This derived secondary quality or signal data include, for example, classification information for the thread, thread fault-signals, technical alarms regarding the operational readiness of the sensor apparatus or the like. The central evaluation unit can proceed still further in the processing of the derived, secondary quality-data. For instance the evaluation unit can execute spectrograms of the thread quality and determine CV-values. This can be done either for all workstations of the textile machine or for individual workstations.
The central evaluation unit is connected by a first communication line with the machine control or, preferably, is directly connected to the machine bus. By the said direct connection of the evaluation unit through the first communication line to the machine bus, the quantity of distributable sensor data to be forwarded from the machine control to the central evaluation unit is substantially reduced. In this way, a diminution of the load on the machine control is attained. The sensor apparatuses are connected by a second communication line to the evaluation unit, wherein the second communications line includes at least the machine bus and the first communication line. With this advantage, the transmission of the sensor data for each of the sensor apparatuses to the central evaluation unit will at least be to some extent picked up on the communication and control structure of the textile machine. It then becomes unnecessary to provide a dedicated, separate communication structure for the sensor apparatus and its evaluation unit. In this way, the expense on the wiring between the sensor apparatuses and the central evaluation unit is considerably reduces If such provision has been made, in this case, for example, also the adjustment of the sensor apparatus can be carried out over this communication structure with the use of the machine bus. In this case, it is of particular advantage to design the second communication line to be bidirectional in nature. Among other advantages, the reaction times are considerably reduced, when the sensor apparatuses emit signals, which, for instance, are to be evaluated only at the central machine control, since the central evaluation unit, in this case, need not be interposed.
As already mentioned, it is preferential, that from the primary, measured characteristic values for data reduction, only the quality or signal data derived therefrom need be transmitted over the communication structure. The transmission of this secondary data is carried out either continuously, that is, as data accumulates with each sensor apparatus, or packetwise, that is, upon the accumulation of a certain quantity of data or upon a demand from the central evaluation unit. Particularly advantageously, the transmission can occur at predetermined time periods, for instance in timed minute spans, wherein the sensor apparatuses are time-adjusted to release their data to the central evaluation unit in an appointed time window.
In the case of a large number of workstations per textile machine, advantageously, correspondingly more workstations would be assigned to a group, that is, coalesced into a section, which in turn would be connected to a section controller which would be tied into the machine bus. The connection between the group of electronic devices with the section unit can be a star-shaped connection, preferably by a section bus. Likewise, in this case, the sensor apparatuses are subdivided again groupwise, whereby, advantageously, the size of the group and the groupings hereof are compatible to those of the electronic apparatus of the workstations. The communication between the central evaluation unit and the sensor apparatuses is done, in this case, sectionally through a third communication line, which runs between a section and the sensor apparatuses. The third communication connection can be provided directly between the section units and the sensor apparatuses or can be accomplished by an interposed switching in of the sectional bus. In the case of a direct connection between the controllers and the section units, this is also advantageously constructed in star formation.
In a further embodiment of the present invention, the sensor apparatuses are not connected directly with the section units, nor with the section bus, but by a sensor-section-element, on which, once again, the sensors are star connected with one another, or communicate with each other by a sensor-section bus.
Forwarding of the sensor data is done, in this case, from the sensor apparatus to the sensor section unit and from this to the section unit either by section bus or by direct connection thereto. Provision can also be made, that from this sensor apparatus the communication can be accomplished directly to machine bus.
Very advantageously, each sensor apparatus possesses a communication means and/or an evaluation unit for making available secondary, derived quality or signal data. With this communication means, digital signals can be directly transmitted and, in the case of a bidirectional tie, also received.
If the captured measured values, i.e., the primary characteristic values, have been already evaluated by the sensor apparatus, then the data to be transmitted have been substantially reduced. If the sensor apparatus possesses both a communication means as well as an evaluation unit, then, an autonomically reacting sensor apparatus is in place. If this is the case, then a sensor section unit may be dispensed with and communication may be established direct to the machine bus, to the section controller, or to the section bus.
Very much to advantage, besides making use of the communication and control structure of the textile machine, is that also an existing power supply can be put to use on the textile machine for the electronic elements of the workstations. Besides sparing the costs of connection for the communication, additionally the wiring costs for a separate, individual electrical current supply are also avoided.
In the case of the procedure for transmission of sensor data where a textile machine is concerned, in accord with claim 12 , the transmission of sensor data, at least batchwise, is accomplished by a machine bus of the textile machine. As mentioned above, also in this case, a separate communication structure for the central evaluation of the sensor data may be discarded.
BRIEF DESCRIPTION OF THE DRAWINGS
With the aid of the drawing, embodiments of the invention are explained in greater detail. There is shown in:
FIG. 1 a communication structure for a spinning machine for the transmission of quality data in accord with a first embodiment,
FIG. 2 a communication structure in accord with a second embodiment wherein further a supply network is presented, and
FIG. 3 a communication structure in accord with a third embodiment example.
DETAILED DESCRIPTION
Reference will now be made in detail to embodiments of the invention, examples of which are shown in the drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention. For example, features shown or described as part of one embodiment may be used with another embodiment to yield still a different embodiment. It is intended that the present invention include these and other modification and variations.
FIG. 1 shows, in a schematic manner, a communication structure in accord with the embodiment for an open-end spinning machine 10 . The open-end spinning machine is controlled by a central machine control 20 . Optionally, this central machine control 20 can be connected through an external line 11 to a general works control 12 . The works control 12 regulates or controls, for example, several parallel operating spinning machines 10 or pre/post-positioned workstations of the spinning machine. The machine control 20 is in communication by a line 21 for data exchange with a CAN-distributor 22 (router). For the data exchange between the elements of the spinning machine 10 , the CAN-distributor 22 operates through a machine bus 25 (CAN-bus). By a communication line 23 , a central quality evaluation unit 24 is connected to the machine bus 25 . The central quality evaluation unit 24 further stands in connection through a still to be described communication structure with thread cleaners 43 for data exchange. The quality evaluation unit 24 operates independently form the central machine control 20 , although it can both send and receive control data therefrom.
Instead of the communication line 23 , in another embodiment, provision can be made for a communication tie link 23 ′ directly between the machine control 20 and the evaluation unit 24 . The communication line 23 is, however, to be preferred, since this relieves the central machine control 20 of nothing more than simple data passage from the bus 25 to the said evaluation unit 24 . Further, the evaluation unit 24 can be installed spatially independently of the machine control 20 .
In addition on the machine bus 25 and connected by communication line 27 is a service cart 26 with a start-up aggregate for the spinning machine 10 . Additionally, although not shown here, startup robots are likewise connected by communication line to the machine bus 25 .
The spinning stations 41 a-d are combined groupwise in a section 30 a-d , whereby in FIG. 1 , only the spinning stations 41 a-d and the section 30 a are shown in detail. Each section includes a section controller 31 a-d , whereby each section controller 31 a-d is connected respectively by communication line 32 a-d to the machine bus 25 . Each section controller 31 a-d also exercises a router function for the data exchange between a section bus 40 and the machine bus 25 . In this way, the section bus 40 is controlled from the section controller 31 a . A section electronic device 42 as well as a thread cleaner 43 is assigned to each spinning station 41 a-d . Each spinning station 41 a-d is connected by a communication line 62 a-d to the section bus 40 . To each section electronic device 42 , for example, is connected a thread monitor, which monitors thread-presence at the spinning station. The section electronic device 42 , being equipped with appropriate sensors and actuators, is also connected to a feeding means, which, for example, inserts a fiber matting band into a disintegrating roll at the spinning station. The communication structure of the spinning machine 10 , as described up to this point, is identical to that of the second and third embodiments as presented in FIGS. 2 and 3 . In the following, on this account, the described elements are provided with the same reference numbers.
In the case of the first embodiment, according to FIG. 1 , the thread cleaners 43 are in connection with a cleaner bus 45 through the tie-lines 64 a-d . Similar to the section controller 31 a , the cleaner bus is controlled and operated by a cleaner section unit 44 . The cleaner section unit 44 has primarily a router function, although it can also, in a sectional manner, evaluate the data transmitted from the thread cleaners 43 and, in some cases, transmit control data especially to the section controller 31 a , in order, for example, to act through the section electronic device 42 on the operation of the spinning stations 41 a-d.
The cleaning section controller 44 is connected directly by a communication line 63 with the section controller 31 a or, in a preferred formulation, by means of a communication line 63 ′ to the section bus 40 through the said section controller 31 a . With this communication structure, communication is effected between the evaluation unit 24 and a thread cleaner 43 through the communication line 23 (that is to say, the communication line 23 ′, the machine control 20 to the distributor 22 ) to the machine bus 25 , the communication line 32 a-d , the section controller 31 a-d , the section bus 40 and the communication line 63 ′ (or the communication line 63 ) the cleaning section unit 44 , the cleaning bus 45 , the communication line 64 a-d and finally to the thread cleaner 43 . Correspondingly, the communication can run in the reversed order.
Examples for the data exchange are stated in the following: From the evaluation unit 24 , a software download/upload is carried out for the thread cleaner 43 as a downlink through this communication structure to the thread cleaner 43 . Or, in a batch, i.e., a party-exchange at the spinning machine 10 , (that is, upon the alteration of the quality or the kind of thread to be produced by the spinning station) new adjustment parameters for thread cleaning are transmitted in the downlink from the quality evaluator to the thread cleaner 43 .
In the case of the embodiment presented here, each thread cleaner 43 possesses its own integral evaluation processor along with a communication processor, so that the thread quality, which has been captured in analog form by means of the sensor component of the thread cleaner 43 , is converted to digital values and subjected to a preliminary evaluation. The preliminary evaluation embraces, among other things, a classification of the measured thread value, as this is generally known, the determination of thread faults, and if a thread break need be carried out. These quality values, i.e., control data, are then transmitted from uplink through the communication structure from the thread cleaner 43 to the central evaluation unit 24 . If, beyond this, for instance at the spinning station 41 a the thread quality requires an artificial thread break, then from the thread cleaner 43 a corresponding control demand is made over the communication line 64 a , the bus 45 , the cleaning section unit 44 , the communication connection 63 ′, the section bus 40 to the section electronic device 41 a (or through the alternate path of the section controller 31 a in case of the connection 63 ). The completion of this message then releases by control means of the feed of the fiber band (stop demand) an artificial thread break. At the same time, of course this information is further forwarded to the evaluation unit 24 for the statistical evaluation.
The central quality evaluation unit 24 then produces statistic data from the input of quality and/or control data. For example, it calculates average or absolute quality schemata in the form of the known quality matrices, this is either concerning a single spinning station 41 a-d , sectionwise 33 a-d or is valid for all spinning stations of the spinning machine 10 . Along with this, it is also possible that spectrograms, CV-values and the like can also be determined with reference to spinning stations, sections of spinning stations. This form of the communication and evaluation is also valid, especially for the further embodiments.
FIG. 2 demonstrates a communication structure according to a second embodiment This represents partially, that of FIG. 1 , with the difference, that in this case the electrical current feed to the individual section electronic devices 42 and the thread cleaners 43 is additionally shown and the communication between the thread cleaners 43 ′ and the cleaner section unit 44 ′ deviates from that of FIG. 1 . The supply of current, however, is applicable to the structure of FIG. 1 .
In this case, the thread cleaners 43 ′ stand individually communicatively connected through connections 65 a-d in star-shaped arrangement with cleaner section unit 44 ′. The thread cleaners 43 ′ could be designed in accord with the thread cleaners 43 , wherein the communication over connection 65 a-d would be carried out in a digital exchange. Advantageously, however, the thread cleaners 43 ′ are analog sensor heads and by the communication connection 65 a-d , principally control-potentials are applied from the cleaning section unit 44 ′ onto the thread cleaners 43 ′, and conversely, by means of the communication connection 65 a-d analog values of the thread cleaner are transmitted to the cleaner section unit 44 ′. In this case, the thread cleaners operate as sensor heads without themselves processing the measured values. The necessary evaluation is then accomplished by the cleaner section unit 44 ′, so that from that source, corresponding control data and quality data for each spinning station 41 a-d are made available. The transmission from the cleaner section unit 44 , for example, to the central evaluation unit 24 is executed analogously to the path described for FIG. 1 , and likewise, the downlinks from the evaluation unit 24 to the cleaner section unit 44 ′. In this case the adjustments, that is, software updates, are not undertaken in the thread cleaners 43 ′, but rather in the cleaner section unit 44 ′.
Further, in FIG. 2 a current supply structure is presented. The voltage supply runs from one central current supply unit 70 through cable 71 , parallel to the machine bus 25 , and from cable 71 through the branches 72 to the section controllers 3 a-d.
In this way, the current supply unit 70 can make available a plurality of supply potentials (for instance, 24 volt, 50 volts or 12 volts) by means of the cable 71 , or principally produce only one supply potential, namely 24 volts. In each section controller 31 a-d,s there is provided a terminal for energy supply. Further, the branches 72 are extended to a distributor cable 73 , which also runs parallel to the section bus 40 . From the distributor cable 73 run again branches 74 to each spinning station electronic 42 , which then supplies the sensors and actuators with voltage. Further a line 75 branches off of the distributor cable 73 which delivers potential to the tread cleaner section unit 4 4 ′. Up to now, the corresponding structure is interchangeable with that of FIG. 1 . Power lines 76 , in star connection, run from the cleaner section unit 44 ′ parallel to the communication connections 65 a-d and supply the thread cleaners 43 ′. Parallel, in the sense of the description is to be interpreted as not necessarily physically parallel, but rather parallel in relation to the communication structure. From the state of the construction, of the spinning machine, however, a physical parallel lay of the lines is also of merit, since then energy supply and communication lines can be bundled together.
In a further embodiment, it is possible that instead of the lines 76 , even branching can be carried out by the extension of the spinning station electronic 42 to the thread cleaners 43 .
FIG. 3 shows a third embodiment of the communication structure, with a further layout design of the current supply system. In deviation from FIG. 1 , in this case omissions included the connections 63 and/or 63 ′, the cleaning section unit 44 and the cleaner bus 45 . Instead of the communication ties 64 a-d to the cleaner bus 45 , in this case the thread cleaner is connected directly to the section bus 40 by means of the communication tie 66 a-d . Similar to the case of the first embodiment, the thread cleaner 67 includes here an evaluator electronic system, with which, possibly, analog measurement data are converted to digital measurement data and is then subjected to a preliminary evaluation. This data is then transmitted through a communication apparatus in the measuring head through the communication connection 66 a-d to the section bus 40 . Data and control data are then available from this bus 40 .
In the case of the power distribution structure of FIG. 3 , the thread cleaners 67 are connected to the distributor 73 by tie lines 78 . Such a structure can also be provided which corresponds to the structures of FIG. 1 and FIG. 2 .
It should be appreciated by those skilled in the art that modifications and variations can be made to the embodiments described herein without departing from the scope and spirit of the invention as set forth in the claims and their equivalents.
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The invention concerns a textile machine ( 10 ) with a multiplicity of workstations ( 41 a-d ), one electronic device ( 42 ) per workstation, a central machine control ( 20, 22 ), a machine bus ( 25 ) for communication between the machine control and each or possibly a group ( 30 a-d ) of electronic device(s) and a sensor apparatus ( 43 ) for each workstation. A central evaluation unit ( 24 ) is provided for the assessment of sensor data from the sensor apparatuses ( 44 ), whereby the sensor data embraces continually measured characteristic values and/or the quality or signal data derived therefrom. The central evaluation unit ( 24 ) is connected by means of a first communication connection ( 23, 23 ′) with the machine control ( 20, 22 ) or so connected by the machine bus ( 25 ). The sensor apparatuses ( 43 ) are connected with the evaluation unit ( 24 ) through a second communication connection ( 23, 25, 31 a , 40, 44, 45 ) and the second communication connection embraces at least the machine bus ( 25 ) and the first communication connection ( 23, 23 ′). A procedure for the transmission of sensor data in the case of a textile machine provides the transmission of the data from sensor apparatuses ( 43 ) to a central evaluation unit ( 24 ) at least by interconnected pathways and through a machine bus ( 25 ) of the textile machine ( 10 ).
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an apparatus for the adjustment of the stroke or lift of a valve actuated by a camshaft.
[0002] Apparatus for the adjustment of the stroke of charge changing valves of internal combustion engines offer great advantages for numerous applications. For example, by reducing the stroke in the partial throttle range the mixture preparation can be improved, thereby reducing consumption and the content of noxious material in the exhaust gas.
[0003] An apparatus of this type is know from U.S. Pat. No. 4,203,397. With this apparatus, the entire U-shaped outer lever is supported on a hydraulic play-compensating element. The inner lever is mounted at the free end of the arms of the outer lever. A blocking device for blocking the pivotability of the inner lever relative to the outer lever is provided with a pivot element that is mounted on the arms of the outer lever adjacent to the free end region of the inner lever; by means of a stationary electro magnet, the pivot element is pivotable into the path of movement of the inner lever, thereby blocking the pivotability of the inner lever relative to the outer lever. The camshaft has a full stroke cam that cooperates with a contact surface of the inner lever, and partial stroke cams that are disposed on both sides of the full stroke cam and cooperate with contact surfaces of the outer lever. The construction of the blocking mechanism is relatively complicated. Furthermore, the outer lever is a relatively complicated, space-consuming and heavy component due to its support upon the valve play-compensating element and the mounting not only of the inner lever but also of the blocking element on the outer lever.
[0004] U.S. Pat. No. 5,544,626 discloses a valve disengagement device that has a two-part valve lever, whereby an outer lever has an overall U-shaped configuration and is supported via its crosspiece on a hydraulic valve play-compensating element. Mounted on the ends of the arms of the U is an inner lever that carries a roller for contacting a cam of the camshaft. The free end of the inner lever can be interlocked on the crosspiece of the outer lever in that a pin, which is movably guided in the crosspiece of the outer lever, is moved into a recess formed on the inner lever by means of hydraulic fluid pressure that acts from the hydraulic valve play-compensating element. When the blocking device is arrested, the valve lever acts like a one-part lever that transfers the cam stroke to the valve. When the blocking device is released, the inner lever extends into the outer lever, so that the valve is not actuated.
[0005] U.S. Pat. No. 5,655,488 describes an apparatus for the adjustment of the stroke of a valve, which is actuated by a camshaft, via an inner lever that is mounted within an outer lever in the region of the support of the outer lever against a component that is secured to the engine. By means of a blocking device, which displaces a blocking component disposed on that end of the outer lever that is on the valve side, the pivotability of the inner lever relative to the outer lever can be blocked.
[0006] It is an object of the present invention to provide an apparatus for the adjustment of the stroke of a valve that is actuated by a camshaft, wherein the apparatus has a straightforward construction and requires little installation space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] This object, and other objects and advantages of the present invention, will appear more clearly from the following specification in conjunction with the accompanying schematic drawings, in which:
[0008] [0008]FIG. 1 is a perspective, exploded view of one exemplary embodiment of an inventive apparatus;
[0009] [0009]FIG. 2 is a perspective view of the inventive apparatus;
[0010] [0010]FIG. 3 is an exploded, perspective view of components of the inventive apparatus;
[0011] [0011]FIG. 4 shows valve stroke curves that can be realized with the inventive apparatus;
[0012] [0012]FIG. 5 is a perspective view, similar to that of FIG. 1, of a modified embodiment of a an inventive apparatus;
[0013] [0013]FIG. 6 is a partial side view of the apparatus of FIG. 5;
[0014] [0014]FIGS. 7 & 8 are partial side views of the apparatus of FIG. 5 in different operating positions; and
[0015] [0015]FIG. 9 shows valve stroke curves that can be achieved with the embodiment of FIG. 5
SUMMARY OF THE INVENTION
[0016] The apparatus of the present invention comprises a valve lever that includes an outer lever and an inner lever and has a first end region that is supported on a fixed component, and a second end region for actuating a valve, wherein the outer lever has an overall U-shaped configuration including two arms and a crosspiece that interconnects the arms and faces the fixed component, wherein at least one of the arms is provided with an abutment surface for contacting the cam or cams of the camshaft, wherein the inner lever is mounted on a free end of the outer lever between the arms thereof, wherein the inner lever has an abutment surface for contacting the cam or cams, and wherein the abutment surface is disposed between the axis of the mounting of the inner lever on the arms of the outer lever and the support of the first end region of the valve lever on the fixed component; and a blocking device for fixing the crosspiece of the lever on an end of the inner lever that is remote from the valve, wherein such end is supported on the fixed component and contains the blocking device.
[0017] Due to the fact that the free end of the inner lever is supported on the fixed component, the inner lever can essentially be designed like a conventional valve lever for valves that have no stroke adjustment device. The outer lever can be produced as a simple sheet metal part that spans the inner lever and is mounted on that end of the inner lever that is on the side of the valve.
[0018] The apparatus of the present invention can be utilized anywhere where it is advantageous to vary the stroke of a valve that is controlled by a camshaft via a valve lever. The present invention is particularly advantageous for use with intake valves of reciprocating piston internal combustion engines.
[0019] Further specific features of the present invention will be described in detail subsequently.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] Referring now to the drawings in detail, pursuant to FIG. 1 an inventive apparatus for the adjustment of the stroke of a valve that is actuated by a camshaft has a valve lever that is composed of an inner lever 4 and an outer lever 6 .
[0021] The inner lever 4 , when viewed in plan, has an overall U-shaped configuration and contains two curved arms 8 and 10 , which are connected via a crosspiece 12 . The arms 8 and 10 have two pairs of holes 14 and 16 that are disposed across from one another, whereby a pin 18 can be inserted into the pair of holes 14 ; this pin 18 is provided with a flat portion 20 for resting against a valve shaft that is not illustrated in FIG. 1. In the installed state, the pin 18 projects laterally out of the arms 8 and 10 .
[0022] A pin 22 can be inserted into the pair of holes 16 for the mounting of a cam roller 24 that can be inserted between the arms 8 and 10 .
[0023] The crosspiece 12 has a body 26 that contains a blind hole 28 into which can be inserted a piston 32 that has a shaft 30 . A threaded ring 34 can be screwed into the blind hole 28 whereby a spring 36 is provided that surrounds the shaft 30 and is supported between the piston 32 and the threaded ring 34 .
[0024] The front ends of arms 38 and 40 of the on the whole U-shaped outer lever 6 can, via a pair of holes 42 , be mounted on the ends of the pin 18 that projects laterally out of the arms 8 and 10 of the inner lever 4 . The arms 38 and 40 can be provided with further holes in order to save weight. Provided in the crosspiece 44 of the outer lever 6 is a hole 46 into which the shaft 30 of the piston 32 can be inserted in the assembled state of the inner lever 4 and outer lever 6 . The upper sides of the arms 38 and 40 are formed with abutment surfaces 48 and 50 . The outer lever 6 can be embodied as a simple sheet metal part that has been bent in a U-shaped manner, whereby the upper sides of the arms 38 and 40 are bent away to form the abutment surfaces 48 and 50 .
[0025] In the assembled state, springs 52 , which are disposed on both sides of the body 26 , are supported between the crosspiece 44 of the outer lever 6 and the crosspiece 12 of the inner lever 4 . The springs 52 have the tendency to cock the outer lever 6 relative to the inner lever 4 in a clockwise direction in FIG. 1.
[0026] The camshaft 54 , which is disposed axially parallel to the pin 22 , has a partial stroke cam 56 and full stroke cams 58 that are disposed on both sides of the partial stroke cam 56 . In the installed state, the partial stroke cam 56 is contacted by the cam roller 24 , and the full stroke cams 58 are contacted by the abutment surfaces 48 and 50 . The base circles of the cams can have different diameters. The geometrical coordination is preferably such that the cam roller 24 rests against the pertaining cam base circle when the valve is closed, thereby reducing the friction.
[0027] The assembly of the inventive apparatus can also be seen with reference to FIGS. 2 and 3. The cam roller 24 is disposed in the inner lever 4 and is mounted by means of the pin 22 . The piston 32 is disposed in the blind hole 28 . The spring 36 is placed upon the shaft 30 , and the threaded ring 34 is screwed into the blind hole 28 . The outer lever 6 is shoved over the inner lever 4 and is secured, so that it can tilt or cock, by inserting the pin 18 into the pair of holes 42 and 14 on the outer lever 6 and inner lever 4 respectively.
[0028] Subsequently, the lever assembly is placed via the underside of the crosspiece 12 upon the hydraulic play-compensating element 60 that is secured to the engine housing, and is placed via the flat portion 20 of the pin 18 upon the stem of a valve 62 , and the camshaft 54 is installed. Toward the top, the hydraulic play-compensating element 60 is provided with a non-illustrated opening that is aligned with a non-illustrated opening disposed on the underside of the body 26 and communicating via a duct with that end of the blind hole 28 that is disposed on the valve side, so that a pressure chamber is formed between the piston 32 and the base of the blind hole 28 . This pressure chamber can be supplied with a lot or little pressure by controlling the pressure that is supplied to the hydraulic play-compensating element and that can be varied via a non-illustrated control device that cooperates with hydraulic valves. When a lot of pressure is supplied to the pressure chamber, the piston moves toward the left in FIG. 1, so that the shaft 30 moves to the outside accompanied by compression of the springs 36 via the threaded ring 34 , and when aligned with the hole 46 and the crosspiece 44 of the outer lever 6 penetrates into the hole and blocks the ability of the outer lever 6 to cock relative to the inner lever 4 .
[0029] The inventive apparatus functions as follows. One first assumes that the pressure chamber is supplied with high pressure, thereby blocking the ability of the outer lever to pivot or cock relative to the inner lever. The base circle of the cam 56 , at an appropriate dimensioning of the cam roller 24 and its arrangement relative to the abutment surfaces 48 , then rests against the cam roller 24 , which leads to a low frictional loss. If the camshaft 54 is rotated further, the full stroke cams 58 project beyond the partial stroke cam 56 and come to rest against the abutment surfaces 48 and 50 of the outer lever, which is locked with the inner lever, so that in conformity with the full stroke cams 58 the valve 62 is opened and a movement is carried out in conformity with the curve labeled “large valve stroke” in FIG. 4.
[0030] If, in conformity with operating parameters of the internal combustion engine, a switch is to be made from a large valve stroke to a small valve stroke, the pressure in the play-compensating element 60 is reduced, at least while the base circle of the cam passes over the valve lever, so that the shaft 30 is moved out of the hole 46 by the force of the spring 36 , and the outer lever can again pivot relative to the inner layer. If, upon further rotation of the camshaft 54 , the full stroke cams 58 now pass over the abutment surface 48 , the outer lever is pivoted or cocked relative to the inner lever in a counter clockwise direction in FIG. 1, so that the cam roller 24 remains in contact against the partial stroke cam 56 and the valve is opened in conformity with such partial stroke cam. The curve indicated by dashed lines in FIG. 4 indicates the opening of the valve via the partial stroke cam 56 .
[0031] The inventive apparatus that has been describesd is extraordinarily compact and, as a result of the very space-saving configuration of the outer lever 6 , requires hardly any additional space relative to a conventional cam drive having a one-piece lever. Furthermore, the inventive apparatus is convenient to assemble and is cost efficient. Installation space required for the inner lever 4 corresponds to that of a conventional valve lever. The blocking device integrated into the body 26 requires no additional installation space toward the outside relative to the side facing away from the valve, so that in the direction of the connecting line between valve and mounting of the inner lever, additional space is required only for the thickness of the crosspiece 44 . The lever has a symmetrical configuration, so that the same components can be utilized for all valves, even for multi-valve engines. In addition, the arrangement is not exposed to lateral cocking forces.
[0032] The inventive apparatus can be modified in a number of ways. For example, the blocking device, which moves only minimally and as a result has little or no disadvantageous effect upon the speed integrity of the valve drive, can be disposed in the inner lever or in a stationary component, and can, for example, be formed by an electromagnet. In the case of the hydraulic actuation of the locking device, a supply of pressure thereto does not necessarily have to be effected by the hydraulic play-compensating element. The cam roller 24 is not mandatory. The inner lever can merely be provided with an abutment surface for the partial stroke cam 56 . The outer lever can also be formed with cam rollers.
[0033] [0033]FIG. 5 shows an embodiment of the inventive apparatus that is modified relative to the embodiment of FIG. 1.
[0034] With this embodiment, the camshaft 54 has only a single cam 64 that passes over the outer lever 6 and the inner lever 4 . Whereas the abutment surfaces 48 and 50 of the outer lever 6 of the embodiment of FIG. 1 are essentially planar or have a slight crown toward the cam shaft, the abutment surfaces 68 and 70 of the embodiment of FIG. 5 are provided with concave regions 72 and 74 , the contour of which corresponds approximately to the contour of the base circle of the cam 64 , in other words, has a radius R (see FIG. 6). The cam roller 24 that is mounted in the inner lever 4 is, in the interlocked state between the inner lever and the outer lever, positioned in such a way that its outer contour is approximately lined up with the location A (FIG. 6) at which the concave region 72 or 74 , viewed from the mounting location or hole 42 of the outer lever 6 , begins. The outer contour of the cam roller 24 can project slightly beyond the location A, thereby ensuring that the cam roller rests against the base circle of the cam.
[0035] The embodiment of FIGS. 5 and 6 functions as follows. One begins on the assumption that the outer lever and the inner lever are blocked relative to one another. The base circle of the camshaft passes over the concave regions 72 and 74 , or rests against the cam roller 24 that minimally extends beyond the introduction into the region (location A). If the cam lobe or elevation now comes into the region of the location A, the cam roller 24 will be pressed away from the axis of the camshaft by the cam lobe, so that the valve is opened somewhat (position shown in FIG. 7). Upon further rotation of the camshaft, the cam lobe becomes free of the cam roller 24 , yet remains in contact against the concave regions 72 and 74 , as a result of which the outer lever is increasingly pivoted together with the inner lever until the valve is completely opened when the position shown in FIG. 8 is reached where the cam 64 passes over the abutment surfaces 68 and 70 behind the end of the concave region 72 or 74 , in other words, the crown of the adjoining convex region. Subsequently, the outer lever and the inner lever are pressed into the closed position by the closure spring of the valve, while maintaining the contact against the cam, until the state shown in FIG. 6 is again reached.
[0036] The resulting valve stroke curve corresponds approximately to the curve II in FIG. 9.
[0037] If the outer lever 6 is pivotable relative to the inner lever 4 , only the cam roller 24 is pressed away during passing over of the cam, whereby the abutment of the cam against the abutment surfaces 68 or 70 effects no further opening of the valve after becoming free of the cam roller 24 , so that a valve stroke curve II pursuant to FIG. 9 results that in the starting phase is synchronized with the curve I.
[0038] If the direction of rotation of the camshaft 54 is opposite to that illustrated, according to which the cam moves from the location A close to the valve over the concave region 74 , there then results, as is readily obligatory, and with the outer lever uncoupled from the inner lever, the valve stroke curve III where the closing side coincides with that of curve I.
[0039] The embodiment of FIG. 5, in particular with regard to the installation space that is required, has the same advantages as does the embodiment of FIG. 1, yet requires a simpler camshaft than does the embodiment of FIG. 1.
[0040] A further modified embodiment of the inventive apparatus, which is not illustrated in detail, operates with a camshaft having only a single cam similar to the embodiment of FIG. 5, and an outer lever similar to that of the embodiment of FIG. 1. The cam roller 24 of this modified embodiment is, however, formed with a smaller diameter, or due to a different arrangement of the pair of holes 16 in the inner lever 4 is mounted in such a way that its outer surface is recessed relative to the abutment surfaces 68 and 70 . In this way, with the pivotability of the outer lever relative to the inner lever being blocked, the abutment surfaces of the outer lever are effective, so that the full stroke of the cam 64 is effective for actuation of the valve 62 . When the pivotability of the outer lever 6 relative to the inner lever 4 is released, the outer lever 6 is first pivoted by the cam 64 against the force of the springs 52 in a counter clockwise direction. Subsequently, the cam 64 comes to rest against the cam roller 24 and actuates the valve merely with a stroke that corresponds to the cam lobe minus the stroke that is used up until the cam 64 comes into contact against the cam roller 24 . So that the transition of the abutment of the cam 64 from the abutment surfaces of the outer lever to the cam roller is smooth or steady, also with this embodiment the abutment surfaces can have a slightly concave configuration.
[0041] It is to be understood that in particular the embodiment of FIG. 5 can also be embodied in such a way that the outer lever 6 is pivotably supported on the hydraulic play-compensating element or some other component, for example the cylinder head, the blocking device is disposed on the crosspiece 44 of the outer lever, and the inner lever is pivotable relative to the outer lever in a counter clockwise direction. The support of the springs 52 is correspondingly different so that the inner lever is pressed upwardly in a clockwise direction. The full stroke transmission is then effected via the inner lever. The partial stroke transmission is effected via the outer lever.
[0042] The specification incorporates by reference the disclosure of German priority document 102 20 904.9 filed May 10, 2002.
[0043] The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
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An apparatus for adjusting the stroke of a valve that is actuated by a camshaft having at least one cam is provided. A valve lever having an outer lever and an inner lever is provided and has a first end region supported on a fixed component, and a second end region for actuating a valve. The U-shaped outer lever includes two arms and a crosspiece that faces the fixed component. At least one of the arms is provided with an abutment surface for contacting the at least one cam. The inner lever is mounted on a free end of the outer lever between the arms, and has an abutment surface, for contacting cams, that is disposed between the mounting axis of the inner lever on the arms and the support of the first end region of the valve lever on the fixed component. A blocking device is provided for fixing the crosspiece of the outer lever on an end of the inner lever remote from the valve, this end being supported on the fixed component and containing the blocking device.
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TECHNICAL FIELD
The present invention relates to the field of medical aid devices. More particularly, the invention relates to a device for treatment of depression, anxiety and pain.
BACKGROUND ART
According to the World Health Organization, 121 million people worldwide suffer from depression, only 25% of whom have access to effective treatment.
The majority of patients are treated with medication, although about 60% of these patients are not helped by the medication. Approximately 29% of Americans suffer from anxiety at some point in their lives.
A further approximately 15% of patients suffering depression are helped with magnetic field and electroconvulsive therapy. A small percentage of people suffer from Seasonal Affective Disorder (SAD), and can be helped with light therapy.
Currently accepted medical treatments for depression include medication, psychotherapy, transcranial magnetic stimulation (TMS—therapy using magnetic fields); electroconvulsive therapy (ECT), and light treatment for SAD.
There is also scientific evidence to back up the use of alternative methods such as meditation and yoga, but there is no conclusive scientific evidence that proves any benefit from reflexology or acupuncture on such illnesses.
ECT and TMS are very expensive treatments, costing tens of thousands of dollars as an ambulatory care treatment using a technician and a doctor. Use of a light therapy device costs the patient US$100-400; it only helps 1-10% of the patient population; and it is only useful for seasonally affected patients.
In a patent search carried out by the Applicant in Google Patents, and other patent databases, no patent publication has been found that intends to solve depression and anxiety problems.
It is an object of the present invention to provide a solution for the abovementioned problems, and other problems of the prior art.
The present invention will help people who have no access to an effective treatment, as well as patients who are not helped by currently existing medications and treatments.
Other objects and advantages of the invention will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
A device ( 100 ) for the treatment of depression, anxiety and pain, the device comprising:
a plurality of adjacent dots ( 11 ) or other shapes, each comprising means for providing a signal being sensible by a touch sense, the signal comprising mechanical signal and/or electrical signal and/or temperature signal and/or magnetic signal; and a controller ( 32 ) for executing each of the means independently, for providing pre-programmed shapes ( 30 , 40 , 40 A, 40 B, 42 , 46 , 48 , 50 , 52 , 54 ) being sensible by the touch sense,
thereby allowing treating the depression, anxiety and pain by generating to the brain, signals resembling the pre-programmed shapes ( 30 , 40 , 40 A, 40 B, 42 , 46 , 48 , 50 , 52 , 54 ) through the signals being sensible by the touch sense.
The pre-programmed shapes ( 30 , 40 , 40 A, 40 B, 42 , 46 , 48 , 50 , 52 , 54 ) being sensible by the touch sense may comprise a procedure of increasing resolution of lines ( 40 , 40 A, 40 B, 42 ) or of other shapes,
thereby utilizing the touch sense for brain discrimination exercises, rather than brain discrimination exercises applied by meditation treatment.
The procedure of increasing resolution of lines ( 40 , 40 A, 40 B, 42 ) or of other shapes may comprise maintaining a constant number of lines.
The procedure of increasing resolution of lines ( 40 , 40 A, 40 B, 42 ) or of other shapes may comprise providing a single distance at each step.
The procedure of increasing resolution of lines ( 40 , 40 A, 40 B, 42 ) or of other shapes may comprise providing a plurality of distances at each step.
The pre-programmed shapes ( 30 , 40 , 40 A, 40 B, 42 , 46 , 48 , 50 , 52 , 54 ) being sensible by the touch sense may comprise a procedure of providing shapes ( 46 ) comprising empty segments ( 48 ) thereof,
thereby utilizing the touch sense for brain completion exercises.
The pre-programmed shapes ( 30 , 40 , 40 A, 40 B, 42 , 46 , 48 , 50 , 52 , 54 ) being sensible by the touch sense may comprise a procedure of
providing a line or shape ( 50 ),
then of providing a portion ( 52 ) of the line or shape ( 50 ), and
then of providing the said line or shape ( 54 ),
thereby utilizing the touch sense for producing an expectation, produced by the line or shape ( 50 ) and by the portion ( 52 ), and for producing a fulfillment of the expectation, produced by said line or shape ( 54 ) again.
The plurality of adjacent dots ( 11 ) or other shapes may comprise one or more groups ( 10 ) of shiftable and retractable pins ( 11 ), each of the pins ( 11 ) being substantially perpendicular to a surface on which the pins are disposed; and
the controller ( 32 ) is adapted for controlling the operation of shifting and retracting each of the pins ( 11 ) individually; and the device ( 100 ) may further comprise a computerized mechanism ( 34 ) for instructing the controller ( 32 ) to shift/retreat each of the pins individually, according to a script, being a group of timed instructions; thereby generating mechanical stimulation signal/pulse to a human organ, according to a script.
The device may further comprise a mechanism for heating the plurality of adjacent dots ( 11 ) or other shapes, for allowing the device to produce a heating pulse/signal.
The device may further comprise a mechanism for chilling the plurality of adjacent dots ( 11 ) or other shapes, for allowing the device to produce a chilling pulse/signal.
The device may further comprise a mechanism for electrifying the plurality of adjacent dots ( 11 ) or other shapes, for allowing the device to produce an electric pulse/signal.
The device may further comprise an electromagnetic mechanism, for magneticizing the plurality of adjacent dots ( 11 ) or other shapes, thereby allowing the device to produce a magnetic pulse/signal.
Each command of the script may define a form of the pulse/signal.
The form may be an intensity and/or duration and/or rhythm and/or a cycle.
Each of the dots ( 11 ) or other shapes may be heated individually.
All of the pins may be heated together by a heated liquid disposed around the pins when being in their retreated state.
Each of the pins may be chilled individually.
All of the pins may be chilled together by a chilling liquid disposed around the pins when being in their retreated state.
The surface may correspond to a surface of a human organ.
The human organ may constitute a palm and/or a foot and/or a sole, and/or a back, and/or a face.
The more sensitive a region of the human organ, the higher the density of the members of the group ( 10 ) of shiftable and retractable pins ( 11 ).
The pins may be shifted out in a geometric form.
The pins may be shifted in a partial geometric form, thereby allowing a patient's brain to complete the full form.
The members of the group ( 10 ) of shiftable and retractable pins ( 11 ) may be arranged in a matrix form.
The device may further comprise:
a first perforated plate ( 12 ) wherein the pins ( 11 ) are shiftable through the perforation; a second plate ( 14 ); a closed space ( 38 ) between the plates, filled with a liquid ( 42 ); and a heating/chilling body ( 40 ) disposed in the liquid ( 42 ), for heating/chilling the liquid ( 42 ), thereby heating/cooling all of the pins when dipped in the liquid.
The plurality of adjacent dots ( 11 ) or other shapes may comprise an electrical mask comprising a plurality of electrical outputting dots or of other shapes.
The reference numbers have been used to point out elements in the embodiments described and illustrated herein, in order to facilitate the understanding of the invention. They are meant to be merely illustrative, and not limiting. Also, the foregoing embodiments of the invention have been described and illustrated in conjunction with systems and methods thereof, which are meant to be merely illustrative, and not limiting.
BRIEF DESCRIPTION OF DRAWINGS
Preferred embodiments, features, aspects and advantages of the present invention are described herein in conjunction with the following drawings:
FIG. 1 pictorially illustrates a device for treatment of depression and anxiety, according to one embodiment of the invention.
FIG. 2 further details the pin matrix of FIG. 1 , by focusing the “magnifying glass” on pins of a matrix.
FIG. 2A . is similar to FIG. 2 , except that the shape of each pin is of a line.
FIG. 3 further details the pins matrix of FIG. 2 .
FIG. 3A depicts steps of a first procedure for applying the treatment.
FIG. 3B depicts a second procedure for applying the treatment.
FIG. 3C depicts a third procedure for applying the treatment.
FIG. 4 is a sectional view that illustrates the cross-section A-A defined in FIG. 1 . In FIG. 4 the pins are lifted up.
FIG. 5 is a sectional view that focuses on the electromechanical mechanism of shifting the pins.
FIG. 6 is a sectional view that focuses on the heating mechanism of the pins.
It should be understood that the drawings are not necessarily drawn to scale.
DESCRIPTION OF EMBODIMENTS
The present invention will be understood from the following detailed description of preferred embodiments (“best mode”), which are meant to be descriptive and not limiting. For the sake of brevity, some well-known features, methods, systems, procedures, components, circuits, and so on, are not described in detail.
The present invention is directed to a device for treating depression, anxiety and pain.
The term “synapse” refers herein to a structure that permits a neuron (or nerve cell) to pass an electrical or chemical signal to another neuron
The term “somato-sensory” refers herein to touch sense.
One of possible explanations for the development of depression is disturbance in the plasticity of the brain. The present invention is directed to improve the plasticity in synaptic activity of the brain, by transmitting touchable signals to the synapses.
Research studies in the field of neurobiology and clinical experiments have shown that by increasing somatosensory discrimination activity, it is possible to improve the condition of patients suffering from clinical depression and anxiety. This is supported also by initial clinical observations.
Through stimulation with special modulated signals to human organs such as foot sole, palm, and so on, the present invention gradually reduces the patient's nervous system's discrimination threshold.
By reducing the “noise” of sensoric and by using sensomotoric signals, a device thereof will improve the condition of patients suffering clinical depression and anxiety.
The technical innovation is introduced by activating a variable modality of generating pulses to sensitive parts of the patient's body. Such a device includes algorithms in the form of software files that will be stored to an electronic card as a result of tests conducted on the patient.
The terms “pulse” and “signal” refer herein to a time period of stimulation. For example, “an electric pulse” is an electric impact that takes a duration such as hundredths of a second, tenth of a second, etc, while “an electric signal” takes at least seconds.
The object is obtained by a device that generates stimulation signals/pulses on sensitive region(s) of the body of a patient, such as palms, hands, feet, soles, face, etc.
The stimulation signal can be controlled by a control system, which may be operated by computer software.
The stimulation signal can be in a form of mechanical force, electrical current, temperature (heat/cold), magnetic, and so on.
The stimulation signal may be sequential, intermittent, repeatable, non-repeatable, in a single pattern or a plurality of patterns, and so on.
According to one embodiment of the invention, the device is adapted to perform a plurality of stimulation signals simultaneously, such as electric pulse along with a heat pulse.
According to one embodiment of the invention, the stimulation device is adapted to incorporate a plurality of stimulation forms into the same device to stimulate the aforesaid sensitive areas of a patient's body.
The device may be designed as a mobile device, as well as a fixed device.
The device can be used by doctors, as well as a self-treatment device.
As a result of treatments with the stimulation device, an improvement may be seen in the condition of a patient suffering from depression, anxiety or pain.
According to one embodiment of the invention, the device uses a group of pins movable by a control system (which may be a computerized mechanism), wherein the end thereof is used as a stimulation terminal, such as means for producing a physical hit, a contact for generating electric pulse, a heating body for generating heat, and so on.
The group of movable pins may be ordered in a form of a matrix, i.e., a group of elements uniformly arranged in rows and columns, or in a different form, not necessarily with uniform dispersal. For example, in sensitive areas of a human body, the dispersal may be more condensed than in less sensitive areas of the human body.
According to one embodiment of the invention, the patient lies on a bed, with his lap flex by a bar that lifts them up. In this situation his feet are approached to the device (or the device is approached to the patient's foot soles. In the first stage, the device resets the pins by approaching each of the pins to the surface of the patient's foot sole. In this situation the stimulation takes place.
The stimulation may be in a form of a physical contact, electric current, magnetic field, heat/cold signal, through the pins, in different geometrical forms, intensities, resolutions, rhythms, repeatable, and so on, according to commands of a computerized command that runs algorithms thereof.
FIG. 1 pictorially illustrates a device for treatment of depression and anxiety, according to one embodiment of the invention.
The device, which is marked herein by reference numeral 100 , is adapted to stimulate the foot soles of a patient.
The device comprises a casing 16 , wherein at the top side thereof are disposed two panels 26 and 28 , correspondingly to human feet soles. In each panel is installed a matrix of movable pins, their movement being controlled by a control, as will be further detailed. The pins of the panels are depressed in order to allow placing thereon a human foot sole.
FIG. 1 also defines a cross-section A-A, the result of which is illustrated in FIG. 4 .
FIG. 2 further details the pin matrix of FIG. 1 , by focusing the “magnifying glass” on pins of a matrix.
In this example pins 11 are dispersed uniformly, but it should be noted that the pins arrangement may not be uniform as a result of treatment and/or technical considerations.
According to the embodiment of FIG. 2 , the shape of each pin 11 is of a dot.
FIG. 2A is similar to FIG. 2 , except that the shape of each pin is of a line.
According to another embodiment, the shape of each pin 11 may be a line or another shape.
In FIGS. 2 and 2A , all the illustrated pins 11 are elevated, but as will be described hereinafter, each of the pins 11 is movable and its state is changeable by a control system.
FIG. 3 further details the pins matrix of FIG. 2 .
The plurality of pins 11 may provide a plurality of pre-selected shapes. In the example of FIG. 3 , the plurality of pins 11 form a triangle 30 , which is generated by elevating the corresponding pins 11 , by a controlling mechanism thereof (not illustrated in this figure). Thus, each of pins 11 can be elevated and lowered by a control mechanism, according to commands from a computerized mechanism that runs algorithms thereof.
Triangle 30 may be generated by other means, rather than by mechanical means applied by pins 11 , such as by electrical means, for supplying electrical current to the skin, or temperature means for heating or cooling dots or other shapes on the skin. The electrical means may apply an electrical mask including a plurality of electrical outputting dots or of other shapes. The temperature means may apply a plurality of heat or cool outputting dots or other shapes.
In general, the patient must sense by somato-sensory thereof, pre-determined shapes produced as a function of time.
A pre-selected procedure is executed, for applying the treatment. One procedure is somato-sensory discrimination, for transmitting to the brain of the patient, through touchable signals, such as of physical, electrical, or temperature signals, discrimination of lines or dots or other shapes in various resolutions.
FIG. 3A depicts steps of a first procedure for applying the treatment.
The discrimination of lines or other shapes may be applied by increasing the resolution of the lines or of the shapes from step to step. According to one embodiment, the number of lines is constant along the steps, for example 1 or 2 or 3 or 4, and the resolution being constant at every step, increases from one step to the next step, as exemplified below
For example, at the first day (1.1.14) of treatment pins 11 within panel 28 may produce one line 40 or another shape, disposed at various locations of panel 28 . Line 40 is not permanently produced, but rather is produced and cancelled repeatedly, e.g., produced for 20 seconds, cancelled for 10 seconds, the produced for 20 seconds or for 18 seconds, etc.
At the second day (2.1.14) of the treatment, pins 11 within panel 28 may produce two lines 42 or another shape, disposed at various locations of panel 28 , wherein at the first step, the distance between lines 42 is 2.5 centimeters one from the other; at the second step, the distance between lines 42 is 2 centimeters one from the other; at the third step, the distance between lines 42 is 1.5 centimeters one from the other; and at the fourth step, the distance between lines 42 is 1 centimeters one from the other. Preferably, lines 42 are not permanently produced, but rather are produced and cancelled repeatedly.
At the third day (3.1.14) of the treatment, pins 11 within panel 28 may produce three lines 40 A or another shape, disposed at various locations of panel 28 , wherein at the first step, the distance between lines 40 A is 2.5 centimeters one from the other; at the second step, the distance between lines 40 A is 2 centimeters one from the other; at the third step, the distance between lines 40 A is 1.5 centimeters one from the other; and at the fourth step, the distance between lines 40 A is 1 centimeters one from the other. Preferably, lines 40 A are not permanently produced, but rather are produced and cancelled repeatedly.
At the fourth day (4.1.14) of the treatment, pins 11 within panel 28 may produce four lines 40 B or another shape, disposed at various locations of panel 28 , wherein at the first step, the distance between lines 40 B is 2.5 centimeters one from the other; at the second step, the distance between lines 40 B is 2 centimeters one from the other; at the third step, the distance between lines 40 B is 1.5 centimeters one from the other; and at the fourth step, the distance between lines 40 B is 1 centimeters one from the other. Preferably, lines 40 B are not permanently produced, but rather are produced and cancelled repeatedly.
According to one embodiment, the distance between the lines may be different within the same set of lines.
For example, at the fifth day (5.1.14) of the treatment, pins 11 within panel 28 may produce a set of five lines 40 C including from left to right the lines 40 C 1 , 40 C 2 , 40 C 4 , 40 C 4 and 4005 , or another shape, disposed at various locations of panel 28 , wherein at the first step, the distance between line 40 C 1 and 40 C 2 is 2.5 centimeters; the distance between line 40 C 2 and 40 C 3 is 2 centimeters; the distance between line 40 C 3 and 40 C 4 is 1.5 centimeters; and the distance between line 40 C 4 and 4005 is 1 centimeters.
At the second step, the distance between line 40 C 1 and 40 C 2 is 2 centimeters; the distance between line 40 C 2 and 40 C 3 is 1.6 centimeters; the distance between line 40 C 3 and 40 C 4 is 1.2 centimeters; and the distance between line 40 C 4 and 4005 is 0.8 centimeters;
And at the following steps, the distances decrease in relation to the previous step accordingly.
This signaling to the brain through the touchable signals, is applied for exercising brain discrimination in an improved manner, since it applies physical means, rather than brain discrimination exercises applied by pure cognitive affecting means applied by known meditation treatments.
FIG. 3B depicts a second procedure for applying the treatment.
According to another procedure of treatment, for being applied by device 100 , device 100 produces shapes, for being completed by the brain. For example, the shape for being completed by the brain may constitute a triangle 46 or a rectangle 46 , each having an empty segment 48 . Empty segment 48 is produced for being completed by the brain.
FIG. 3C depicts a third procedure for applying the treatment.
According to another procedure of treatment, for being applied by device 100 , device 100 produces expectations for being fulfilled. The embodiment includes producing sequenced shapes, for producing expectations, and for being later completed by device 100 .
For example, at the first step, device 100 produces a line 50 ; at the second step, device 100 produces one or more dots or other segments 52 being a portion of line 50 . The patient expects the remainder of line 50 . Then device 100 fulfils, at the third step, the expectation by producing a line 54 being similar to line 50 .
Preferably, the shapes produced by device 100 are not permanently produced, but rather are produced and cancelled repeatedly.
A physical hit can be generated by elevating a pin, and then immediately retreating to its lowered state.
The pins may provide a plurality of stimulation forms. For example, the pin which is designed to generate a physical hit may also comprise a heating body which heats the pin. As a result, the pin not only hits the sole, but also provides a heat pulse.
A pin may also generate an electrical current. Thus, each pin may be used for generating a pulse of: physical, electrical, and temperature nature, in combination or not.
FIG. 4 is a sectional view that illustrates the cross-section A-A defined in FIG. 1 . In
FIG. 4 the pins are lifted up.
FIG. 5 is a sectional view that focuses on the electromechanical mechanism of shifting the pins.
FIG. 5 illustrates two pins, the left one being lowered down, and the right one lifted up. Reference numeral 36 denotes a hole of the perforation of plate 12 , from which the pin thereof has been “removed”.
As mentioned, reference numeral 12 denotes a perforated plate. Each of the holes 36 of the perforated plate is a conduit used for passing therethrough a pin 11 . It should be noted that each of the pins is perpendicularly shiftable to the surface of the panel at the pin's location.
Reference numeral 14 denotes a lower plate (in the figure's orientation). Reference numeral 20 denotes an upper electromagnet and reference numeral 22 denotes a lower electromagnet (in the figure's orientation). Reference numeral 24 denotes a ferric element, attached to pin 11 .
It should be noted that one of the electromagnets 20 or 22 may be replaced by a spring, thereby obtaining a simplified mechanism. When using a spring instead of an electromagnet, each pin has two states: an idle state, wherein the spring pushes the pin towards on of the plates 12 , 14 ; and an active state, where the pin is pulled to the opposite direction.
When the upper electromagnet 20 is activated, it pulls up the ferric element 24 , and therefore the pin is lifted up. When the lower electromagnet 22 is activated, it pulls down the ferric element 24 , and therefore the pin is lowered down.
As illustrated, the ferric element 24 is larger than the width of hole 36 , and therefore the perforated plate 12 limits the movement of pin 11 upwards. In addition, plate 14 limits the movement of the pin downwards.
It should be noted that in FIG. 5 , each of the pins has a tip in a conic form. This structure provides a tingle, which is a form of stimulation. Of course, the pin's tip may be dull.
Referring again to FIG. 4 , each of the electromagnets is controlled by a controller 32 . Thus, the controller is in charge of providing power to the upper electromagnet 20 and the lower electromagnet 22 of each of the pins.
The computerized mechanism 34 is in charge of instructing controller 32 to which electromagnet of the pins to provide power. The commands from the computerized mechanism to controller 32 , and therefrom to the pins of matrix 10 are transferred via a bus 18 .
The term “script” refers herein as to a group of timed instructions (to perform a physical operation by a machine).
The computerized mechanism may use scripts for activating the pins, and the stimulation thereof (heating, chilling, electrifying, etc.). For example, the triangle form 30 of the pins which is illustrated in FIG. 3 can “move” forth and back in a repeatable manner, while each of the pins is heated. Thus, the computerized mechanism “decides” when to lift up a pin, and when to lower a pin, and the controller is the mechanism that provides the power to the required electromagnets to perform the computerized mechanism's commands
While the term “controller” refers herein to a mechanism for carrying out a physical operations, the term “computerized mechanism” refers herein a group of instructions to the controller. A computerized mechanism may include a CPU and memory for executing a program (which is a group of commands stored in the memory). Of course, presently a computerized mechanism can be implemented merely by a circuitry.
Preferably, the computerized mechanism may comprise a user interface, by which a user (doctor, therapist, the patient, etc.) selects the stimulation treatment (script), sets parameters of the treatment (such as the duration, the intensity of the pulses, etc). Using the user interface, the user also may determine the script, may define new stimulation scripts, and so on.
Preferably, the surface form of each of plates 12 that forms each of the panels 26 and 28 should correspond to a human foot sole, and in general to a human organ to be stimulated. However, in order to facilitate the understanding of the invention, in the accompanying figures the plate 12 is flat.
A magnetic pulse/signal can be generated by an electromagnetic mechanism. An electric pulse/signal can be generated by a circuitry for this purpose, which presently is well known.
As per a magnetic pulse/signal, the device can be designed such that when a pin is lifted up, it closes a circuit which generates an electric/magnetic pulse/signal. Thus, the same mechanism that moves the pins may also be used for generating a physical hit, a heat/chill pulse/signal, and so on.
FIG. 6 is a sectional view that focuses on the heating mechanism of the pins.
According to this embodiment of the invention, the space 38 between the upper and lower plate can be filled with liquid 42 , which can be heated by a heating body 40 . As a result, when the pins are in their lower state, i.e., dipped in the heated liquid 42 , they are heated, and when they are lifted up, the heat is propagated to the human body at the contact points. This mechanism is simpler than heating each of the pins by its individual heating body. The same mechanism can be applied to chilling the pins.
In the figures and/or description herein, the following reference numerals (Reference Signs List) have been mentioned:
numeral 100 denotes a device for treatment of depression and anxiety, according to one embodiment of the invention; numeral 10 denotes a group of pins 11 ; numeral 11 denotes a movable pin, controllable by a controller 32 by a computerized mechanism 34 ; numeral 12 denotes a perforated plate; numeral 14 denotes a lower plate, which limits the movement of each of the pins downwards (in the figures' orientation); numeral 16 denotes a casing, wherein at the top side thereof are disposed two panels 26 and 28 , correspondingly to human feet soles; numeral 18 denotes a bus (a data communication channel) that passes commands from the computerized mechanism 34 , to the controller 32 ; numeral 20 denotes an upper electromagnet (in the figures' orientation); numeral 22 denotes a lower electromagnet (in the figures' orientation); numeral 24 denotes a ferric element; numeral 26 denotes a left panel, correspondingly to a human left foot sole; numeral 28 denotes a right panel, correspondingly to a human right foot sole; numeral 30 denotes a triangle form, generated from the pins 11 of matrix 10 ; numeral 32 denotes a controller; numeral 34 denotes a computerized mechanism (e.g., that includes a CPU and memory); numeral 36 denotes a hole in a perforation in plate 12 ; numeral 38 denotes a space between plate 12 and plate 14 ; numerals 40 , 40 A, 40 B, 40 C, and 42 denote lines or set of lines produced; numerals 40 C 1 , 40 C 2 , 40 C 3 , 40 C 4 and 4005 denote single lines within a set of lines produced; numeral 46 denotes a shape, such as a triangle or a rectangle or a circle, having an empty segment; numeral 48 denotes an empty segment of the produced line or shape; numeral 50 denotes a line or shape to be produced; numeral 52 denotes a dot or another segment of the line or the other produced shape; and numeral 54 denotes difference between two produced shapes.
The foregoing description and illustrations of the embodiments of the invention has been presented for the purposes of illustration. It is not intended to be exhaustive or to limit the invention to the above description in any form.
Any term that has been defined above and used in the claims, should to be interpreted according to this definition.
The reference numbers in the claims are not a part of the claims, but rather used for facilitating the reading thereof. These reference numbers should not be interpreted as limiting the claims in any form.
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A device ( 100 ) for the treatment of depression, anxiety and pain, the device comprising: a plurality of adjacent dots ( 11 ) or other shapes, each comprising means for providing a signal being sensible by a touch sense, the signal comprising mechanical signal and/or electrical signal and/or temperature signal and/or magnetic signal; and a controller ( 32 ) for executing each of the means independently, for providing pre-programmed shapes ( 30, 40, 40 A, 40 B, 42, 46, 48, 50, 52, 54 ) being sensible by the touch sense, thereby allowing treating the depression, anxiety and pain by generating to the brain, signals resembling the pre-programmed shapes ( 30, 40, 40 A, 40 B, 42, 46, 48, 50, 52, 54 ) through the signals being sensible by the touch sense.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to vessels used in applications requiring uniform fluid collection and distribution and more particularly relates to a toroidal vessel for use in such applications.
[0003] 2. State of the Art
[0004] Many processes, such as chromatography, ion exchange, adsorption bed processes and reactor vessel processes, require a uniform, homogenous contact of various fluids with a medium. The contact is usually accomplished in enclosed vessels, or cells, which have been filled with a bed of the needed medium. Since most of the applications require sharp fluid interfaces, the bed depth must be constant and this requirement results in vessels having flat tops and bottoms.
[0005] In most cases, the vessels operate with some degree of pressure. Most vessels are shaped cylindrically, with reinforced flat tops and bottoms, to easier hold the pressure. Flat tops and bottoms are often reinforced with curved pressure heads; this also has the disadvantage of increasing the difficulty of routing fluid conduits to the flat surface.
[0006] Prior solutions to balancing the need for uniform distribution and collection with a vessel built to withstand pressure have resulted in improved manifolds and vessels having many independent conduits and plenums for distribution and collection of the fluid. U.S. Pat Nos. 4,99,102 and 5,354,460, both of which are herein incorporated by reference, are examples of solutions that provide uniform plug-flow distribution over a wide flow range at a low-pressure drop. The present invention provides the possibility of simpler fluid transport designs utilizing the principles of these patents.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention provides a new design of vessel, allowing for a simpler distribution and collection system. In essence, the vessel body is constructed in the shape of a toroid. A toroid is formed by rotating a closed geometric shape around an axis in the same plane as the shape, but not intersecting the shape. The most common toroidal shape is a circle, creating a doughnut shape when rotated about the axis. The preferred shape for the present invention is a rectangular toroid, thus providing the flat bottoms and tops desired in many applications. A system is provided, wherein two plenums are located axially within the toroid, one for collection, one for distribution. Each plenum is connected to the toroidal vessel by a plurality of conduits extending radially therefrom and into the vessel, said conduits opening into the vessel and in open fluid communication with the plenums. Each plenum is also in open fluid communication with one other conduit, providing intake/outflow to/from the vessel.
[0008] The construction of a toroidal vessel allows for numerous advantages over the prior art. First, the distribution and collection manifolds may be located within the void formed by the toroid and both may be symmetrical due to their location. The symmetry provides greater uniformity to fluid flow with a simpler construction as all collection and distribution conduits are identical or at least have identical hydraulic paths. The inner wall of the toroidal body provides more support than compared to a cylindrical vessel, and the span for flat tops and bottoms is reduced, thereby reducing exponentially the bending moments caused by operating pressures. The construction also has a smaller lateral distance between the walls, thereby reducing internal volume as compared to a cylinder and correspondingly reducing material needed to fill the vessel. When using a rectangular toroid, the preferred embodiment, distribution conduits may be kept external to the body, providing unobstructed, flat internal surfaces. The void allows for easier access to internal manifold components, thus allowing for tighter arrangements of multiple vessels.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] [0009]FIG. 1 is a side elevation of the present invention, showing internal components in shadow.
[0010] [0010]FIG. 2 is a perspective view of half of the invention taken along a vertical cross-section, with arrows depicting fluid flow.
[0011] [0011]FIG. 3 is a vertical cross-section of the present invention.
[0012] [0012]FIG. 4 is a horizontal cross-section of the present invention.
[0013] [0013]FIG. 5 is a perspective section of the invention, focusing on an upper corner of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] With reference to the appended drawings, the improved vessel of the present invention will now be described. Specifically referring to FIGS. 1 and 2, the improved vessel body 1 is toroidal. Ideally this toroidal shape is based on a rectangle rotated about a rotational axis, said rectangle being in a same plane as, but not being intersected by, the axis. The toroidal shape incorporates the pressure containment advantages inherent with a cylindrical shape and allows collection and distribution systems to be located axially in the void within the toroid. This positioning allows for more efficient and uniform distribution and collection of fluids, as a single distribution plenum 3 and a single collection plenum 8 are required. Toroidal body 1 also has two circumferential walls 10 , 11 as opposed to one, as with a cylinder. The inner wall 11 provides additional support to the toroidal body 1 as compared to a cylinder.
[0015] The toroidal vessel allows for a centrally located collection/distribution system. One such system is shown in the appended figures. Referring to FIG. 2, an intake conduit 2 enters the void through inner and outer body walls 11 , 10 and makes a right-angled turn along the rotational axis of the toroidal body 1 . At a location approximate to the upper plane of the toroidal body 1 , conduit 2 interfaces distribution plenum 3 . Plenum 3 is located so that the plenum's normal axis is coaxial to the rotational axis of toroidal body 1 . Plenum 3 has a plurality of outlets, each connected to a distribution conduit 4 . Conduits 4 all have an identical hydraulic path and are symmetrical relative to the normal axis of the plenum 3 . Each distribution conduit interfaces the toroidal body 1 at a distribution element 5 . The distribution elements 5 , shown in FIG. 5 are all in a planar relation to the top of the toroidal body 1 . A collection system is similarly constructed and oppositely oriented, Shown in FIG. 4, with collection elements 6 planar with the bottom of the toroidal body 1 , a plurality of collection conduits 7 , a collection plenum 8 , and an outflow conduit 9 .
[0016] [0016]FIG. 3 depicts the flow of liquid through the improved system. Fluid enters the distribution manifold through intake conduit 2 and into distribution plenum 3 . From plenum 3 , fluid disperses through distribution conduits 4 and into toroidal body 1 via flat dispersion elements 5 . The symmetrical construction of this system provides uniform distribution of the fluid with a much simpler construction. Fluid passes down, through toroidal body 1 , interacting with a contained medium and is collected by collection elements 6 . Fluid then passes through the collection manifold in a manner similar to distribution.
[0017] The symmetrical distribution advantages afforded by the toroidal vessel design can be retrofitted within conventional cylindrical vessels by inserting an inner cylinder.
[0018] Though the disclosure presents a best mode for practicing the invention and an associated manifold system, it is to be understood that numerous variations may be made to the above-disclosed embodiment and still practice the present invention. It is, therefore to be understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description.
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The present invention is an improved vessel body for use in uniform plug-flow fluid applications, such as chromatography and adsorption bed processes. The improved vessel is toroidal shaped and allows for a simpler distribution and collection system, which is likewise claimed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a clothes washing machine which agitates the laundry by forward and reverse rotations of a pulsator.
2. Description of the Prior Art
As shown in FIG. 1, a conventional clothes washing machine includes a washing tub 20 fixedly disposed in a body 10 of the washing machine, a motor 30 arranged under the washing tub 20, and power transmission means 50 installed under a middle portion of the washing tub 20 which receives a drive power of the motor 30 through a belt 40 and then transmits it to a spin-drying tub 60 or a pulsator (agitator) 70.
The spin-drying tub 60 for spin-drying the laundry by way of centrifugal force generated by the motor 30 is mounted at the end of the power transmission means 50 within the washing tub 20. The pulsator 70 is rotatably disposed at an inner bottom of the spin-drying tub 60, and the pulsator 70 repeats forward and reverse rotations (i.e., oscillates) according to the power of the power transmission means 50. That oscillation disturbs a water current in the spin-drying tub 60, and simultaneously agitates the laundry thereby carrying out the washing.
As shown in FIG. 2, a plurality of vanes 73 radially protrude from an upper surface of the pulsator 70 at regular intervals with a central shaft 72 formed at a center of the pulsator 70 so as to disturb the water current and at the same time agitate the laundry during washing and rinsing steps.
In addition, water supply means 80 for supplying the washing water into the spin-drying tub 60 is disposed at a rear of the body 10 of the washing machine.
The washing tub 20 is provided at a bottom area thereof with drainage means 90 for draining out the washing water within the spin-drying tub 60.
As shown in FIG. 1, the water supply means 80 is provided at a bottom area thereof with detergent dissolution means 100 for dissolving detergent therein by supplied water and for supplying the dissolved detergent solution into the washing tub 20 and the spin-drying tub 60.
However, there is a problem in the conventional washing machine thus constructed, in that the plurality of vanes 73 produce a water current shown in FIG. 3 which causes the laundry to be entwined and entwisted when the pulsator 70 oscillates during the washing and rinsing steps.
The entwinement and entwistment of the laundry cause reduction of washing and rising efficiencies in the washing machine.
SUMMARY OF THE INVENTION
Accordingly, the present invention is disclosed to overcome the above-mentioned disadvantages, and it is an object of the present invention to provide an apparatus for injecting central water currents in a washing machine in which an axial flow fan oscillates and ejects a washing water upwards from a central area of a pulsator (agitator) by oscillation of a fan driving unit disposed between the lower surface of the pulsator and a bottom surface of a spin-drying tub during the oscillation of the pulsator, thereby dispersing the laundry, preventing the entwinement and entwistment of the laundry, and improving the washing and rising efficiencies.
In accordance with the object of the present invention, there is provided an apparatus for injecting central water currents in a washing machine, the apparatus comprising:
an axial flow fan disposed within a through hole of agitating means which oscillates along with the agitating means and forms water currents jetted toward a central upper portion of the agitating means; and
a fan driving unit disposed at one side of the lower surface of the agitating means which rotates the axial flow fan through a turning effect generated by friction with a bottom surface of a spin-drying tub according to rotation of the agitating means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view for illustrating a conventional washing machine;
FIG. 2 is a plan view for illustrating a pulsator of the conventional washing machine;
FIG. 3 is a schematic diagram for illustrating water currents formed by the pulsator of the conventional washing machine;
FIG. 4 is an exploded perspective view for illustrating central water current injection means and a pulsator according to a first embodiment of the present invention;
FIG. 5 is a top plan view (with filter removed) for showing the central water current injection means and the pulsator of FIG. 4;
FIG. 6 is a longitudinal sectional view for illustrating the central water current injection means and the pulsator of FIG. 4;
FIG. 7 is an enlarged sectional view of portion A in FIG. 6;
FIG. 8 is sectional view taken along line B--B of FIG. 7;
FIG. 9 is a fragmentary sectional view for illustrating a fan driving unit according to a second embodiment of the present invention;
FIG. 10 is a perspective view for illustrating a guide member according to the second embodiment of the present invention;
FIG. 11 is a sectional view taken along line C--C of FIG. 9; and
FIG. 12 is a schematic diagram for illustrating water currents formed by the central water current injection means according to the first and second embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first embodiment of the present invention will now be described in detail with reference to FIGS. 4 through 8. Throughout the drawings, like terms and reference numerals are used for designation of like or equivalent parts or portions as in FIGS. 1 through 3 and redundant references will be omitted for simplicity of illustration and explanation.
FIG. 4 shows a pulsator (agitator) 210 which creates disturbed water currents, and a central water current injection means 200 which disperses the laundry by a central jet water current when the pulsator 210 repeats forward and reverse rotations (i.e., oscillates) during the washing and rinsing steps so as to prevent the entwinement and entwistment of the laundry.
As shown in FIG.6 the central water current injection means 200 comprises an axial flow fan 220, disposed within the pulsator 210, which rotates (oscillates) simultaneously with the forward and reverse rotations (oscillation) of the pulsator 210 and forms water currents jetted toward a central upper portion of the pulsator 210 so as to prevent the entwinement and entwistment of the laundry. A fan driving unit 230 is disposed on one side of the lower surface of the pulsator 210, which rotates the axial flow fan 220 through a turning effect generated by friction with a bottom surface of a spin-drying tub 60 during the rotation of the pulsator 210.
A plurality of radial pulsator vanes 211 protrude upwardly from the upper surface of the pulsator 210 at regular intervals, and a through hole 212 formed at the center of the pulsator 210 allows the axial flow fan 220 to be installed and the water currents to be circulated. As shown in FIG.7, a support member 213 having an axial hole 213a for supporting the axial flow fan 220 is disposed within the through hole 212.
The axial flow fan 220 comprises a fan body 221 having a female screw 221a which is installed within the through hole 212 formed at the center of the pulsator 210, and a plurality of fan blades 222 protruding radially on the outer circumferential surface of the fan body 221 at regular intervals so as to form water currents jetted from the lower portion to the upper portion of the through hole 212 of the pulsator 210.
As shown in FIG. 8, the fan blades 222 have curved wedge-shaped cross sections.
As shown in FIGS. 4 and 6, the fan driving unit 230 includes an outer support member 240 and an inner support member 241, a roller member 250, and a connection member 260. The outer support member 240 and the inner support member 241 are attached at one side of the lower surface of the pulsator 210 at a predetermined interval by a plurality of fastening bolts 120, respectively. The roller member 250 is rotatably disposed between the outer support member 240 and the inner support member 241, so that the roller member 250 rotates simultaneously with the rotation of the pulsator 210 and rolls by means of friction against the bottom surface of the spin-drying tub 60. The connection member 260 connects the roller member 250 to the axial flow fan 220, and rotates flexibly according to the rotation of the roller member 250 at the same time, thereby rotating the axial flow fan 220 at a higher rotation speed than that of the pulsator 210.
A roller axle 251 is integrally protruding from the center of both sides of the roller member 250 and is rotatably inserted into symmetrical roller holes 242 formed in the outer and inner support members 240 and 241, and a plurality of embossments 252 are formed on the outer circumferential surface of the roller member 250 so as to increase friction with the bottom surface of the spin-drying tub 60.
The connection member 260 comprises a terminal connection axle 270 protruding from the bottom of the axial hole 213a formed at the center of the support member 213 and screwed into the female screw 221a formed in the fan body 221 of the axial flow fan 220. The member 260 also includes a connection shaft 280 the ends of which are connected respectively to the terminal connection axle 270 and the roller axle 251 of the roller member 250.
A male screw 271 is formed at the upper end of the terminal connection axle 270 and is screwed into the female screw 221a formed in the fan body 221 of the axial flow fan 220. A protrusion 272 is formed on the outer circumferential surface of the lower portion of the terminal connection axle 270 so that the terminal connection axis 270 is not detached from the through hole 212 of the pulsator 210 when the axial flow fan 220 rotates.
The central connection shaft 280 can be made of an elastic steel, a stainless steel, or a plastic material, and the stainless steel is preferable in order to prevent the possibility of corrosion.
A filtering member 290 is disposed at the upper end of the through hole 212 of the pulsator 210 in order to remove any foreign particles included in the water currents and simultaneously to protect the axial flow fan 220 from any foreign particles and the laundry.
The operation and effect according to the first embodiment of the present invention will be hereinafter described in detail.
During a washing process, the laundry, detergent and washing water are inserted into the spin-drying tub 60. The washing shaft 51 and the pulsator 210 are rotated (oscillated) in the forward and reverse direction, and then the pulsator vanes 211 arranged radially on the upper surface of the pulsator 210 form water currents traveling upward then towards the center of the spin-drying tub 60 as shown by outside arrows of FIG. 12.
When the pulsator 210 rotates, the roller member 250 attached to the lower surface of the pulsator 210 rotates by means of friction with the bottom surface of the spin-drying tub 60. The rotation of the rolling member 250 rotates (oscillates) the axial flow fan 220 installed within the through hole 212 of the pulsator 210 in the forward and reverse directions through the connection member 260 connected to the roller axle 251. At this time, the axial flow fan 220 rotates forward and reverse at a higher speed than that of the pulsator 210.
The plural fan blades 222 arranged radially around the fan body 221 of the axial flow fan 220 form central water currents jetted from the central lower side to the upper side of the spin-drying tub 60 as shown by central arrows of FIG. 12, so that the laundry os dispersed by the collision with the water currents thereby preventing the entwinement and entwistment of the laundry.
At this time, the filtering member 290 disposed at the upper end of the through hole 212 of the pulsator 210 prevents the laundry and the foreign particles included in the washing water from flowing into the axial flow fan 220 through the through hole 212 during the washing and rinsing processes. The plural fan blades 222 of the axial flow fan 220 jets the washing water to the central upper portion powerfully, and the jet water currents collide against the laundry with force.
After the washing process is finished, the washing water is drained through a drainage means 90 connected to the bottom of the washing tub 20.
During the rinsing process, a valve of the drainage means 90 is closed and simultaneously a rinsing water is supplied into the washing tub 20 and spin-drying tub 60 by way of water supply means 80. At this time, the pulsator 210 and the axial flow fan 220 disturb the rinsing water by the same operation as the aforementioned washing process, thereby reducing the required rinsing time and the necessary amount of the rinsing water.
After the rinsing process is finished, the rinsing water is drained through drainage means 90 connected to the bottom of the washing tub 20.
During the spin-drying process, a spin-drying shaft (not shown) of power transmission means 50 rotates the spin-drying tub 60 at a high speed for several seconds consecutively, thereby removing the residual rinsing water in the laundry.
As described above, according to the first embodiment of the present invention, the dispersion of the laundry is increased, the entwinement and entwistment of the laundry is prevented, and the washing efficiency is improved.
The second embodiment of the present invention will now be described in detail with reference to FIGS. 9 through 11. Throughout the drawings, like terms and reference numerals are used for designation of like or equivalent parts or portions as in FIGS. 4 through 8 and redundant references will be omitted for simplicity of illustration and explanation.
In FIG. 9, reference numeral 300 is a fan driving unit disposed between the pulsator 210 and the spin-drying tub 60 which transmits a stable power to the axial flow fan 220 in a positive manner and minimizes noise.
As shown in FIG. 9, the fan driving unit 300 comprises a guide member 310 fixed to the bottom surface of the spin-drying tub 60 by means of a plurality of fastening bolts 120, and outer and inner support members 320 and 321 mounted vertically at one side of the lower surface of the pulsator 210 at a predetermined interval, a rotation member 330 joined by teeth to the guide member 310 and disposed rotatably between the outer support member 320 and the inner support member 321 so as to rotate along the guide member 310 and to move simultaneously according to the rotation of the pulsator 210. Elastic members 340 are installed within the outer and inner support members 320 and 321 which push the rotation member 330 by an elastic force so that the rotation member 330 can be stably joined to the guide member 310. A connection member 350 connects the rotation member 330 to the axial flow fan 220, and rotates flexibly according to the rotation of the rotation member 330 at the same time, thereby rotating the axial flow fan 220 at a higher rotation speed than that of the pulsator 210.
As shown in FIG. 10, the guide member 310 is a circular ring shaped rack 311 formed on the upper surface of the guide member 310 so that the rotation member 330 can be meshed with the rack 311, and a plurality of flanges 312 are integrally formed at predetermined positions on the outer circumferential surface of the guide member 310, so that plural fastening bolts 120 can be screwed through the flanges 312 into the bottom of the spin-drying tub 60.
The rotation member 330 includes a roller 331 having a roller axle 331a protruding from both sides thereof which is rotatably inserted into insertion holes 322 formed in the outer and inner support members 320 and 321, and a pinion 332 formed on the outer circumferential surface of the roller 331 which is meshed with the rack 311 of the guide member 310.
The pinion 332 and rack have an inclination relative to horizontal as shown in FIG. 9.
Contact portions of the rack 311 and the pinion 332 are coated with a friction reducing substance 360 made of polyester elastomer so as to minimize friction noise generated when the pinion 332 rotates along the rack 311.
Elastic members 340 are coiled compression springs which are inserted into the outer and inner support members 320 and 321.
The operation and effect according to the second embodiment of the present invention will be hereinafter described in detail.
Since the pinion 332 of the rotation member 330 is disposed rotatably in the outer and inner support members 320 and 321 of the fan driving unit 300 and is meshed with the rack 311 of the guide member 310 fixed on the bottom surface of the spin-drying tub 60, the pinion 332 rotates simultaneously according to the forward and reverse rotations of the pulsator 210.
Rotation of the pinion 332 causes the connection member 350 connected to one side of the pinion 332 to rotate, and then the connection member 350 rotates the axial flow fan 220 in forward and reverse directions at a higher speed than that of the pulsator 210.
At this time, the axial flow fan 229 forms central water currents jetted from the central lower side to the upper side of the spin-drying tub 60 as shown by the central arrows of FIG. 12, so that the laundry is dispersed by the collision with the water currents thereby preventing the entwinement and entwistment of the laundry.
Since the contact portions of the rack 311 and the pinion 332 are coated with the friction reducing substance 360, the friction noise can be minimized when the pinion 332 rotates along the rack 311.
Since the pinion 332 is rotatably inserted into the outer and the inner support members 320 and 321, and is stably meshed with the rack 311 by the elastic force of the elastic member 340 pushing the pinion 332, the pinion 332 will not run off the rack 311, and the rotation force of the pinion 332 is stably transmitted through the connection member 350 to the axial flow fan 220.
As described above, according to the second embodiment of the present invention, since the fan driving unit is installed between the pulsator and the spin-drying tub, and transmits the power through the rack and pinion in order that the pulsator and the axial flow fan can be rotated simultaneously during the washing and the rinsing processes, the power is stably transmitted to the axial flow fan and the friction noise can be minimized.
Having described specific present embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
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A clothes washing machine includes a spin-dry tub and an oscillatory agitator disposed at the bottom of the tub. The agitator includes a centrally located vertical hole in which an axial fan is mounted. A drive mechanism oscillates the axial fan relative to the agitator about a vertical axis to generate an upward water jet that disperses the laundry in a manner preventing entwinement and entanglement thereof. The driving mechanism comprises a roller mounted on an underside of the agitator. The roller engages the bottom of the tub and is oscillated by frictional contact therewith during oscillation of the agitator. Oscillation of the roller is transmitted to the axial fan by a flexible shaft.
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FIELD OF THE INVENTION
The present invention relates to telecommunication apparatus, and more particularly to techniques for dynamically controlling the amplification of communication signals to be transmitted by radio telephones in response to a measure of prevailing signal propagation conditions. The term "radio telephones" is used in its broad sense to include wireless two-way communication devices, including handheld, portable and mobile (i.e., vehicularly mounted) units.
BACKGROUND OF THE INVENTION
Known radio telephones have variable-gain power amplifiers for amplifying modulated radio-frequency ("RF") signals prior to transmission. The gains of the power amplifiers are typically controlled by automatic gain control ("AGC") circuits. Conventional AGC circuits operate dynamically to maintain the amplifier outputs within defined power output tolerances or ranges, and usually at or near nominal values (e.g., intermediate points) within those ranges. Various factors, including changes in ambient temperature and in power supply (e.g., battery) power level, can cause the amplifier output to vary from the targeted output power level. It is the job of the AGC circuits to correct for such variations.
For cellular telephony, generally recognized standards specify the nominal value and a range or tolerance for the amplifier output power. For instance, the Electronic Industries Association/ Telecommunications Industry Association Standard "Mobile Station-Land Station Compatibility Specification", EIA/TIA-553, September, 1989, Section 2.1.2.2. specifies that the power level must be maintained within a 6 dB range from +2 dB to -4 dB of its likewise-specified nominal level over the ambient temperature range of -30 degrees Celsius to +60 degrees Celsius and over the supply voltage range of ±10 percent from the nominal value. Thus, according to that specification, the amplifier output power must be controlled by the AGC circuit so as to fall within a 6 dB range about a nominal power level.
Conventional AGC circuits in such telephones typically target the nominal power level regardless, e.g., of the distance of the station that is to receive the transmitted signal or of other conditions which would otherwise suggest the transmission of stronger or weaker signals from the telephone.
In developing transmission signals of that power level, the transmitter's power amplifier itself consumes most of the dc power required by the radio telephone during audio or voice communication (called "talktime"). As radio telephones become increasingly self-powered, e.g., through the use of on-board, rechargeable storage batteries, its power needs have become an increasingly significant design consideration.
This comes into focus when one considers that, typically, the greater the power requirements of the power amplifier, the shorter the talktime on a single charge of the batteries in the telephone. If steps could be taken to reduce the power requirements by, e.g., reducing the output power of the transmitter amplifier, performance of the telephone could be improved.
SUMMARY OF THE INVENTION
Briefly, the present invention resides in using a signal ("RSSI") indicating the strength of received communication signals as a measure of prevailing transmission propagation conditions in controlling the gain of a power amplifier at the output of the transmitter of a radio telephone.
More specifically, a digital representation of an RSSI is derived from a received communication signal and provided to a central processing unit ("CPU") on-board the radio telephone, which uses the RSSI data in generating a digital control signal. The digital values of this control signal correspond generally to the amplitude, over time, of the RSSI, and, therefore, to prevailing propagation parameters. In addition, the digital values are selected to produce a transmitter output power level tailored to those prevailing propagation parameters. An AGC circuit converts this control signal into an appropriate analog AGC signal for controlling the gain of the RF power amplifier of the transmitter, whereby its output power level reflects the prevailing propagation parameters indicated by the RSSI.
The strength (i.e., field strength or energy) of communication signals over particular channels as indicated by RSSI varies due to terrain and cultural ( e.g., buildings) obstructions or impairments to signal propagation, and to distance between the radio telephone and the base station or cell site with which it is to communicate. The prevailing conditions are, of course, variable; for instance, as the radio telephone is moved, e.g., as an automobile carrying the telephone travels along, the conditions experienced by the telephone communication signal can change. Such prevailing conditions affecting the strength of communication signals as measured by the RSSI can be called signal propagation parameters.
Basic to the invention is the recognition that such an RSSI signal is indicative of signal propagation parameters not only for received signals, but also for transmitted signals. In other words, the transmission propagation parameters characterizing the path taken by the communication signals received by the radio telephone will be generally the same as those characterizing the path taken by the communication signals sent by the radio telephone, provided the communication signals are sent and received at about the same time and location.
Where conditions are favorable, the amplifier's gain can be reduced without deleterious effects on transmitted signals, and with a resulting reduction in the power drain on the radio telephone's power supply (e.g., batteries). In this way, talktime on a single battery charge can be significantly lengthened.
On the other hand, where conditions are adverse, e.g., at outlying or fringe areas of a cellular telephone system of which the radio telephone is a station, the gain can be increased to produce stronger transmitted signals, at times extending the effective coverage area of such systems.
Preferably, the output of the power amplifier remains at all times within a power range prescribed by applicable standards, and is increased or decreased within that power range in accordance with prevailing conditions. In this way, for example, the latitude afforded by the 6 dB range specified by the above-reference standards can be more effectively used by radio telephones embodying the present invention.
Instead of attempting to maintain the amplifier output power at some nominal level, e.g., at an intermediate point within the range, the AGC circuit in accordance with the invention preferably drives the output power to the lowest level within the specified range that provides an adequately strong communication signal in light of prevailing propagation conditions. An "adequately strong" communication signal from a radio telephone used within a cellular telephone system is one which can be received at the intended base station with sufficient strength so as to produce a received baseband signal with at least about a 14 dB signal-to-noise ratio.
Overall, the invention can enhance performance of radio telephones within the dictates of applicable standards, both temporally (due to extended battery life) and geographically (due to improved signal strength in outlying areas).
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned aspects, features and advantages of the invention, as well as others, are explained in the following description taken in connection with the accompanying drawings, wherein:
FIG. 1 is a block diagram of a radio telephone in accordance with a preferred embodiment of the invention;
FIG. 2 is a block diagram of the FM receiver and RSSI detector of FIG. 1;
FIG. 3 is a block diagram of the central processing unit of FIG. 1;
FIG. 4 is a block diagram of the power control circuit of FIG. 1;
FIG. 5 is an algorithm in flow chart form suitable for execution by the CPU of FIG. 3 in deriving RSSI-based digital control signals; and
FIG. 6 is a graph of the relationship between the power amplifier output power (dB relative to nominal) and RSSI (dBm) for an illustrative application of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 shows a radio telephone 10 in accordance with a preferred embodiment of the invention. The radio telephone 10 includes a user unit 12, a transceiver 14, a conventional antenna system 16, and a conventional regulated power supply, e.g., including batteries 18.
The user unit 12 provides a user/telephone interface, and includes a microphone 22 for converting sounds, e.g., messages spoken by a user or other audio data, into an electrical signal representing those sounds, called a "transmit audio signal." The user unit 12 also includes a speaker 24 for converting an electrical signal containing audio data, called a "receive audio signal," into sound, e.g., messages being communicated to the user. Where the user unit 12 is a handset, which is most often the case today, a mouthpiece (not shown) of the handset contains the microphone 22 and an earpiece thereof (not shown) contains the speaker 24. The user unit 12 typically includes also a keypad and display (not shown).
The transceiver 14 has a transmitter 26, a receiver 28, and a central processing unit ("CPU") 30 for controlling many of the operations of the transmitter 26 and receiver 28 (and for receiving and providing information to the user unit 12).
The transmitter 26 includes a signal processor 32 for processing (e.g., filtering and amplifying) audio signals from the microphone 22 and control signals from the CPU 30. The output of the signal processor 32 is called the "transmit baseband signal." This signal is fed to a modulator and converter 34. There, an RF carrier signal is, preferably, frequency modulated with the transmit baseband signal.
The transmitter 26 also includes a conventional, variable-gain, RF power amplifier 36 for boosting the power of the modulated RF signal from the modulator and converter 34. The power amplifier 36 receives the modulated RF signal at a signal input 36a thereof, and produces an amplified version of the signal at its output 36b. The amplified signal from the power amplifier 36 is fed to the antenna system 16.
The antenna system 16 includes both an antenna 38 and a duplexer 40 for full-duplex two-way conversations, i.e., for permitting the antenna 38 to be used both for transmitting the output from the power amplifier 36, and for receiving communication signals broadcast from base stations (not shown). The duplexer 40 includes a filter arrangement, which is not separately shown.
The receiver 28 has a conventional front-end converter and mixer 44 for converting the RF signal from the duplexer 40 into an intermediate-frequency ("IF") signal. The receiver 28 also has an FM receiver and RSSI detector 46, which both (i) extracts the received baseband signal from the RF signal, and (ii) produces an RSSI having a voltage amplitude that varies in response to the strength of the IF signal, and, thus, of the in-coming RF signal.
The received baseband signal is fed to a conventional signal processor 45. The signal processor 45 processes (e.g., filtering and amplifying) the received baseband signal, separating it into audio and control signals. The audio signals are provided to the speaker 24, and the control signals go to the CPU 30.
FIG. 2 shows the FM receiver and RSSI detector 46 in more detail. The chain of boxes across the top of the drawing together form an FM receiver 46a. An IF filter 52 filters the IF signal from the front-end converter and mixer 44 so as to reduce broadband noise, and thereby improve the signal-to-noise ratio. The IF filter 52 passes its output to an IF log amplifier 54. Next, an interstage filter 56 further eliminates noise from the IF signal for an even better signal-to-noise ratio, and passes its output to a limiter amplifier 58. The output of the limiter 58 is fed directly to a first input of a conventional quadrature detector 62. The output of the limiter amplifier 58 is also shifted by 90 degrees in a phase shifter 64, and thence is provided to a second input of the quadrature detector 62. The quadrature detector 62 performs demodulation, and its output is the received baseband signal.
The rest of FIG. 2 constitutes the RSSI detector 46b. Current sensors 66, 68 sense the magnitude of the dc current drawn respectively by the RF amplifier 54 and by the limiter amplifier 58 from the power supply 18. The amounts of current drawn by amplifiers 54, 58 correspond to the degree of amplification performed by them in obtaining respective pre-selected outputs, and, thus, depend on the strength of the signals received by the amplifiers 54, 58. It should be pointed out that the amplification performed by the amplifiers 54, 58 does not affect the content of the signal, since the signal is frequency modulated in the illustrated embodiment.
The RSSI detector 46b also has a current summer 72 and an RSSI amplifier 74. The current summer 72 sums the outputs of the current sensors 66, 68. The resulting signal has a current whose magnitude corresponds to that of the IF signal. The RSSI amplifier 74 converts this signal into an RSSI, that is, into a signal whose voltage level corresponds inversely to the magnitude of the IF signal, which, in turn, corresponds to the strength of the received RF signal.
In high signal-strength areas, e.g., close to transmitting antenna of base stations or cell sites, RSSI values typically are large (e.g., greater than about -60 dBm), while in outlying or fringe areas, e.g., far from transmission sources, RSSI values typically are low (e.g., less than about -100 dBm).
Conventional radio telephones often derive a signal indicative of the strength of received communication signals as well, and this signal is also sometimes referred to as a "received signal strength indicator" or "RSSI". Heretofore, however, the uses to which RSSI measurements have been put have been unduly limited. RSSI has long been used to provide the radio telephone user with a crude indication of received signal strength. More importantly, radio telephones used in cellular telephone systems contain RSSI circuitry for purposes of tuning to the strongest available channels. This is prescribed by applicable standards, such as the above-mentioned EIA/TIA 553, Sections 2.6.1.1.1., 2.6.1.2.1., and 2.6.3.2. The RSSI measurements specified by the standards provide a general indication of the strength of received communication signals for each available channel, and this indication is then used to select the appropriate channel, usually the strongest channel, for communication. Herein, a novel use for RSSI signals is proposed, as will be made clear in the following discussion.
With renewed reference to FIG. 1, the RSSI signal from the FM receiver and RSSI detector 46 is fed to an analog-to-digital converter ("A/D") 82. The A/D 82 converts the RSSI from an analog signal into a digital signal, whose digital values correspond to the amplitude of the analog RSSI signal. The A/D 82 passes the digitized RSSI to the CPU 30 for processing.
FIG. 3 shows the CPU 30 in more detail. The CPU 30 has a processor 84, a read-only memory ("ROM") 86 for storing, e.g., a telephone operating program, a non-volatile memory ("NVM") 88, for storing, e.g., various databases (described below) a universal asynchronous receiver/transmitter ("UART") interface 92 for communication with the keyboard and display unit of the user unit 12, input port 94 for receiving the RSSI from the A/D 82, output port 96, and a control bus 98 interconnecting all of the other CPU components, among other conventional components (not shown). The CPU 30 stores various data concerning the RSSI, and computes a digitized power control signal using the digitized RSSI from the A/D 82, as will be described shortly.
Again with reference to FIG. 1, the radio telephone 10 also has an automatic gain control circuit 100, as mentioned above, for controlling the gain of the power amplifier 36. In accordance with the invention, the AGC circuit 100 processes the digitized power control signal obtained from the output port 96 of the CPU 30 to derive an AGC signal. This AGC signal is applied to a control input 36c of the power amplifier 36 to regulate the gain of the power amplifier 36.
The AGC circuit 100 has a digital-to-analog converter ("D/A") 102 for converting the digital power control signal from the CPU 30 into an analog signal, whose voltage varies in accordance with the digital values of the digital power control signal. The AGC circuit 100 also has a power control circuit 104.
FIG. 4 is a schematic representation of the power control circuit 104. An RF power detector 106, e.g., a diode detector, receives a portion of the output of the power amplifier 36 as a power amplifier feedback signal, and provides a feedback voltage that is proportional to the power level of the power amplifier's output to a power control amplifier 108 at its first input 108a. The power control signal from the D/A 102 is provided to a second input 108b of the power control amplifier 108.
Amplifier 108 is adapted with a suitable feedback-capacitor arrangement C to integrate the difference between the signals on its inputs 108a, 108b, with a gain controlled by an RC network 110. The integration thus performed ensures that the AGC circuit 100 exhibits an appropriate dynamic response, i.e., that the AGC circuit 100 is not overly sensitive to transient conditions in the input signals to the power control amplifier 108. The output of the differential amplifier 108 is the AGC signal. A further understanding of the power control circuit 104 can be had with reference to U.S. Pat. No. 4,760,347, issued Jul. 26, 1988, and entitled "Controlled-Output Amplifier and Power Detector Therefore."
It should be apparent from the foregoing discussion that the power control signal plays a central role in the generation of the AGC signal. Accordingly, a further description of the method by which the power control signal is derived shall now be given.
FIG. 5 shows an algorithm 120 in flow chart form for deriving the power control signal based on the RSSI. When an enable signal is asserted by the CPU 30 over line 30a to the power amplifier 36 to indicate that the radio-telephone 10 is to transmit, algorithm 120 starts in block 122. In block 124, the algorithm 120 initializes variables, including RSSI SUM and RSSI AVERAGE. Next, the algorithm 120 enters into a do-loop 126 in which the RSSI is sampled repeatedly over a period of time sufficient to provide an adequate update, e.g., over a period of approximately 2.5 seconds, or sixty-two iterations of the loop 126.
In each iteration, the algorithm 120, a block 128, takes in plural (e.g., two) samplings of the RSSI signal from the A/D 82, preferably at fixed time intervals (e.g., at 20 msec. apart). The reason for taking the double sampling of the RSSI is to avoid an aberrationally low reading resulting, e.g., from temporary fading of the RF signal during its propagation to the radio telephone 10. Accordingly, the higher of the readings is selected for further processing, and, in block 130, is added to a running total, called RSSI SUM. Then, as indicated by block 132, the loop 126 is repeated (starting with block 128) until sixty- two iterations have been completed, at which time the loop 126 is exited.
Next, in block 134, the algorithm 120 calculates a time-averaged value, called RSSI AVERAGE, by dividing RSSI SUM by the number of iterations of the loop 26 (in the example, by 62). This further eliminates any false or short term fluctuations in the RSSI measurement.
Then, also in block 134, an RSSI calibration factor is added (or, e.g., otherwise applied) to the calculated RSSI AVERAGE to yield a calibrated or absolute RSSI value. The RSSI calibration factor is preferably stored in a calibration look-up table ("LUT") 88a in the NVM 88 of the CPU 30. The LUT 88a is a database in which calibration factors are stored in locations corresponding to measured RSSI values, and the channels or frequencies to which the receiver 28 (FIG. 1) can be tuned. Thus, the calibration factor is the entry corresponding to the particular measured RSSI value, and to the particular channel over which the communication signal that produced that value was received.
Calibration of the measured RSSI is required for various reasons. First, the RSSI value provided to the CPU 30 can have a transient component due to non-linearities in the frequency characteristics of the duplexer 40 (FIG. 1) and other components of the radio telephone 10. Thus, the measured RSSI's can vary from one channel to the next, despite identical strengths of the received signals on the various channels. Second, the measured RSSI will depend on the normally-otherwise-acceptable manufacturing tolerances of these components that cause their characteristics to vary from unit to unit. Third, the measured RSSI will depend on the selection of the output level of the IF and limiter amplifiers 54, 58 (FIG. 2), since that level dictates the level of currents drawn by amplifiers 54, 58 (FIG. 2), which currents are detected in deriving the RSSI. For all these reasons, RSSI calibration is appropriate.
After obtaining a calibrated RSSI AVERAGE, algorithm 120 calculates, in block 136, the power amplifier output desired for the prevailing conditions indicated by the absolute RSSI just calculated. This, too, can be achieved expeditiously using an appropriate look-up table 88b stored in NVM 88 (FIG. 2) in the CPU 30 (FIG. 1). The entries in the look-up table 88b establish an RSSI/output-power relationship.
FIG. 6 depicts graphically the inverse relationship between calibrated RSSI and the power amplifier output power for an illustrative cellular-telephone application. As can readily be seen, for this application, output power increases in steps as RSSI decreases.
Between a first threshold, e.g., about -100 dBm, and a second threshold, e.g., about -90 dBm, nominal output power can be used. For lower RSSI values, i.e., below the first threshold, higher output power can be used advantageously, that is, the output power can be raised above the nominal value. As depicted, for example, output power can be increased by 1 dB for each 10 dBm decrease in RSSI below the first threshold. For higher values of RSSI, i.e., above the second threshold, the output power can be lowered from nominal power. The graph shows output power being lowered by 1 dB for each 10 dBm increase in RSSI. Of course, the rates of increase in output power per drop in RSSI values below the first threshold and of decrease in output power per rise in RSSI values above the second threshold can be any desired amounts, and certainly need not be equal.
In other words, for RSSI values above the first threshold, the power amplifier can be controlled so as to render its output power lower than the nominal output power established by applicable standards and typically targeted by conventional AGC circuits. Consequently, the power amplifier consumes less power, and battery life is therefore extended significantly, depending on the type of telephone and prevailing conditions. Thus, for a given battery charge and under favorable conditions, a radio telephone in accordance with the invention can provide the user with significantly more talktime per battery charge.
In addition, for RSSI values below the second threshold, the power amplifier can be controlled so as to render its output power greater than the nominal value, thereby improving transmission strength when (and only when) such improvement is most needed, e.g., in fringe or outlying areas.
With reference again to FIG. 5, in block 138, the algorithm 120 obtains the power control voltage that would produce the desired output power (computed in block 136), e.g., again through the use of a suitable, stored look-up table 88c. The entries of the power-control-voltage/amplifier output-voltage look-up table 88c are preferably empirically derived to account for, and substantially eliminate, unit-to-unit variations in the responses of power amplifiers to control signals. In other words, each entry of the LUT 88c is the precise control signal needed to produce a specified output power in the power amplifier 36.
The entry of LUT 88c identified by the target output power is applied to D/A 102 as the power control voltage, and continues to be applied thereto until such time as a different power-control voltage is determined in block 138. Then, after step 138, the algorithm 120 returns to its starting block 122.
A suitable methodology for deriving the calibration look-up table 88a for RSSI values is as follows: An RF signal generator provides RF signals to an antenna port 40b (FIG. 1) of the duplexer 40 (FIG. 1). These signals are of known power levels, and of known and tunable frequencies. The radio telephone 10 (FIG. 1) treats each signal from the signal generator as it would a received communication signal, and derives the RSSI AVERAGE value for that signal, as described hereinabove. This derived RSSI AVERAGE value is compared with a known value corresponding to that RF signal, and the difference is stored as an entry in the look-up table 88a at a location corresponding to the frequency of the applied signal. Typically, it is necessary to sample RSSI at only a single received level provided by the RF signal generator for each of a plurality of frequency segments or bands. Preferably, RSSI calibration is performed at the radio telephone manufacturing facility.
The operation of radio telephone 10 will now be described. In accordance with the invention, when a communication signal is received over a voice channel, the FM receiver and RSSI detector 46 produces an RSSI signal to indicate the prevailing signal propagation conditions encountered by the received signal. A digitized version of the RSSI is supplied to the CPU 30 by receiver 28.
The CPU 30 samples this RSSI signal and derives an average value for the signal over a reasonably long period of time (e.g., 2.5 seconds). This average value is then calibrated to provide a truer indication of prevailing signal propagation conditions. To accomplish such calibration, the average RSSI value and the frequency of the received signal are used as pointers into the calibration table 88a. The resulting calibrated absolute RSSI value is used in deriving a desirable transmission power for the signal propagation conditions indicated by the RSSI. To do so, the absolute RSSI is used as a pointer into a further look-up table, 88b. The resulting target output power for the amplifier 36 is then used to obtain a suitable power control signal, which, when applied to the AGC circuit, will produce an output power from the amplifier 36 equal to the computed target output power. This can be accomplished by using the target output power value as a pointer into look-up table 88c. The entry so located is provided to the AGC circuit 100.
The AGC circuit 100 also receives a portion of the output of the power amplifier 36 as a feedback signal, and derives an AGC signal proportional to the difference between the power control signal and the power amplifier feedback signal. Completing a feedback loop, the AGC signal is applied to the control input 360 of the power amplifier 36 so as to control its gain, and drive the power level of its output toward the target power level computed by the CPU 30.
Preferably, the output of the power amplifier 36 remains at all times within a power range prescribed by applicable standards, and is increased or decreased within the power range by operation of the AGC circuit 100 in accordance with prevailing conditions indicated by the RSSI. The AGC circuit 100 preferably drives the output power to the lowest level within the specified range that provides an adequately strong communication signal in light of prevailing propagation conditions.
The foregoing description has been limited to a specific embodiment of this invention. It will be apparent, however, that variations and modifications may be made to the invention, with the attainment of some or all of the advantages of the invention. For example, for many applications, the look-up tables can be consolidated into a single table, which, when referenced by the average RSSI, will yield the digital power control signal for use by the AGC circuit 100. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the invention.
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A radio telephone uses a signal indicating the strength of received communication signals as a measure of prevailing signal propagation conditions to control the gain of a power amplifier in its transmitter. Where conditions are favorable, the gain can be reduced without deleterious effects on transmitted signals, and with a resulting savings in power drain on the radio telephone's power supply (e.g., batteries). In this way, talktime on a single battery charge can be significantly lengthened. Where conditions are adverse, e.g., at outlying or fringe areas of a cellular telephone system of which the radio telephone is a station, the gain can be increased to produce stronger transmitted signals, at times extending the effective coverage area of such systems. Preferably, the output of the power amplifier remains at all times within a power range prescribed by applicable standards, and is increased or decreased within the power range in accordance with prevailing conditions indicated by the received signal strength signal.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
This invention relates generally to multi-zone forced-air HVAC systems, and specifically to control methods for reducing conditioning and energy consumption.
2. Background Art
Most zone control systems for residential forced-air HVAC systems have a small number of zones in combination with HVAC equipment that has fixed capacity or variable capacity over a limited range or discrete steps of capacity. Simple zone control systems have a convention thermostat for each zone. Each zone has and airflow control damper that is opened or closed by signals from the thermostat for that zone. The calls for conditioning from each thermostat are combined using a logical OR function. The conditioning equipment runs when one or more thermostats make a call for conditioning. When a thermostat calls for conditioning, the damper for that zone is open. When the zone thermostat is not calling for conditioning, the damper for that zone is closed. Each zone operates independently without knowledge of the conditioning of the other zones.
One problem with simple zone control is that the amount of conditioned airflow needed depends on the number of zones calling for conditioning. For example, in a system with four equal zones, each zone might be capable of receiving only 25% of the total capacity. If the HVAC equipment has fixed capacity and only one zone calls for conditioning, 75% of the airflow is excess capacity. Various strategies are used in the prior art for dealing with this excess airflow capacity.
A simple strategy is to oversize the duct work to each zone so it can receive 100% of the airflow produced by the HVAC equipment. However, the extra ducting is expensive to install and requires space that may not be available. This is usually not practical for retrofit. In addition, when multiple zones call for conditioning, the airflow velocity to each zone is reduced, so the conditioned air may not mix properly with the unconditioned air in the zones. This may produce warm and cool areas within the zones.
Another strategy for managing the excess airflow is to use a controllable bypass duct to shunt supply airflow directly to the return airflow. The bypass typically opens automatically as the supply pressure increases, providing a path for some of the excess conditioned airflow. U.S. Pat. No. 5,249,596 issued Oct. 5, 1993 to Hickenlooper, III et al. describes a bypass damper for use in such zone control systems.
A significant problem with using a bypass is the return air becomes heated or cooled. When in heating mode, excessive bypass airflow can heat the return air temperature above 85°. This exceeds the recommend operating conditions for most residential HVAC equipment, voiding the manufacturer's warranty. When in cooling mode, excessive bypass can reduce the return air temperature sufficiently to freeze the evaporator coil. To prevent excessive return air temperatures in most HVAC systems, the maximum bypass airflow must be less than about 20% of the total conditioned airflow.
Another problem with using a bypass is that it shifts the effective operating temperature of the heat exchange process. This usually reduces the energy efficiency of the equipment and can reduce equipment lifetime.
Another strategy for dealing with excess conditioned airflow is to only partially close the dampers of at least some of the zones that are not calling for conditioning. In some systems, the dampers have mechanical stops that must be set and adjusted during the installation process or in a follow up service call. In other system, the damper positions are set dynamically by a control process. U.S. Pat. No. 5,829,674 issued Nov. 3, 1998 to Vanostrand, et al. describes a multi-zone control system that uses modulating dampers. These control systems are designed primarily for temperature balancing between zones to maximize comfort. The control methods are not optimized for energy savings.
Another strategy for dealing will excess conditioned airflow is to use HVAC equipment that has variable capacity. In these systems, the total needs of all the zones are considered when setting the output capacity of the HVAC equipment. Some variable capacity HVAC equipment provides two discrete stages where the first-stage produces 60% to 70% of the conditioned airflow as the second-stage. Other equipment can be adjusted continuously from about 30% to 100% based on the required airflow for the zones that require conditioning. U.S. Pat. No. 5,863,246 issued Jan. 26, 1999 to Bujak, Jr. describes a zone control system where the conditioning capacity of the HVAC equipment is adjusted to match the needs of the zones calling for conditioning.
Any zone system should improve the temperature control in a building. More zones provide better temperature control. Zone systems can potentially reduce the energy used to condition a building, but the energy savings depends on the details for the building, the zone system, and how the occupants set the zone temperatures. Some zone systems actually use more energy because the excess airflow is inefficiently managed.
Zone systems can save energy by selectively conditioning areas based on occupancy and activity. Areas that are occupied are conditioned only as much as needed, and areas that are unoccupied are conditioned as little as possible. Energy savings depends on the zone areas matching occupancy areas and the ability of occupants to easily set temperatures that match their occupancy patterns. In addition, settings that save energy when an area is unoccupied should not affect the comfort of that area when occupied.
In a typical zone control system for use in single family homes, a zone includes several rooms. The airflows to all rooms in the zone are controlled by one thermostat. To provide good temperature control, all rooms in the zone must have good thermal coupling with the zone thermostat. Zones must be related to the geometry of the home rather than the use of the rooms in the zone. For example, a two-zone system typically divides a home into a living area and a sleeping area or an upstairs area and a downstairs area. Using different temperature settings for each zone for different times of the day can reduce the energy used for conditioning. However, the actual occupancy pattern may not match the zone organization. For example, one bedroom might be used as a home office. Or one bedroom may be a nursery occupied full time by an infant. School children may use their bedroom in the afternoon for homework or play, or use it all day in the summer. If one room in the zone is occupied, then the entire zone must be conditioned for occupancy. Likewise one person may use one room of the living space early in the morning and a different person use another room in the living space late at night. With only two zones, it is likely that at least one room in each zone is occupied most of the time. There is little opportunity to reduce the conditioning to save energy.
The best opportunity for energy savings while maximizing comfort is to make every room a separate zone, providing a temperature sensor, temperature settings, and airflow control for every area that has a supply vent and a door or different thermal environment. An average 2500 square ft home has 10-15 separate rooms and areas with different thermal environments, so a 10-15 zone system should be used. Such a multi-zone control system for residential use is disclosed in U.S. Pat. No. 6,786,473 issued Sep. 7, 2004 to Alles, U.S. Pat. No. 6,893,889 issued Jan. 10, 2004 to Alles, U.S. Pat. No. 6,997,390 issued Feb. 14, 2006 to Alles, U.S. Pat. No. 7,062,830 issued Jun. 20, 2006 to Alles, U.S. Pat. No. 7,162,884 issued Jan. 16, 2007 to Alles, U.S. Pat. No. 7,188,779 issued Mar. 13, 2007 to Alles, and U.S. Pat. No. 7,392,661 issued Jul. 1, 2008 to Alles. These patents describe various aspects of a HVAC zone control system that uses inflatable bladders and various control methods. This system is designed for retrofit and to use the existing HVAC systems in residential single family homes. Homes larger than 2500 sq ft typically have 12-30 vents, each with an airflow capacity only a small fraction of that supplied by the HVAC equipment. Therefore any time the HVAC equipment is run, a minimum number of vents must be open to provide sufficient airflow capacity to allow the HVAC equipment to operate efficiently. Even if a single room calls for conditioning, the HVAC equipment should be run to provide comfort in that room. This means that several rooms that are not calling for conditioning must also be conditioned.
U.S. Pat. No. 7,188,779 issued Mar. 13, 2007 to Alles describes a method for selecting zones to receive a portion of the excess conditioning from among those zones not calling for conditioning. Non-calling zones are incrementally selected for conditioning until total airflow capacity is sufficient to receive the airflow generated by the HVAC equipment. The priority for selecting non-calling zones is primarily based on the zone's nearness to needing conditioning. In the simplest terms, this is determined by the difference between the zone's temperature and its set point. The unconditioned and non-calling zone with its temperature closest to its set point is the next zone selected for conditioning.
This method produces good results for comfort, but may use more energy for conditioning than necessary when many zones are unoccupied. If many zones are set for minimum conditioning because they are unoccupied, the excess conditioned air tends to be distributed to all of the non-calling zones such that their temperatures are all about the same. In most cases, energy can be saved by conditioning only a specific subset of the non-calling zones while providing little or no conditioning to other non-calling zones. As a result, the temperature difference between some non-calling zones can be quite large. However, less total conditioning, and therefore less energy is needed to condition the occupied zones to their set temperatures.
OBJECT OF THIS INVENTION
The object of this invention is to provide an improved method for selecting non-calling zones to receive excess conditioning in a multi-zone HVAC system such that the improved method reduces the need for conditioning, thereby saving energy.
SUMMARY
The invention is an energy saving method for controlling multi-zone forced air HVAC systems where the minimum conditioned airflow produced by the HVAC equipment significantly exceeds the airflow capacity of many of the zones. When satisfying calls for conditioning from one or a few zones, excess conditioned airflow is directed to non-calling zones. The method selects non-calling occupied zones based on a priority that provides comfort and selects non-calling unoccupied zones based on a priority that provides energy savings. Limits are provided for each zone to prevent excessive conditioning.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be understood more fully from the detailed description given below and from the accompanying drawings of the methods of the invention which, however, should not be taken to limit the invention to the specific methods described, but are for explanation and understanding only.
FIG. 1 is a logic flow diagram of the improved method for selecting non-calling zones for excess conditioning.
FIG. 2 compares the relative energy efficiency of methods for selecting non-calling zones in an idealized building where only an end zone is occupied.
FIG. 3 compares the relative energy efficiency of methods for selecting non-calling zones in an idealized building where only a middle zone is occupied.
FIG. 4 is a floor plan of a typical home with heat flow and conditioning parameters.
FIG. 5A and FIG. 5B compare the relative energy efficiency of methods for selecting non-calling zones in a typical home where only one zone on the end is occupied.
FIG. 6A and FIG. 6B compare the relative energy efficiency of methods for selecting non-calling zones in typical home where only one zone near the middle is occupied.
FIG. 7A and FIG. 7B compare the relative energy efficiency of methods for selecting non-calling zones in typical home where only one zone on the opposite end is occupied.
FIG. 8 is a diagram of a touch screen interface for entering heat flow coefficients for each room in a home.
DETAILED DESCRIPTION
FIG. 1 is a logic flow diagram of the improved method for selecting non-calling zones to receive excess conditioned airflow. The method makes decisions based on the occupancy of each zone. Each zone is either occupied or unoccupied so the total of the occupied zones and unoccupied zones equals the total number of zones in the HVAC system.
The set temperature of a zone can be used to determine its occupancy. For example if the heating set temperature is less than a preset heating threshold such as 55°, it is reasonable to assume the zone is unoccupied. Likewise if the cooling set temperature is greater than a preset cooling temperature such as 90°, it is reasonable to assume the zone is unoccupied.
Other ways to determine occupancy can be used with the improved method. For example the temperature sensor for each zone can have a switch or button for communicating the occupied or unoccupied state to the zone control system. The occupant is responsible for setting the state. As another example, at the human interface where the set temperature schedules for the zones are entered, an explicit “unoccupied” selection can be provided. This selection is made for the schedule times when the zone is unoccupied. When the zone is scheduled to be occupied, a specific set temperature is selected. Various motion sensors are commercially available that can automatically detect and communicate occupancy. These may be preferred in some applications.
The first part of the flow diagram in FIG. 1 is similar to the prior art. The temperature T° in each room (occupied or unoccupied) is compared to it current set temperature TS°. The sign of the compare depends on whether heating or cooling. Heating is called if T° is less than the heat TS°. Cooling is called if T° is greater than the cool TS°. A flag is set for each zone calling for conditioning and the airflow percentages for all calling zones are accumulated. After testing all the zones, if the accumulated airflow %=0, then no zones are calling for conditioning and the logic flow is started over.
If the accumulated airflow % is equal to or greater than 100%, then there is no excess conditioned airflow. There is no need to select a non-calling zone, so a conditioning cycle is run.
If at least one zone is calling for conditioning and the accumulated airflow % is less than 100%, then at least one non-calling zone must be selected to receive the excess conditioned airflow. Non-calling occupied zones are considered first. If an occupied zone is close to needing conditioning, then receiving the excess conditioned airflow reduces or eliminates the calls for conditioning from this zone. However, excessive over conditioning can reduce comfort, so a limit temperature is provided.
Non-calling occupied zones are selected one at a time based on the difference between its temperature and its set temperature. If the zone temperature is greater than the conditioning limit, the difference is set to zero. The one non-calling zone selected is the zone with the smallest non-zero difference. Of all the non-calling zones, that zone is closest to needing conditioning. The flag for this zone is set and its airflow added to the accumulated airflow. If the accumulated airflow is equal to or greater than 100%, then a conditioning cycle is run.
If the accumulated airflow is less then 100%, then the non-calling occupied rooms with their flag not set for conditioning are processed again. The next zone closest to needing conditioning is selected, its flag set for conditioning, and its airflow added to the airflow accumulation.
If all available non-calling occupied zones have been selected without the accumulated airflow reaching 100%, then the non-calling unoccupied zones are processed. A selection priority is calculated for each unoccupied zone. The priority of a zone is based on the total heat flow between all occupied zones and that unoccupied zone. The unoccupied zone that has the largest heat flow with occupied rooms is selected to receive excess conditioned airflow. Determining the heat flow requires the heat flow coefficients between adjacent rooms. These can be calculated using a standard process called “Manual J” provided by the ACCA. They can also be approximated from a floor plan or by inspecting the home. The heat flow between two zones is the temperature difference between the two zones times the heat flow coefficient between the two zones.
The priority of each unoccupied and unconditioned zone is calculated, provided the zone temperature is less than the limit temperature. The heat flow between the unoccupied zone and all occupied zones is calculated by summing the product of the temperate difference between the unoccupied zone and each occupied zone and the corresponding heat flow coefficient. Temperature differences less than one degree are rounded up to one degree to ensure each heat flow coefficient has consistent influence on the calculated priority. The one unoccupied zone with the highest priority is selected for the excess conditioned air and its flag is set. Its airflow is added to the accumulated airflow. If the accumulated airflow is 100% or more, the conditioning cycle is run.
If the accumulated airflow is less than 100%, the remaining unoccupied and unconditioned zones are processed again to find the next zone to receive excess conditioning. This is repeated until there are no unoccupied zones with heat flow to the occupied zones.
The method finally considers the unoccupied zones that are most thermally isolated from the occupied zones, provided the zone temperature is less than the limit temperature. All heat flow coefficients between these unoccupied zones and the occupied zones are equal to zero. However, there are non-zero heat flow coefficients between unoccupied and unconditioned zones and unoccupied zones that are receiving excess conditioning. The priority of each unoccupied and unconditioned zone is calculated. The heat flow between the unoccupied zone and all conditioned zones (the ones with their flag set) is calculated by summing the product of the temperate difference between the unoccupied zone and each conditioned zone and the corresponding heat flow coefficient. Temperature differences less than one degree are rounded up to one degree to ensure each heat flow coefficient has consistent influence on the calculated priority. The one unoccupied zone with the highest priority is selected for the excess conditioned air low and its flag is set. Its airflow is added to the accumulated airflow. If the accumulated airflow is 100% or more, the conditioning cycle is run.
If after all zones are processed, the accumulated airflow is less than 100%, there is no acceptable way to have sufficient airflow, so a conditioning cycle is not run. This can happen when most zones are conditioned to their limit while one or more calling zones can not be adequately conditioned because of insufficient airflow. The method will continue to process the zones while temperatures equalize until conditioning can be run.
In summery, the improved method selects non-calling unoccupied zones to receive excess conditioning such that the zones thermally coupled to the occupied zones receive the most conditioning. Zones least thermally coupled to the occupied zones receive the least conditioning.
FIG. 2 compares the relative energy efficiency for two methods of selecting non-calling zones in an idealized home 100. Each parameter has a symbolic representation and a specific value for this example. The representation is general and the example is provided to facilitate understanding.
Home 100 has 4 zones labeled Room 1 through Room 4 . Each zone has a measured temperature referred to as T 1 through T 4 . Each zone has a set temperature referred to as ST 1 through ST 4 . The set temperature is used to identify occupied and unoccupied zones. Zones with a ST at or below a threshold temperature are treated as unoccupied. Room 1 is occupied with ST 1 =70°, and Room 2 through Room 4 are unoccupied with ST 2 =ST 3 =ST 4 =50°. The outside temperature is referred to as TOUT=50°, so this specific example is for the HVAC equipment providing conditioned airflow for heating.
The heat flow coefficient from each zone to the outside is referred to as HF 1 :OUT=HF 4 :OUT=3 and HF 2 :OUT=HF 3 :OUT=2. This heat flow coefficient is the total heat flow per degree difference between the inside and outside so that the heat flow between Room 1 and the outside is (T 1 −TOUT)*HF 1 :OUT.
The heat flow coefficient between adjacent zones is represented by HF 1 : 2 =HF 2 : 3 =HF 3 : 4 =4. For example the total heat flow between Room 1 and Room 2 is (T 1 −T 2 )* HF 1 : 2 .
Each zone can receive a portion of the conditioned airflow produced by the HVAC equipment referred to as AF 1 through AF 4 . The sum of the conditioned airflows to each zone must be significantly greater then the conditioned airflow produced by the HVAC equipment. With AF 1 =AF 2 =AF 3 =AF 4 =50%, at least two zones must be conditioned when the HVAC equipment operates. If 3 zones receive conditioning, the airflow to each conditioned zone is 33% of the HVAC equipment capacity. If 4 zones receive conditioning, the airflow to each zone is 25% of the HVAC equipment capacity.
The individual symbolic equations representing the equilibrium heat flow for each zone are straightforward. At equilibrium, sum of the heat flows into each zone must be zero. For example consider Room 2 :
( T 2 −T out)* HF 2:OUT+( T 2 −T 1)*HF1:2+( T 2 −T 3)*HF2:3=0
Solving the symbolic equations for determining the equilibrium temperatures while using conditioning are quite complex. The benefit of the improved method is best understood and appreciated by using numerical examples and a simulator to calculate the heat flows and equilibrium temperatures. Those skilled in the art can use a commercially available simulator or can construct a simulator using a spreadsheet model. The results presented in this disclosure were calculated using Microsoft Excel spreadsheets and Visual Basic programs.
For the example shown in FIG. 2 , one non-calling zone must be conditioned each time the occupied zone requires conditioning to maintain its set temperature. All of the non-calling zones are also unoccupied. The prior art method for selecting the non-calling zone prioritizes selection based on the difference between the zone's measured temperature and the zone's set temperature. The non-calling zone with the smallest temperature difference is selected. Since the set temperatures are the same for all non-calling zones, the zones are selected such that their equilibrium temperatures are about equal. The simulation finds T 2 =T 3 =T 4 ˜64.5°. After reaching equilibrium, it takes 49 units of heating per unit of time to maintain Room 1 at 70°. Therefore 49 equal units of heating are distributed among the three unoccupied zones. Room 2 receives 5 units, Room 3 receives 17 units, and Room 4 receives 27 units. The zone most thermally isolated from the occupied zone receives the most conditioning. The zone most thermally coupled to the occupied zone (Room 2 ) receives the least conditioning because it is partially conditioned by heat flow from the occupied zone (Room 1 ).
The improved method for selecting the non-calling unoccupied zone for conditioning prioritizes the selection based on the heat flow between the occupied zone and the non-calling unoccupied zone. The non-calling unoccupied zone with the largest heat flow from the occupied zone is selected. The heat flow is the temperature difference multiplied by the heat flow coefficient between the zones. For the example of FIG. 2 , only Room 2 is selected. Room 3 and Room 4 receive none of the excess conditioned airflow. Using the improved method, 40 units of heating are needed to maintain Room 1 at 70°. Therefore Room 2 also receives 40 units of heating. Since all of the excess heating goes to Room 2 , its temperature will be as high as possible. Therefore the heat flow from Room 1 to Room 2 is as small as possible. Although Room 2 receives the same amount of heat as Room 1 , its temperature is less because the heat flows to Room 3 and the outside are greater than the heat flow from Room 1 . The equilibrium temperatures for the unoccupied zones are T 2 ˜68.4°, T 3 ˜59.5°, and T 4 ˜55.5°. The improved method for selecting reduced the needed heat from 49 units to 40 units, a reduction of about 18.4%.
FIG. 3 compares the efficiency of home 100 when Room 2 is occupied and the other 3 zones are unoccupied. Using the method of the prior art, 48 units of heat are needed to maintain Room 2 at 70° and the unoccupied zones reach an equilibrium temperature of about 64.90. Room 1 receives 15 units of heat, Room 3 receives 6 units, and Room 4 receives 27 units. Using the improved method, 44 units of heat are needed to maintain Room 2 at 70°. The equilibrium temperatures for the unoccupied zones are T 1 =T 3 ˜65.8° and T 4 ˜59.8°. Room 1 receives 19 units of heating, Room 3 received 25 units, and Room 4 received 0 units. The improved method reduced the needed heat from 48 units to 44 units, a reduction of about 8.3%.
FIG. 4 is a floor plan of a representative small home with 10 zones. Each zone is referred to as R 1 through R 10 . Typically R 1 , R 5 , and R 7 are bedrooms, R 2 , R 3 , and R 4 are the master suite, R 6 is a bath, R 8 is a dining room, R 9 is a kitchen, and R 10 is a family room. The values for the heat flow coefficients between all zones HF 1 : 2 through HF 9 : 10 and between each zone and the outside HF 1 :OUT through HF 10 :OUT are shown. For TOUT=50° and all room occupied with ST=70°, approximately 33.7 units of heat for each simulation time period is needed to maintain 70° in each zone. The percentage of the total heat that each zone receives is shown for each zone. For example, R 1 :12.5% means zone R 1 receives 12.5% of the 33.7 units of heat to maintain its temperature at 70°. For zones that are occupied, the zone name, heat percentage, and zone temperature are in bold type and underlined. All zones in FIG.4 are occupied and all zones have a temperature of 70°.
FIG. 5A and FIG. 5B are smaller representations of the home shown in FIG.4 . Zone R 2 is the only occupied zone with ST=70°. R 2 is at an end of the building and thermally isolated from five of the other zones. All other zones are unoccupied with ST=50°. FIG. 5A shows the results of using the method of the prior art to select non-calling zones for conditioning. All unoccupied zones receive heat such that they all reach an equilibrium temperature of about 66.4°.
FIG. 5B shows the results when using the improved method. The total heat to maintain R 2 at 70° is 27.6% less when using the improved method. The improved method selects unoccupied zones adjacent to R 2 for receiving excess conditioned airflow. Very little excess conditioned airflow is sent to zones thermally isolated from R 2 . The temperatures of the unoccupied zones range from 53.3° to 71.0°. The limit conditioning temperature is 71°, so zone R 4 is selected for excesses airflow whenever its temperature drops below 71°.
FIG. 6A and FIG. 6B compares the methods when R 7 is the only occupied zone. R 7 is centrally located in the building with more thermal coupling to the entire home than the example in FIG. 5 .
FIG. 6A shows the results using the prior art method. The total heat needed to maintain R 7 at 70° is 29.2 units per simulation period. All unoccupied zones receive heat such that they all reach an equilibrium temperature of about 67.2°.
FIG. 6B shows the results when using the improved method. The total heat to maintain R 7 at 70° is 14.0% less when using the improved method. The improved method selects unoccupied zones adjacent to R 7 for receiving excess conditioned airflow. Very little excess conditioned airflow is sent to zones thermally isolated form R 7 . The temperatures of the unoccupied zones range from 58.8° to 69.9°. The energy savings is less for this example than for the example of FIG. 5 because R 7 is more centrally located and heat flows from R 7 to more rooms.
FIG. 7A and FIG. 7B compares the methods when R 10 is the only occupied zone. R 10 is located at the end of building with thermal coupling to a large open area. FIG. 7A shows the results using the prior art method. All unoccupied zones receive heat such that they reach an equilibrium temperature of about 66.5°.
FIG. 7B shows the results when using the improved method. The total heat to maintain R 10 at 70° is 26.0% less when using the improved method. The improved method selects unoccupied zones adjacent to R 10 for receiving excess conditioned airflow. Very little excess conditioned airflow is sent to zones thermally isolated form R 10 . The temperatures of the unoccupied zones range from 53.6° to 69.6°. In this example, zones R 1 through R 4 are thermally isolated from R 10 , so they receive very little conditioning.
These examples demonstrate that the improved method for selecting non-calling unoccupied rooms for receiving excess conditioned airflow significantly reduces the conditioning needed to maintain the set temperatures of occupied zones, thereby saving energy. The reductions increase and the savings increase when many zones are unoccupied. Many zones are unoccupied most of the time because homes usually have many more zones than occupants. When every room is controlled as a separate zone, most of the zones are unoccupied most of the time.
The improved method requires knowledge of the heat flow coefficient between adjacent rooms. Approximate values are sufficient for the improved method to make selections that save energy. For example, six values can be used for typical single family homes:
Name
Value
Description
None
0
The two zones share no walls, floors, or ceilings
Very Small
1
The ceiling of one zone is the floor of the other zone
Small
1.5
The two zones share a common wall
Medium
2
The two zones share a common wall with a door
Large
2.5
The two zones share a common wall with an
open passage
Very Large
3
The two zones share a large open passage
These relative values can be easily determined for each pair of zones using floor plans or inspection of the existing building.
The multi-zone control system patented by Alles and described in the forgoing includes a graphics touch screen for entering information. FIG. 8 shows an example of a human interface using a touch screen 800 for entering the heat flow coefficients for the zones of the home shown in FIG. 4 . Typically room names are used in FIG. 8 rather than RI through R 10 . There is a similar screen for each zone in the building.
The name of the zone is displayed in area 801 . Touch areas 802 and 803 are used to scroll forwards or backwards through an alphabetical list of zones to select a specific zone. The screen for each zone has a touch area for each other zone in the home. For example, the touch area for the Kitchen 812 is area 810 . The heat flow coefficient between the Master BR 801 and the Kitchen 812 is set to NONE 811 . Each time the area associated with a zone is touched, the display increments through the sequence of available values for the heat flow coefficient; for example NONE, VERY SMALL, SMALL, MEDIUM, LARGE, VERY LARGE, NONE . . . as described in the foregoing. When a value other than NONE is selected, the touch area is graphically inverted to make it visually obvious which zones are thermally coupled to the zone 801 . The touch area 813 for the Master Bath is touched 3 times to reach the value of MEDIUM and the touch area is graphically inverted. Touching the area three more times changes the display to NONE and the area is not graphically inverted. Touch areas CANCEL 830 and OK 831 are used to navigate to other screens used for other purposes.
CONCLUSION
From the forgoing description, it will be apparent that there has been provided an improved method for selecting non-calling unoccupied zones to receive excess conditioned airflow. The method maintains comfort in the occupied rooms while reducing the energy used. Variation and modification of the described method will undoubtedly suggest themselves to those skilled in the art. Accordingly, the forgoing description should be taken as illustrative and not in a limiting sense.
The various features and examples illustrated in the figures may be modified in many ways, and should not be interpreted as though limited to the specific methods or conditions in which they were explained and shown. Those skilled in the art having the benefit of this disclosure will appreciate that many other variations from the foregoing description and drawings may be made within the scope of the present invention. Indeed, the invention is not limited to the details described above. Rather, it is the following claims including any amendments thereto that define the scope of the invention.
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In a multi-zone control system for central forced air HVAC systems where the minimum conditioned airflow produced by the HVAC equipment significantly exceeds the airflow capacity to many of the zones, the invention is an energy saving method for choosing non-calling zones to receive excess airflow in. When satisfying calls for conditioning from one or a few zones, excess conditioned airflow is directed to non-calling zones. The method chooses occupied non-calling zones using a priority that provides comfort, and chooses unoccupied non-calling zones using a different priority that provides energy savings. Limits are provided for each zone to prevent excessive over conditioning in non-calling zones.
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INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
BACKGROUND
[0002] 1. Field
[0003] The disclosure relates to non-magnetic metal alloys with excellent wear properties for use in dynamic three-body tribological wear environments where an absence of magnetic interference is required.
[0004] 2. Description of the Related Art
[0005] Conditions of abrasive wear can be damaging as they often involve sand, rock particles, or other extremely hard media wearing away against a surface. Applications which see severe abrasive wear in the prior art typically utilize materials of high hardness, 40 R c +, encompassing hard metals or carbides.
[0006] In certain wear applications, e.g., exploration wells in crude oil or natural gas fields such as directional bores and the like, it is advantageous for drilling string components including drill stems to be made of materials with magnetic permeability values below about 1.02 or possibly even less than 1.01 (API Specification 7 regarding drill string components), in order to be able to follow the exact position of the bore hole and to ascertain and correct deviations from its projected course.
[0007] A number of other disclosures are directed to non-magnetic alloys for use in forming drilling components including U.S. Pat. No. 4,919,728 which details a method for manufacturing non-magnetic drilling string components. US Patent Publication No. 2005/0047952 describes a non-magnetic corrosion resistant high strength steel. Although both patents describe magnetic permeability of less than 1.01, the compositions described have a maximum of 0.15 wt % carbon, 1 wt % silicon and no boron. The low levels and absence of the above mentioned hard particle forming elements suggests that the alloys would not precipitate sufficient, if any, hard particles. It can be further expected that inadequate wear resistance and hardness for high wear environments would be provided. U.S. Pat. No. 4,919,728 describes alloys which contain carbon levels below 0.25 wt % while US Patent Publication No. 2005/0047952 details carbon levels below 0.1 wt %, significantly below the alloys discussed in this disclosure. With these levels of carbon in conjunction with the absence of boron, few hard particles can form which impart wear resistance to a hardband. Also in U.S. Pat. No. 4,919,728, a method for cold working at various temperatures is used to achieve the desired properties. Cold working is not possible in coating applications such as hardfacing. The size and geometry of the parts would require excessive deformations loads as well as currently unknown methods to uniformly cold work specialized parts such as tool joints.
[0008] US Patent Publication No. 2010/0009089 details a non-magnetic for coatings adapted for high wear applications where non-magnetic properties are required. The alloys listed in this publication are nickel-based with preformed tungsten carbide hard spherical particles poured into the molten weld material during welding in the amount of 30-60 wt %.
[0009] Disclosures offering alloying solutions for competing wear mechanisms in oil & gas drilling hardfacing applications include but are not limited to U.S. Pat. Nos. 4,277,108; 4,666,797; 6,117,493; 6,326,582; 6,582,126; 7,219,727; and US Patent Publication No. 2002/0054972. US Publication Nos. 2011/0220415 and 2011/0042069 disclose an ultra-low friction coating for drill stem assemblies. U.S. Pat. Nos. 6,375,895, 7,361,411, 7,569,286, 20040206726, 20080241584, and 2011/0100720 disclose the use of hard alloys for the competing wear mechanisms.
[0010] There is still a need for non-magnetic alloy compositions for hardbanding components for use in directional drilling applications that have resistance to abrasion. There is also a need for an improved method to protect drill collars from heavy abrasion during drilling operations.
[0011] The austenite phase described as a component of this disclosure is naturally paramagnetic while ferrite which composes typical hardbanding is ferromagnetic. When a magnet is brought into close proximity or contact with a ferromagnetic hardband, it exhibits attractive forces. A magnet exhibits no detectable attraction to an entirely austenitic material.
[0012] Magnetic permeability is the measure of how well a material can support a magnetic field within it. The relative magnetic permeability of a vacuum is 1. The definition of a non-magnetic material suitable for use on a drill collar is <1.01 according to API Specification 7. Even slight amounts of ferrite or martensite in a mainly austenitic material can cause the magnetic permeability to exceed 1.01. Ferrite and martensite have a magnetic permeability greater than 50 depending on the alloy composition. The magnetic permeability of magnetic hardbanding materials is not readily available because it is generally not of concern in applications where they are used. However, it can be inferred that the magnetic permeability will be similar to that of traditional magnetic materials such as alloy steels.
[0013] According to API Specification 7, a non-magnetic material for use on drill collars must maintain a magnetic field gradient of ±0.05. The magnetic field gradient is a measure of the uniformity of the magnetic field.
SUMMARY
[0014] In one aspect, the disclosure relates to a drilling component for use in directional drilling applications capable of withstanding service abrasion. The drilling component has at least a surface protected by a welded layer comprising an alloy composition containing in wt. %: Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5, balance Fe and impurities as trace elements. The welded layer exhibits a hardness of at least 40 R c , in the as-welded condition, a wear rate of less than 0.6 grams of mass loss as measured according to ASTM G65-04, Procedure A, and a magnetic permeability value of less than 1.01.
[0015] In a second aspect, a hardbanding for protecting a drilling component for use in directional drilling is provided. The hardbanding comprises: a layer comprising an alloy composition having in wt. %: Mn: 8-16, Cr: 3-6, Nb: 3-6, V: 0-1, C: 1.5-5, B: 0-1.5, W: 3-6, Ti: 0-0.5, balance Fe and impurities as trace elements. The layer forms an austenitic microstructure containing embedded hard particles in an amount of less than 50 vol. %.
[0016] In a third aspect, a method for prolonging service life of a drilling component for use in directional drilling is provided. The method comprises: welding onto at least a surface of the drilling component an alloy composition containing in wt. %: Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5, balance Fe and impurities as trace elements. The welding is by any of laser welding, shielded metal arc welding (SMAW), stick welding, plasma transfer arc welding (PTAW), gas metal arc-welding (GMAW), metal inert gas welding (MIG), submerged arc welding (SAW), open arc welding (OAW), and combinations thereof. The welded layer exhibits a hardness of at least 40 R c , a wear rate of less than 0.6 grams of mass loss as measured according to ASTM G65-04, Procedure A, and a magnetic permeability value of less than 1.01.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1A is a Scanning Electron micrograph of an austenitic alloy demonstrating large, interconnected carbides providing paths for crack propagation.
[0018] FIG. 1B is an optical micrograph of one embodiment of the alloy in this patent which demonstrates finely distributed hard particles in a soft austenitic matrix.
[0019] FIG. 2 is a magnetic permeability survey done at an independent testing facility showing the permeability of one embodiment of the present disclosure.
[0020] FIG. 3 is a magnetic field gradient survey done at an independent testing facility showing the uniformity of the magnetic field of one embodiment of the present disclosure.
[0021] FIG. 4 is a Stainless Steel tool joint welded with an embodiment of the present disclosure with 3 parallel beads.
[0022] FIG. 5 is the weld bead examined with optical micrographs.
DETAILED DESCRIPTION
[0023] The following terms will be used throughout the specification and will have the following meanings unless otherwise indicated.
[0024] “Casing” is defined as a metal pipe or tube used as a lining for water, oil, or gas well.
[0025] “Coating” is comprised of one or more adjacent layers and any included interfaces. Coating also refers to a layer placed directly on the substrate of a base body assembly to be protected, or the hardbanding placed on a base substrate material. In another embodiment, “coating” refers to the top protective layer.
[0026] A “layer” is a thickness of a material that may serve a specific functional purpose such as reduced coefficient of friction, high stiffness, or mechanical support for overlying layers or protection of underlying layers.
[0027] “Hardband” (or “hardface”) refers to a process to deposit a layer of a special material, e.g., super hard metal, onto drill pipe tool joints, collars and heavy weight pipe in order to protect both the casing and drill string components from wear associated with drilling practices.
[0028] “Hardbanding” (or “hardband” or “hardfacing”) refers to a layer of superhard material to protect at least a portion of the underlying equipment or work piece, e.g., tool joint, from wear such as casing wear. Hardbanding can be applied as an outermost protective layer, or an intermediate layer interposed between the outer surface of the body assembly substrate material and the buttering layer(s), buffer layer, or a coating.
[0029] “Coating” may be used interchangeably with “hardbanding,” referring to the layer of superhard material to protect the underlying equipment.
[0030] “Hard particles” refer to any single or combination of hard boride, carbide, borocarbide particles.
[0031] “As-welded” refers to the condition of a weld without work hardening, heat treating, etc. or any other process which alter the properties or microstructure through post-welding processing.
[0032] The disclosure relates to a non-magnetic metal alloy for use in single or multi-stage tribological processes involving multiple bodies of varying hardness, and applications employing the metal alloy, e.g., hardbanding (or hardfacing) applications.
Metal Alloy Composition
[0033] The metal alloy for hardfacing is characterized as having an austenitic microstructure (face centered cubic gamma phase) and consisting essentially of: Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5, balance Fe and impurities as trace elements, for a non-magnetic composition with desirable effects including minimal, if any, cracking in the coating and a high resistance to abrasive wear.
[0034] In one embodiment, the alloy is any of the followings in wt. %:
[0035] A33: Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 4, W: 5, Ti: 0.25
[0036] A34: Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3.5, W: 5, Ti: 0.20
[0037] A36: Fe: bal, Mn: 16, Cr: 5, Nb: 4, V: 0.5, C: 3.25, W: 5, Ti: 0.20
[0038] A35: Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20
[0039] The alloy incorporates the above elemental constituents a total of 100 wt. %. In some embodiment, the alloy may include, may be limited to, or may consist essentially of the above named elements. In one embodiment, the alloy may include 2% or less of impurities. Impurities may be understood as elements or compositions that may be included in the alloys due to inclusion in the feedstock components, through introduction in the manufacturing process. In another embodiment, the feedstock contains silicon in the amount such that the final alloy contains 0.15 wt % although the ingot form did not contain any.
[0040] In all embodiments of the present disclosure, the hard particles are precipitated from the molten metal during solidification of the alloy. The soft austenite matrix provides toughness and ductility to the alloy while the hard particles impart the wear resistance. The soft matrix prevents spalling of the hard particles. The fine distribution of hard particles also allows for uniform wear and prevents selective wear of the soft matrix.
[0041] Other alloys such as those listed in US Patent Publication Nos. 2010/0009089 use preformed carbides or borides which are poured into the solidifying metal during welding. These carbides and borides are larger where the particle size ranges from 50-180 μm. Particles this large often spall due to poor adhesion with the matrix and break leading to reduced wear resistance
[0042] Using preformed carbides requires a large hopper directly above the welding arc in order to feed the particles into the molten weld. In this process, feeding the carbides into the weld too quickly or too slowly can be detrimental to the performance of the weld. Also, not only does the welding wire need to be purchased, but preformed carbides as well increasing the overall cost of applying the hardface. The alloys described in the present disclosure can be deposited using standard welding process without feeding preformed carbides into the weld. This simplifies the application process allowing for more uniform and repeatable hardfaced layers both on a single part and between multiple parts.
[0043] In one embodiment, the metal alloy is applied as a coating of Fe-based (austenitic) matrix containing fine-scaled hard boride, carbide, and complex carbide, e.g., borocarbide particles (e.g., M 2 B or MC, where M is a transition metal) having average particle sizes of 100 nm-20 μm, in an amount of less than 50 vol. %. In another embodiment, the hard particles are present in an amount of less than 30 vol. %. In one embodiment, the carbide particles have an average particle size of 1-5 μm.
[0044] In one embodiment, the boride phase is represented as M 2 B, wherein M is a transition metal. In another embodiment, the embedded hard particles in the austenitic Fe-based matrix contain Nb, Cr, and W with both carbon and/or boron. In yet another embodiment, the particles are in the form of embedded Nb carbide and Fe—W-boro carbide precipitates. In another embodiment, the Nb carbide precipitates are less than 5 μm in size. In every embodiments, the Nb carbide precipitates first at higher temperatures, acting as a site for lower temperature forming carbides to nucleate.
Method for Designing Hardbanding
[0045] In one embodiment, the alloy may be formed by blending various feedstock materials together, which may then be melted in a hearth or furnace and formed into ingots. The ingots can be re-melted and flipped one or more times, which may increase homogeneity of the ingots.
[0046] Each ingot produced was evaluated examining its microstructure, hardness and magnetic permeability. Incremental changes in composition were made in each successive ingot, leading to the final alloys. The compositions of the ingots made are listed in Table I.
[0000]
TABLE I
Ingot Compositions
amounts in weight percent
Alloy
Name
Fe
Mn
Cr
Nb
V
C
B
W
Si
Ti
Ni
A1
54.5
2
18
4
2
1.25
0.85
7
0.15
0.25
10
A2
60.5
2
15
4
2
1.25
0.85
7
0.15
0.25
7
A3
60.25
2
15
4
2
1.5
0.85
7
0.15
0.25
7
A4
60.5
2
15
4
2
1
1.1
7
0.15
0.25
7
A5
60.25
2
15
4
2
1
1.35
7
0.15
0.25
7
A6
60
2
15
4
2
1
1.6
7
0.15
0.25
7
A7
59.2
2
15
4.3
2
1.5
1.6
7
0.15
0.25
7
A8
79.1
1.5
5
4
0.5
1.5
1
5
0.15
0.25
2
A9
78.31
2.50
4.95
3.96
0.50
1.49
1.00
4.95
0.15
0.25
2.00
A10
76.74
2.45
4.85
3.88
0.49
1.46
0.98
4.85
0.15
0.24
4
A11
75.21
2.40
4.75
3.80
0.48
1.43
0.96
4.75
0.14
0.24
6.00
A12
72.58
6.00
4.59
3.67
0.46
1.38
0.93
4.59
0.14
0.23
5.79
A13
65.25
10.00
5
4
0.5
1.5
1
5
1.5
0.25
6.00
A14
72.75
10
5
4
0.5
1.5
1
5
0
0.25
0
A15
72.25
10
5
4
0.5
1
1
5
1
0.25
0
A16
72.00
10
5
4
0.5
1.25
1
5
1
0.25
0
A17
71.28
11.00
4.95
3.96
0.50
1.24
0.99
4.95
0.99
0.25
0.00
A18
69.85
13.00
4.85
3.88
0.49
1.21
0.97
4.85
0.97
0.24
0.00
A19
69.25
12
5
4
0.5
1.5
1
5
1.5
0.25
0
A20
68.75
12
5
4
0.5
1.5
1.5
5
1.5
0.25
0
A21
70.25
12
5
4
0.5
2
1
5
0
0.25
0
A22
68.8
14.0
4.9
3.9
0.5
2.0
1.0
4.9
0.0
0.2
0.0
A23
67.00
16.00
4.80
3.84
0.48
1.92
0.96
4.80
0.00
0.24
0.00
A24
67.80
16.00
5.00
4.00
0.50
1.50
0.00
5.00
0.00
0.20
0.00
A25
66.80
16.00
5.00
4.00
0.50
2.50
0.00
5.00
0.00
0.20
0.00
A26
66.30
16.00
5.00
4.00
0.50
3.00
0.00
5.00
0.00
0.20
0.00
A27
72.80
10.00
5.00
4.00
0.50
2.50
0.00
5.00
0.00
0.20
0.00
A28
72.30
10.00
5.00
4.00
0.50
2.50
0.50
5.00
0.00
0.20
0.00
A29
69.41
9.60
4.80
3.84
0.48
2.40
0.48
9.00
0.00
0.19
0.00
A30
72.80
10.00
5.00
4.00
0.50
0.50
2.00
5.00
0.00
0.20
0.00
A31
68.23
16.00
4.60
3.66
0.47
0.47
1.88
4.70
0.00
0.19
0.00
A32
65.30
16.00
5.00
4.00
0.50
4.00
0.00
5.00
0.00
0.20
0.00
A33
71.30
10
5.00
4.00
0.50
4.00
0.00
5.00
0.00
0.20
0.00
A34
71.80
10
5.00
4.00
0.50
3.50
0.00
5.00
0.00
0.20
0.00
A35
72.30
10
5.00
4.00
0.50
3.00
0.00
5.00
0.00
0.20
0.00
A36
72.05
10
5.00
4.00
0.50
3.25
0.00
5.00
0.00
0.20
0.00
A37
65.80
10.00
12.00
4.00
0.50
2.50
0.00
5.00
0.00
0.20
0.00
[0047] Each composition after melting into ingot form is sectioned on a wet abrasive saw as to avoid heating the ingot and subsequently altering the microstructure. The magnetic permeability is measured using a Low-Mu Magnetic Permeability Tester manufactured by Severn Engineering. A reference standard with a known magnetic permeability is placed in the tester. The tester is comprised of the reference standard and a pivoting magnet. The magnet extends from the side of the tester opposite the reference standard. The magnet tip is brought into contact with the surface of the ingot. If the magnet is not attracted to the ingot, then the magnetic permeability is less than that of the reference standard being used. The magnetic permeability of each ingot composition is listed in Table II.
[0000]
TABLE II
Alloy
Magnetic
Hardness
Name
Permeability.
(HRc)
A1
no
24
A2
no
29
A3
no
33
A4
yes
27.5
A5
no
31
A6
no
32
A7
no
35
A8
Yes
NA
A9
Yes
NA
A10
Yes
NA
A11
Yes
NA
A12
>1.04
NA
A13
<1.03
34
A14
<1.02
53.5
A15
>1.04
47
A16
>1.04
NA
A17
>1.04
43
A18
<1.02
38
A19
>1.04
46.5
A20
>1.04
NA
A21
>1.04
56
A22
<1.03
57.5
A23
>1.04
60
A24
<1.01
29
A25
<1.01
37
A26
<1.01
40
A27
<1.01
35
A28
<1.01
48
A29
<1.01
36
A30
>1.04
54
A31
>1.04
35
A32
<1.01
50
A33
<1.01
52
A34
<1.02
41
A35
<1.01
41.5
A36
<1.01
46
A37
<1.01
39
[0048] Each ingot composition after magnetic permeability testing is measured, the hardness is determined using a Rockwell C hardness tester. An average of 5 hardness measurements is recorded as the hardness of that ingot. The hardness of each ingot composition is detailed in Table II.
[0049] Achieving both a sufficiently low magnetic permeability and high as-welded hardness is difficult. The non-magnetic austenite is softer than the magnetic ferrite. Examining a magnetic and a non-magnetic alloy with the same volume percentage of hard particles, the non-magnetic alloy will be significantly softer.
[0050] For ingots A1-A11, they were made prior to having a magnetic permeability test method. They were evaluated using a hand-magnet as either magnetic or non-magnetic. Only those alloys showing no magnetism using the hand magnet were hardness tested.
[0051] The microstructure of each ingot is evaluated by optical microscopy. The desired microstructure contains a sufficient amount of the ductile austenite matrix along with embedded hard particles. Furthermore, a large volume fraction of finely distributed hard particles is desired. Large interconnected hard particles are undesirable due to increasing the brittleness of the ingot as shown in FIG. 1A . Fine disconnected hard particles as shown in FIG. 1B reduce or eliminate paths for crack propagation, decreasing the likelihood of cracking during the welding process or in service.
[0052] Combinations of powders may be contained in conventional steel sheaths, which when melted may provide the targeted alloy composition. The steel sheaths may include plain carbon steel, low, medium, or high carbon steel, low alloy steel, or stainless steel sheaths.
[0053] The ingots may then be melted and atomized or otherwise formed into an intermediate or final product. The forming process may occur in a relatively inert environment, including an inert gas. Inert gasses may include, for example, argon or helium. If atomized, the alloy may be atomized by centrifugal, gas, or water atomization to produce powders of various sizes, which may be applied to a surface to provide a hard surface.
[0054] The alloys may be provided in the form of stick, wire, powder, cored wire, billet, bar, rod, plate, sheet, and strip. In one embodiment, the alloys are formed into a stick electrode, e.g., a wire, of various diameters, e.g., 1-5 mm. In some embodiments, the cored wire may contain flux, which may allow for welding without a cover gas without porosity-forming in the weld deposit.
[0055] In one embodiment, the metal alloys are applied onto a surface using techniques including but not limited to thermal spray coating, laser welding, weld-overlay, laser cladding, vacuum arc spraying, plasma spraying, and combinations thereof. In another embodiment, the alloys are deposited as wire feedstock employing hardfacing known in the art, e.g., weld overlay. The alloys can be applied with mobile or fixed, semi or automatic welding equipment. In one embodiment, the alloys are applied using any of laser welding, shielded metal arc welding (SMAW), stick welding, plasma transfer arc welding (PTAW), gas metal arc-welding (GMAW), metal inert gas welding (MIG), submerged arc welding (SAW), or open arc welding (OAW).
[0056] In one embodiment, the alloy is deposited onto a machined surface or alternatively, a surface blast cleaned to white metal (e.g., ISO 8501-1). The depth of the machined surface is grooved for flush type application depends on the welding applicator. In one embodiment for application on a used pipe, the existing hardbanding is first completely removed by gouging, grinding, or using other suitable techniques.
[0057] In one embodiment, the surfaces for deposition are first preheated at a temperature of 200° C. or greater, e.g., 275-500° C., for 0.01 hours to 100 hours. In one embodiment, the preheat may reduce or prevent cracking of the deposited welds.
[0058] The alloy may be applied to a surface in one or more layers as an overlay. In one embodiment, each layer having an individual thickness of 1 mm to 10 mm. In one embodiment, the overlay has a total thickness of 1 to 30 mm. In one embodiment, the width of the individual hard-band ranges from 5 mm to 40 mm. In another embodiment, the width of the total weld overlay ranges from 5 mm to 20 feet.
[0059] After deposition on a substrate, the alloy is allowed to cool to form a protective coating. In one embodiment, the cooling rate ranges from 100 to 5000 K/s, a rate sufficient for the alloy to produce iron rich phases containing embedded hard particles (e.g., carbides, borides, and/or borocarbides). After weld deposition, cooling in open air can cause a cooling rate which is too rapid, leading to cracking of the weld. In most cases, wrapping of the welded part with a thermally insulating blanket is sufficient to reduce the cooling rate to an acceptable level.
Properties
[0060] A work piece having at least a portion of its surface coated or having a welded layer of the austenitic alloy composition, e.g., a hardbanding layer, is characterized as having an as-welded macro-hardness as measured via standard Rockwell C test of greater 40 R c in one embodiment; 45 R c in a second embodiment; and at least 50 R c in a third embodiment.
[0061] The alloy composition as deposited on the surface of a work piece is characterized as being crack-free, as inspected by any of magnetic particle inspection, eddy current inspection, etching, visual inspection, hardness checking, dye penetration inspection, or ultrasound inspection. The absence of cracks in the coating protects the underlying part from exposure to any corrosive media present.
[0062] The alloy composition in one embodiment is further characterized has having magnetic permeability values (using a Low-Mu Permeability Tester) of less than 1.02 in one embodiment, less than 1.01 in a second embodiment, and less than 1.005 in a third embodiment. The alloy when applied as hardbanding on drill stem components provides the necessary paramagnetic behavior for the operator to be able to monitor the progress of the bore hole required in directional drillings. In one embodiment, the magnetic permeability was measured at a commercial testing facility and FIG. 2 shows the material survey. The entire survey stayed below the 1.01 maximum.
[0063] In one embodiment, the commercially measured magnetic field gradient was <0.05 microtesla. No hot spots exceeding the 0.05 microtesla range were found. This indicates a uniform magnetic field as shown in FIG. 3 .
[0064] When applied as coatings, e.g., hardbanding, for protection of work pieces, the fine-grained microstructural features in the alloy provide durability and prevent wear on secondary “softer” bodies which come into contact with the work piece protected by the coatings. The component protected by the alloy is characterized as having elevated wear resistance with a dry sand abrasion mass loss (ASTM G65-04 procedure A) of less than 0.6 grams in one embodiment; and less than 0.35 grams in a second embodiment.
Applications
[0065] The alloy in one embodiment is suitable for use as hardbanding in hard bodies wear applications. In these applications, the material loss in coatings is typically caused by abrasive wear of the harder abrading particles. To reduce the material loss in this process, one should increase the hardness of the coating and/or increasing the amount of comparably hard particles (comparable as related to the abradable particles) or phases within the coating. The alloys contain a sufficient amount of hard particles and display a sufficient hardness property for the protected equipment under these conditions.
[0066] The alloys are particularly useful for oil & gas applications, e.g., for work pieces employed in directional drilling operations as coating for drill stem assemblies, exposed outer surface of a bottom hole assembly, coatings for tubing coupled to a bottom hole assembly, coatings for casings, hardbanding on at least a portion of the exposed outer surface of the body, and as coatings for oil and gas well production devices as disclosed in US Patent Publication No. 2011/0042069A1, the disclosure is included herein by reference in its entirety. Examples include devices for use in drilling rig equipment, marine riser systems, tubular goods, wellhead, formation and sandface completions, lift equipment, etc. Specific examples include drillpipe tool joints, drill collars, casings, risers, and drill strings. The coating can be on a least a portion of the inner surface of the work piece, at least a portion of the outer surface, or combinations thereof, preventing wear on the drill collar). The coatings provide protection in operations with wear from vibration (stick-slip and torsional) and abrasion during straight hole or directional drilling, allowing for improved rates of penetration and enable ultra-extended reach drilling with existing equipment.
[0067] The coating can be applied as raised (“proud”) or flush (“recessed”) coating. The coating can be applied on used equipment, e.g., pipe with no previous hardbanding, or to be hardbanded on new work pieces. The coating can be deposited over pre-existing weld deposits and many other previous hard-facing and hard-banding deposits. In one embodiment, the old hardbanding on the equipment is first removed before the application of the alloy.
[0068] Besides the use as protective coatings, the alloy lends itself to use in the fabrication of articles of manufacture, including drill collars and housings for containing measurement-while-drilling equipment used in the directional drilling of oil and gas wells. A drill collar is made from a bar, which is trepanned to form an internal bore to desired dimensions. Following trepanning, at least the interior surface is treated so as to place it into compression, for example as by burnishing or peening.
[0069] Outside the oil & gas industry, the alloys can also be used as coatings or forming work pieces in many other applications, including but not limited to coatings for fuel cell components, cryogenic applications, and the like, for equipment operating in corrosive environments with non-magnetic requirements.
EXAMPLES
[0070] The following examples are intended to be non-limiting.
Example 1
[0071] An alloy composition of Alloy 1 (Mn: 10%, Cr: 5%, Nb: 4%, V: 0.5%, C: 3.5%, W: 5%, Ti: 0.25%, Fe: balance) was produced in the form of a 1/16″ cored wire. The alloy was arc-welded onto a 6⅝″ outer diameter box Stainless Steel tool joint pre-heated to 450° F. The joint was rotated at a rotation rate of one full rotation every 2 min and 30 sec. The welding parameters are 290 amps, 29.5 volts and a 1″ wire stickout. The welding head was moved through the action of an oscillator at a rate of 58 cycle/min, resulting in a weld bead approximately 1″ wide and 4/32″ thick. Three consecutive beads were made, one next to another to produce three adjacent 1″ beads for a total width of roughly 3″. The joint was wrapped in insulation to reduce the cooling rate and allowed to cool to room temperature. The as-welded tool joint can be seen in FIG. 4
[0072] The microstructure of the weld bead was examined with optical micrographs as shown in FIG. 5 . A section of a weld was taken and wear tested producing an ASTM G65 wear loss of 0.35 g. Relative magnetic permeability was measured with a probe and provided a value of less than 1.01. Rockwell C hardness was measured at 43 .
[0073] For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present disclosure. It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural references unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.
[0074] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. The patentable scope is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. All citations referred herein are expressly incorporated herein by reference.
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Disclosed are non-magnetic metal alloy compositions and applications that relate to non-magnetic metal alloys with excellent wear properties for use in dynamic three-body tribological wear environments where an absence of magnetic interference is required. In one aspect, the disclosure can relate to a drilling component for use in directional drilling applications capable of withstanding service abrasion. In a second aspect, a hardbanding for protecting a drilling component for use in directional drilling can be provided. In a third aspect, a method for prolonging service life of a drilling component for use in directional drilling can be provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a drive system, and more particularly, to a propulsion system for a bicycle, or the like, having a vertically oriented, rectilinear motion path, wherein the rectilinear motion is converted to a rotary motion.
2. Description of Related Art
Humankind has long aspired to achieve a more physically fit body. Devices of all sizes, shapes and configurations have been created with this purpose in mind; exercises designed to develop specific muscles in particular ways have been designed by scientists, doctors, engineers and the weekend athlete. Some of these machines and techniques improve strength, some improve conditioning and others improve muscular tone.
Regardless of this multitude of mechanisms and techniques, many deficiencies yet exist with many physical conditioning devices. Such deficiencies include non-efficient application of muscle strength from the human body to the object of the exercise as well as lost power transference. Bicycles illustrate a class of widely used exercise machines which have been the subject of various refinements. Athletes often employ bicycles for exercise as well as competition. Bicycles are also used in many countries as a mode of transportation, in addition to a means of exercise. While bicycle manufacturers have sought to produce lighter bicycles, more flexible bicycles and more durable bicycles through the use of a variety of materials, the conventional bicycle continues to employ a less than completely efficient drive train. Although this area has received considerable attention in recent years a more efficient exercise and transportation apparatus yet remains to be developed.
Conventional bicycles incorporate an axle located approximately midway between the front and rear tires. Perpendicularly affixed to the axle are shafts, at the end of which are pedals that project outwardly from the bicycle. The pedals allow the user to utilize the propulsive power generated by the human body. The axle usually has a sprocket that engages a chain driving the rear tire, and which propels the bicycle forward. Thus, the axle, shaft, pedal configuration of the bicycle drive mechanism to force the rider to drive his or her feet and legs in a generally circular motion. This motion while effective in creating sufficient force to propel the bicycle forward, does not do so with maximum efficiency.
The rotational motion forced upon a rider by the drive mechanism of a conventional bicycle results in lost motion and wasted energy. The bicycle's drive is developed from the downward push of the rider's legs and feet along the circular path of the pedals, and the circular path makes it difficult for the rider to exert a constant propulsive force. This inherent lost motion problem decreases the rider's ability to pace himself or herself during a long journey. Thus, a drive system which eliminates lost motion and increases the length of the power stroke would be a marked advance over the prior art. The present invention accomplishes this goal, while increasing power uniformity and decreasing the length of the rider's reset stroke. In addition, the improved drive system results in a more efficient means for the application of propulsive power and for increasing the endurance of the rider.
SUMMARY OF THE INVENTION
The present invention relates to a drive system for converting rectilinear motion to rotary motion. In one aspect, the invention includes an improved bicycle drive system of the type wherein bicycle pedals are driven by the feet of a rider in opposite directions for rotating a drive sprocket which is coupled to, and drives, a wheel sprocket thereby propelling the bicycle in a forward direction. The improvement comprises a means for mounting the pedals to create oppositely disposed rectilinear motion. A means for producing a first bi-directional rotary motion in response to rectilinear actuation of each of the pedals is provided and is linked to the pedals. Also provided is a means for transducing the primary bi-directional rotary motion into a secondary uni-directional motion. The secondary uni-directional motion is coupled to the drive sprocket by a coupling means and results in the propulsion of the bicycle.
In another aspect, the invention includes a drive system comprising a pair of vertically oriented, parallel rectilinear motion guide. A pair of force blocks are separately and slidably mounted on the motion guides. Means are provided for reversibly oscillating the force blocks, wherein the force blocks are disposed at opposite ends of the parallel rectilinear motion guides. A drive force resistance means is coupled to the force blocks. Means are then provided for transferring the drive force from the force blocks to the resistance means when a rectilinear force is applied to the force blocks. A unidirectional clutch means links, and is disposed between, the transfer means and the force blocks for transferring the drive force in a single direction for the generation of rotary motion.
In another aspect, the invention includes the drive system described above wherein the transfer means comprises an idler axle mounted at one end of the parallel rectilinear motion guides and having two idler sprockets. One of the idler sprockets is linked to one of the force blocks, with the other of the idler sprockets being linked to the other of the force blocks. A drive axle is mounted at the other end of the parallel rectilinear motion guides, with the drive axle being aligned parallel to the idler axle. The drive axle comprises a shaft having a drive wheel mounted thereon for rotation therewith and a pair of driving sprockets also mounted thereon. The drive axle further is coupled to the unidirectional clutch means, wherein the unidirectional clutch means is mechanically interconnected to one of the pair of driving sprockets. The other of the pair of unidirectional clutch means is mechanically interconnected to the other of the pair of driving sprockets. Furthermore, one of the pair of driving sprockets is linked to one of the force blocks, with the other of the pair of driving sprockets being linked to the other of the force blocks. Each of the force blocks is connected to one of a pair of drive chains which link the idler sprockets, the drive sprockets and the force blocks together. The drive chains are trained around one of the idler sprockets and drivingly trained around one of the driving sprockets. The driving sprockets function unidirectionally, thus providing a drive force in only one direction. The unidirectional clutch means causes the driving sprockets to actively engage the drive axle when turned in the proper direction.
In another aspect, the above described invention is constructed with the pair of parallel rectilinear motion guides mounted on a bicycle frame, with the drive wheel connected to the rear bicycle wheel thereby transferring a propulsion force thereto. An outer housing covers the mechanics of the apparatus. The outer housing defines a guide for the horizontal member protruding from the force block. The outer housing also includes an arcuate mounting guide which is adjustably fixed to the bicycle frame.
In an alternative embodiment, the bicycle may be a stationary bicycle, for example of the type used for exercise, rather than a conventional bicycle. As used herein, the term "bicycle" refers to both stationary and conventional bicycles.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be better understood and its numerous objects, features and advantages become apparent to those skilled in the art by referencing the accompanying drawings in which:
FIG. 1 is a side elevational view of a bicycle having incorporated thereon a drive system constructed in accordance with the principles of the present invention; and
FIG. 2 is an enlarged, fragmentary, perspective view of the drive system of FIG. 1 illustrating the mechanical linkage for converting rectilinear motion to rotational motion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, there is shown a side elevational view of a bicycle 18 having a vertically oriented, rectilinear travelling drive system 10 constructed in accordance with the principles of the present invention. The bicycle 18 is assembled with an upper frame member 20 extending from a front frame member 22 to a rear frame member 24. Below the upper frame member 20 is an apparatus support bracket or frame member 14, which also extends from the front frame member 20 to the rear frame member 24. The lowermost end of the rear frame member 24 intersects with the lower end of the drive system 10. The rear wheel 28 is mounted between the rear fork 30. The rear fork 30 extends from the point of engagement between the rear frame member 24 and the rectilinear travelling drive system 10. The front wheel 32 is mounted between a front fork 34. The front fork 34 extends from the bottom of the front frame member 22.
The drive system 10 includes an outer housing 12 in which the mechanics of the drive system 10 reside. The outer housing 12 of the drive system 10 is affixed at its uppermost portion to a mounting bracket 36. The mounting bracket is affixed to the apparatus support bracket or frame member 14. The outer housing 12 is mounted to the mounting bracket 36 by means of an arcuate slotted guide 16. The mounting bracket 36 projects from the underside of the apparatus support bracket VC3 or frame member 14 and receives an adjustably secured pin 38, which passes into the arcuate slotted guide 16. Once in place, the adjustably secured pin 38 is tightened to provide frictional engagement between the arcuate slotted guide 16 of the drive system 10 and the mounting bracket 36.
The lowermost end of the drive system 10 is secured to bicycle 18 at the lowermost portion of the rear frame member 24. Drive axle 50 projects into the outer housing 12 and through the bicycle frame. Thus, drive axle 50 holds the lower end of the drive system 10 in place. The drive axle 50 rotates within the bicycle frame and permits the outer housing 12 to pivot about the drive axle 50. By employing the adjustably secured pin 38 in coordination with the arcuate slotted guide 16, the mounting bracket 36 and the pivoting attachment of the drive axle 50, the outer housing 12 of the drive system 10 may be angularly shifted. As a result, the outer housing may sit completely vertical within the bicycle 18, or the rider may shift the outer housing 25 degrees forward or 25 degrees to the rear. The angular shift is illustrated by notional lines 52 and 54.
Still referring to FIG. 1, there is shown two foot pedals 56 and 58. The foot pedals 56 and 58 travel within the pedal guide 60 located on either side of the outer housing 12. As foot pedal 56 is pushed downward by the rider, foot pedal 58 will automatically rise within the pedal guide 60. The up and down motion of the foot pedals 56 and 58 causes the internal mechanics of the drive system 10 to turn the drive axle 50. Drive sprocket 62 is fixedly attached to the drive axle 50, such that the rotation of the drive axle 50 causes the drive sprocket to rotate as well. Drive chain 64 engages the drive sprocket 62 and transfers the drive energy from the drive system 10 to the rear wheel 28 by means of the rear drive gears 66.
Referring now to FIG. 2, there is shown a perspective view of the rectilinear travelling drive system 10 mounted within the frame of the bicycle 18. The outer housing 12 is shown in phantom such that the internal mechanics of the drive system 10 can be viewed. Mounting screws 100 secure the outer housing to the two parallel rectilinear motion guides 102, 104. The two parallel rectilinear motion guides 102 and 104 comprises the frame for the drive system 10. Cross-frame members 106 fixedly connect the parallel rectilinear motion guides 102 and 104, thereby creating the necessary structural strength.
The force block 108 is slidably mounted upon the rectilinear motion guide 102, while the force block 110 is slidably mounted upon the rectilinear motion guide 104. The force blocks 108 and 110 include a number of force block rollers 112. The force block rollers 112 are located about the force blocks 108 and 110. The force block rollers 112 slide along the rectilinear motion guides 102 and 104, thus enabling the force blocks to move along the rectilinear motion guides 102 and 104. Further included on the force blocks 108 and 110 are cable clamps 114 and 115. The cable clamp 114 secures flexible cable 116 to the force blocks 108 and 110. Located on the opposite side of the force blocks 108 and 110 from each of the cable clamps 114 and 115 are chain clamps 118 and 119 which secure the power transference chains 120 and 122 to the force blocks 108 and 110. Further included upon the force blocks 108 and 110 are horizontal force receiving bars 124 and 126. The force receiving bars 124 and 126 project orthogonally from the force blocks 108 and 110 and are provided so that the user can apply the drive force intended. In the preferred embodiment, foot pedals 128 are mounted on the force receiving bars 124 and 126.
Still referring to FIG. 2, there is illustrated upper direction reversing wheel 130 and lower direction reversing wheel 132. The flexible cable 116 is trained about the upper direction reversing wheel 130 and the lower direction reversing wheel 132, forming a closed loop. The upper direction reversing wheel rotates about upper reversing wheel axle 134, while the lower direction reversing wheel 132 rotates about lower reversing wheel axle 136. The flexible cable 116 passes through each of the cable clamps 114 and 115, thereby affixing the force blocks 108 and 110 to the flexible cable 116. The flexible cable connects the force blocks 108 and 110 in order to maintain their oppositely disposed positions along the parallel rectilinear motion guides 102 and 104. Thus, when a downward force is applied to the force block 108, it causes the flexible cable 116 to move as well. The movement of the flexible cable 116 pulls the force block 110 upward along the rectilinear motion guide 104. Consequently, a force on one of the force blocks 108 or 110 causes the other force block to automatically move in the opposite direction along the rectilinear motion guide upon which it is mounted. As a result of this automatic oscillation, the two force blocks 108 and 110 maintain their oppositely disposed positions. The upward movement of the force block 110 is terminated by force block stop 138 which is mounted upon rectilinear motion guide 104. Force block stop 140 terminates the upward movement of force block 108.
As the force blocks 108 and 110 oscillate up and down along their respective rectilinear motion guide 102 or 104, the power transference chains 120 and 122 are driven along their loop. The power transference chain 120 begins its loop at the chain clamp 118 affixed to the force block 110. The power transference chain 120 then engages the teeth of idler sprocket 142 and proceeds to the teeth of power sprocket 148. The idler sprocket 142 is mounted on the idler axle 146, which is affixed to the inner wall of the outer housing 12 and runs perpendicular to the parallel rectilinear motion guides 102 and 104. The idler sprocket 142 is mounted on one end of the idler axle 146 and a second idler sprocket 144 is mounted on the opposite end of the idler axler 146. The idler sprockets 142 and 144 are mounted on idler bearings 152 and 154 which are directly mounted on the idler axle 146. The idler bearings 152 and 154 permit the idler sprockets 142 and 144 to rotate in either a clockwise or counter-clockwise direction.
The power transference chains 120 and 122 engage the power sprockets 148 and 150 at the lower end of the drive system 10. The power sprockets 148 and 150 are mounted on unidirectional clutches 156 and 158, which, in turn, are mounted upon the drive axle 50. The unidirectional clutches 156 and 158 enable the drive axle 50 to turn when the power sprockets 148 and 150 are rotated in the proper direction (clockwise) by the power transference chains 120 and 122. Thus, when the power transference chain 120 is rotated clockwise, e.g., the power block 110 is pushed down, the unidirectional clutch 156 is not engaged and allows the power sprocket 148 to turn the drive axle 50. At the same time, the power block 108 is pushed up, which causes power sprocket 150 to rotate counter-clockwise, thereby engaging the unidirectional clutch 158 which prevents the power sprocket 150 from attempting to rotate the drive axle 50. Consequently, there is always a rotational force being applied to the drive axle 50 by either one of the power sprockets 148 or 150. In this way the drive sprocket 62 is turned and causes drive chain 62 to rotate rear drive gears 66.
Thus, there has been described and illustrated herein a drive device. Those skilled in the art, however, will recognize that many modifications and variations besides those specifically mentioned may be made in the techniques described herein without departing substantially from the concept of the present invention. Accordingly, it should be clearly understood that the form of the invention as described herein is exemplary only and is not intended as a limitation on the scope of the invention.
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A drive system for the application of rectilinear drive force, wherein the rectilinear force is converted to a rotational force. The apparatus employs power blocks which are slidably mounted upon opposing parallel rectilinear motion guides. The power blocks are connected together and are disposed at opposite ends of the apparatus. Connected to each of the power blocks is a power transference chain which rotates an idler sprocket and a power sprocket when force is applied to the power blocks. The idler sprocket rotates in both clockwise and counter-clockwise directions, while the power sprocket coupled thereto applies force in solely a clockwise direction and is disengaged from its mounting axle by a unidirectional clutch when rotated in a counter-clockwise direction. The power sprocket applies a force to the drive resistance point, which in the case of a bicycle comprises the rear wheel thereof.
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This is a division, of application Ser. No. 033,297, filed Apr. 15, 1979, now U.S. Pat. No. 4,245,577.
DESCRIPTION
BACKGROUND OF THE INVENTION
This invention is concerned with sewing machines, more particularly with a lockstitch sewing machine.
Heretofore known lockstitch sewing machines utilize an upper needle having a thread carrying eye located at the tip thereof to carry an upper thread downwardly through a work material to a looptaker, for pickup thereby and concatenation about a lower thread. Since the early days of the sewing machine, the growth of the industry has been predicated upon improvements to this basic method of forming a lockstitch. The instant invention, however, is not concerned with an improvement to the old basic method of generating a lockstitch, but pertains to an entirely new means by which a lockstitch may be accomplished.
SUMMARY OF THE INVENTION
In this invention, the upper thread passes through the sewing machine thread tension and takeup lever as heretofore known. However, thereafter the upper thread is acted upon by deflecting levers in order to position the thread to be accepted by a hook needle carried by a needle looper. The needle looper is best implemented by an outer, work material piercing, needle; which outer needle surrounds an inner hook needle. The needle looper is capable of endwise reciprocation up through a work material from the bottom side thereof, and to expose the inner hook needle portion thereof to permit an upper thread to be deflected therein. The inner hook needle is thereupon retracted into the outer needle in order to prevent escape of the upper thread therefrom, and the needle looper assembly is retracted through the work material to a lowered position. Means are provided to re-extend the inner hook needle from the outer needle when at the lower extremity of travel of the needle looper assembly so as to permit the upper thread retained thereby to be caught by a looptaker and withdrawn from the inner hook needle in order to be cast about a lower thread carrying bobbin for concatenation with the lower thread prior to the upward excursion of the needle looper assembly in the formation of the succeeding lockstitch. The lockstitch sewing machine thus described does not require a needle which must be threaded, using instead the needle looper assembly, which in conjunction with the loop deflecting levers catches an upper thread for each stitch.
DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. The invention itself, however, both as to its organization and method of operation thereof may be best understood by reference to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of a sewing machine including fragments of a typical work feeding mechanism and illustrating the physical elements necessary to an embodiment of this invention applied thereto;
FIG. 2 is an elevation of the end of the needle latch assembly as it would appear during penetration of a work material;
FIG. 3 is an elevation similar to FIG. 2 showing however the arrangement of parts of the needle latch assembly as they would appear at both the uppermost and lowermost exteme position thereof;
FIG. 4 is an elevation of the needle latch assembly as it would appear after the upper thread had been caught by the needle latch assembly and is being transported to the looptaker;
FIG. 5 is an end elevation of the sewing machine shown in FIG. 1 showing the needle looper assembly in the uppermost position;
FIG. 6 is a cross sectional view of the needle looper assembly shown in the lowermost position and its relation to the looptaker;
FIG. 7 is a perspective view of a portion of the looptaker, needle looper assembly, work material and thread manipulating members indicating the positions thereof at the moment of loop seizure;
FIG. 8 is a plan view of the looptaker and bobbin case supported therein in the process of loop expansion and casting about the bobbin case;
FIG. 9 is a perspective view similar to FIG. 7, shown however after grasping an upper thread and during transit of the needle looper assembly to a lowermost position; and,
FIG. 10 is a plan view of the presser foot, needle looper assembly and thread manipulating members to show the action thereof which directs the upper thread into the hook of the needle looper assembly.
With reference to the drawings, the invention is incorporated in a sewing machine having a frame shown in phantom and including a hollow work supporting bed 10 with a hollow standard 11 rising from one end thereof and terminating at its upper end in a hollow bracket arm 12 that extends laterally over the work supporting bed.
A main shaft 13 is rotatably mounted within the hollow bracket arm 12 and extends longitudinally therethrough. The main shaft 13 has a crank 15 formed in an intermediate portion thereof with a cam surface thereon. A pitman 16 is pivotably mounted in the hollow standard 11 by means of pintal screws 17. At its upper end, the pitman 16 is slotted to provide a cam follower 18 in engagement with the cam surface of the crank 15.
A stitch forming mechanism drive bar 20 is pivotally connected to the bottom of the pitman 16 by means of a pivot screw 21. A rack element 23 and a cam member 24 are connected to the free end of the drive bar 20. The teeth of the rack 23 are in engagement with the teeth of a drive pinion or gear 26 which is connected by means of a set screw 27 to the bottom of a vertical axis looptaker shaft 28 to which a conventional form of looptaker 29 is affixed. Supported within the looptaker 29 against oscillation therewith is a bobbin case 31 which carries internally thereof bobbin 32. Thus, as the main shaft 13 is turned under the urgings of a main drive motor (not shown), the pitman 16 is urged to undergo oscillation by the action of the crank 15 against the slotted cam follower 18 of the pitman, this action causing the drive bar 20 to engage in to and fro motion oscillating the looptaker 29 and by means of cam 24 encouraging lift of the feed dogs (not shown).
At the outer end of the main shaft 13, there is supported a handwheel 38. Adjacent the handwheel 38 there is connected a sprocket 40, which sprocket carries a chain 42 connected to a lower sprocket 44 carried on a lower shaft 45. The lower shaft 45 is journalled in bearings which are carried in extensions 47 depending from the work supporting bed 10. A feed eccentric 49 is supported by the lower shaft 45, the eccentric being encircled by a collar 51 which is connected by a link 52 to the rock arm of a feed rock shaft 54 for imparting feed and return motion to the feed dogs (not shown) alternately with the lifting and falling action imparted by cam 24.
Referring to FIG. 6, on the end of the lower shaft 45 opposite the sprocket 44 there is supported a crank 60, and spaced inwardly thereof a cam disk 62. The crank 60 is connected by way of connecting rod 61 to a lug 64 transverse of and affixed to an upright needle looper assembly 66 by means of screw 65. The needle looper assembly 66 is urged in vertical endwise reciprocation by the crank 60 and connecting rod 61 within bearings provided in appendages 68 affixed to an adjacent extension 47. The needle looper assembly 66 includes a tube 72 which slides within bearings in the appendages 68, the tube having a constricted bore at the upper end to receive an outer needle bar 75 therein. The outer needle bar 75 is fashioned with a hollow interior and at the end thereof tapers to a point 76 at a shallow angle so as to provide ready penetration of a work material (see FIG. 2). Approximately midway of the taper there is formed a scallop 78 for a purpose to be explained below.
Internally of the outer needle bar 75 there is situated a rod-like inner needle bar 80. The inner needle bar 80 extends the length of the outer needle bar 75 and into the tube 72 where it is fastened to a piston 85 by a screw 83, which screw slides in a slot 84 in the tube so as to maintain orientation of the inner needle bar to the outer needle bar. The upper end of the inner needle bar 80 is fashioned with a hook 82, which hook in certain positions of the inner needle bar with respect to the outer needle bar 75 creates a thread carrying eyelet with the scallop 78 in the outer needle bar (see FIG. 4). The lower end of the piston 85 is fashioned into a spindle 86, the bottom end of which is threaded to receive a cap 89. A spring 88 is carried on the spindle 86 between the cap 89 and a cup 87 threadedly attached to the bottom end of the tube 72. Thus, by reference to FIG. 6 it can be seen that the cap 87 is urged into engagement with the cam disk 62 by the spring 88 so that the inner needle bar 80 may be raised or lowered and extended from the outer needle bar in accordance with the periphery on the cam disk. The entire needle looper assembly 66 reciprocates endwise through the looptaker 29 adjacent the looptaking beak 30 thereof and upward through a presser foot 56 carried on a presser bar 57. Thus, the needle looper assembly 66 is urged in endwise reciprocation by the crank 60 while simultaneously the inner needle bar 80 thereof partakes of independent motion in syncronism with the outer needle bar under the urgings of the cam disk 62. Referring to FIG. 2 there is shown the position of the inner needle bar 80 with respect to the outer needle bar 75 during its ascent and when the point 76 of the outer needle bar is penetrating the work material supported on the work supporting bed 10 of the sewing machine. In FIG. 3 there is shown the position of the inner needle bar 80 with respect to the outer needle bar 75 when the needle looper assembly 66 is at either extreme of its upper or lower position. As will be explained below, in this position the hook 82 of the inner needle bar 80 is exposed to receive an upper thread in the upper position, or to release the upper thread in the lower position. In FIG. 4 there is shown the position of the inner needle bar 80 with respect to the outer needle bar 75 after an upper thread has been picked up by the hook 82 of the inner needle bar and while the upper thread is being transported through the work material to a lower position for release.
Referring to FIGS. 1 and 5, the end of the main shaft 13 supports a gear and crank combination 90 which is affixed to the main shaft by screw 91. The gear and crank 90 actuates a takeup lever 93 to provide, as is well known in the sewing machine art, thread to the looptaker 29 for enlarging of the loop and passing it around the bobbin case 31 and bobbin 32 and subsequent takeup of the slack thread. The gear and crank combination 90 also drives intermediate gears 96 supported on idler shaft 97 in the head of the sewing machine. An intermediate gear 96 is connected to a gear 100 to which there is adjustably attached two one lobe cams 102 and 104. The cam 102 includes a face cam portion 101 on the gear 100. A thread guide lever 106 is fashioned with an abutment 107 in engagement with one lobe cam 102 and the face cam portion 101. The end of the thread guide lever 106 opposite the abutment 107 is fashioned with a thread guide 109 having an eyelet 110 in one end and attached to the lever 106 by screw 108. Movement of the thread guide lever 106 by the one lobe cam 102 and face cam portion 101 manipulates the eyelet 110 at the end of the lever for a purpose which will be explained below. The thread guide lever 106 pivots on screw 111 carried by the head end of the sewing machine. A biasing spring 112 is carried on a bracket (not shown) affixed to the head end of the sewing machine and is attached to the thread guide lever in a fashion to maintain contact between the abutment 107 thereof and the one lobe cam 102 and face cam portion 101.
A notched lever 114 is pivoted on screw 115 attached to the head end of the sewing machine and is biased by spring 116 connected to a bracket (not shown) so as to maintain the abutment 117 of the notched lever in engagement with the one lobe cam 104. The notched end 118 of the notched lever 114 is arranged adjacent the line of stitching so that it will engage the upper thread extending to the work material and wrap that thread about the inner needle bar 80 into the hook 82 thereof when the needle looper assembly 66 is positioned as shown in FIG. 3 of the drawings in the uppermost position. The cam 102 and the face cam portion 101 will operate upon the thread guide lever 106 to cause the thread guide 109 and eyelet 110 thereof to pivot about the screw 111 initially in a rearwardly direction and when actuated by the face cam portion laterally to the right. This motion is shown in FIG. 10 where the initial position of the eyelet 110 is shown in phantom and the final position thereof is shown in full. This motion will step the upper thread initially to a position behind the hook 82 of the inner needle bar 80 and then to a position laterally to the other side of the inner needle bar. Thereafter the cam 104 will actuate the notched lever 114 to have the notched end 118 thereof sweep the end of the upper thread extending through the throat plate into the hook 82 so that as the hook is retracted to the position shown in FIG. 4 an upper thread will be grasped in the eyelet formed with the scallop 78 of the outer needle. Thereafter, as is shown in FIG. 9, the inner needle bar 80 is withdrawn to the interior of the outer needle bar 75 and the needle looper assembly 66 draws the upper thread down to the looptaking beak 30 of the looptaker 29 (see FIG. 9). In FIG. 1 it will be seen that the needle looper assembly 66 is in the uppermost position with the inner needle bar 80 extended in a thread receiving attitude. The follower end of the inner needle bar 80 is engaged with the cam disk 62 adjacent an abrupt discontinuity thereof, and continued counterclockwise movement of the cam disk, as viewed from the crank 60, will permit the inner needle bar to fall and assume the position shown in FIG. 4. Thereafter the contour of the cam disk 62 is fashioned to synchronize the travel of the inner needle bar 80 with the outer needle bar 75. When the needle looper assembly 66 approaches the lower position of its travel the cam disk 62 is formed so as to reinitiate the relative position of the outer needle bar and inner needle bar illustrated in FIG. 3 to permit the looptaker to seize the loop therefrom. A stop screw 120, supported by bracket 121 affixed to the head of the sewing machine limits the retrograde motion of the thread guide lever 106 as urged by the biasing spring 112. A similar stop screw 123 is also supported by a bracket in order to limit the retrograde movement of the notched lever 114.
In FIG. 7 there is shown a view of the needle looper assembly 66 in the lowermost position with the inner needle bar 80 extended from the outer needle bar 75. When the inner needle bar 80 is elevated by the cam disk 62 to extend out of the outer needle bar 75, the tension on the upper thread is relieved and a loop is thrown which may be picked up by the beak 30 of the looptaker 29, and enlarged about the bobbin case 31 and the bobbin 32 supported therein. In the process of casting the loop about the bobbin case 31, the upper thread is withdrawn from the hook 82 of the inner needle bar 80, as shown in FIG. 8. As the loop is cast about the bobbin case 31, the takeup lever 93 operates as is well known in the sewing machine art, to remove the excess thread from the system. After the upper thread is shed from the needle looper assembly 66, the needle looper assembly may once again rise to an uppermost position to once again draw down an upper thread in preparation for the next succeeding stitch.
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A lockstitch sewing machine utilizing a needle looper to extend upwardly through a work material to grasp an upper thread and pull it downwardly through the work material to a looptaker which casts the upper thread about a lower thread in order to form a lockstitch. When the needle looper is in an upper position to catch an upper thread, a hook needle is exposed and thread is deflected into the hook thereof. As the needle looper is retracted to a depressed position the hook needle is moved to a guard position so as to retain the upper thread therein during transit. When the needle looper is at its lower position, the hook is again exposed to release its thread to a looptaker for concatenation with a lower thread.
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BACKGROUND
[0001] The present invention relates to a power conservation method in a processor.
[0002] [0002]FIG. 1 is a block diagram illustrating the process of program execution in a conventional processor. Program execution may include three stages: front end 110 , execution 120 and memory 130 . The front-end stage 110 performs instruction preprocessing. Front end processing 110 typically is designed with the goal of supplying valid decoded instructions to an execution core with low latency and high bandwidth. Front-end processing 110 can include branch prediction, decoding and renaming. As the name implies, the execution stage 120 performs instruction execution. The execution stage 120 typically communicates with a memory 130 to operate upon data stored therein.
[0003] [0003]FIG. 2 illustrates high-level processes that may occur in front-end processing. A front-end may store instructions in a memory, called an “instruction cache” 140 . A variety of different instruction formats and storage schemes are known. In the more complex embodiment, instructions may have variable lengths (say, from 1 to 16 bytes in length) and they need not be aligned to any byte location in a cache line. Thus, a first stage of instruction decoding may involve instruction synchronization 150 —identifying the locations and lengths of each instruction found in a line from the instruction cache. Instruction synchronization typically determines the location at which a first instruction begins and determines the location of other instructions iteratively, by determining the length of a current instruction and identifying the start of a subsequent instruction at the next byte following the conclusion of the current instruction. Once the instruction synchronization is completed, an instruction decoder 160 may generate micro-instructions from the instructions. These micro-instructions, also known as uops, may be provided to the execution unit 120 for execution.
[0004] Conventionally, front end processing 110 may build instruction segments from stored program instructions to reduce the latency of instruction decoding and to increase front-end bandwidth. Instruction segments are sequences of dynamically executed instructions that are assembled into logical units. The program instructions may have been assembled into the instruction segment from non-contiguous regions of an external memory space but, when they are assembled in the instruction segment, the instructions appear in program order. The instruction segment may include microinstructions (uops).
[0005] A trace is perhaps the most common type of instruction segment. Typically, a trace may begin with an instruction of any type. Traces have a single entry, multiple exit architecture. Instruction flow starts at the first instruction but may exit the trace at multiple points, depending on predictions made at branch instructions embedded within the trace. The trace may end when one of number of predetermined end conditions occurs, such as a trace size limit, the occurrence of a maximum number of conditional branches or the occurrence of an indirect branch or a return instruction. Traces typically are indexed by the address of the first instruction therein.
[0006] Other instruction segments are known. Intel engineers have proposed an instruction segment, which they call an “extended block,” that has a different architecture than the trace. The extended block has a multiple-entry, single-exit architecture. Instruction flow may start at any point within an extended block but, when it enters the extended block, instruction flow must progress to a terminal instruction in the extended block. The extended block may terminate on a conditional branch, a return instruction or a size limit. The extended block may be indexed by the address of the last instruction therein. The extended block and methods for constructing them are described in Jourdan, et al., “eXtended Block Cache,” HPCA-6 (January 2000).
[0007] A “basic block” is another example of an instruction segment. It is perhaps the most simple type of instruction segment available. The basic block may terminate on the occurrence of any kind of branch instruction including an unconditional branch. The basic block may be characterized by a single-entry, single-exit architecture. Typically, the basic block is indexed by the address of the first instruction therein.
[0008] Regardless of the type of instruction segment used in a processor 110 , the instruction segment typically is stored in a segment cache 170 for later use. Reduced latency is achieved when program flow returns to the instruction segment because the instruction segment may store instructions already decoded into uops and assembled in program order. Uops from the instruction segments in the segment cache 170 may be furnished to the execution stage 120 faster than they could be furnished from different locations in an ordinary instruction cache 140 .
[0009] Many instruction segments, once built and stored within a segment cache 170 , are never used. This may occur, for example, because program flow does not return to the instructions from which the instruction segment was constructed. Some other instruction segments may be reused quite often. However, because a segment cache 170 may have a limited capacity (say, 1024 uops), low segment reuse causes even frequently-used instruction segments to be overwritten by other instruction segments before their useful life otherwise might conclude. Thus, with a high eviction rate in the segment cache 170 , the advantages of instruction segments can be lost.
[0010] Conventionally, a front end stage 110 may include a segment builder 180 provided in communication with the instruction decoder 160 to capture decoded uops and build instruction segments therefrom. The segment builder 180 typically includes buffer memories to store the uops and a state machine to detect segment start and end conditions and to manage storage of instruction segments within the segment cache 170 .
[0011] The techniques for implementation and management of instruction segments consume tremendous amounts of power. Power must be provided for the segment cache 170 and the segment builder 180 . The segment cache 170 must be integrated with other front-end components, such as one or more branch predictors (not shown). And, of course, as implementation of instruction segments becomes more complex, for example, to employ concepts of traces or extended blocks, the power consumed by the circuits that implement them also may increase. By way of example, the front-end system of the IA- 32 processors, products commercially available from Intel Corporation of Santa Clara, Calif., consumes about 28% of the overall processor power.
[0012] As mobile computing applications and others have evolved, raw processor performance no longer is the paramount consideration for processor designs. Modern designs endeavor to provide maximize processor performance within a given power envelope. Given the considerable amount of power spent in front-end processing, the inventors perceived a need in the art for a front end unit that employs power control techniques. It is believed that such front end units are unknown in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram illustrating the process of program execution in a conventional processor.
[0014] [0014]FIG. 2 illustrates high-level processes that may occur in front-end processing.
[0015] [0015]FIG. 3 illustrates a block diagram of a front-end unit according to an embodiment of the present invention.
[0016] [0016]FIG. 4 illustrates a method according to an embodiment of the present invention.
[0017] [0017]FIG. 5 is a block diagram of an instruction cache with the functionality of an access filter integrated therein according to an embodiment of the present invention.
[0018] [0018]FIG. 6 illustrates an access filter according to an embodiment of the present invention.
[0019] [0019]FIG. 7 is a block diagram of a cache according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0020] Embodiments of the present invention introduce an access filter to a front end system for power conservation. The access filter may selectively enable or disable segment builders within the front end to ensure that only instruction segments that are likely to be reused by program flow will be stored in the segmentation cache, e.g. segment cache. Simulation studies suggest that many instruction segments, once stored in the segment cache, are never used. For example, one simulation suggested that up to 67% of all segment cache lines are replaced before being used even once in a simulated segment cache having 6 ways, 64 sets and 6 uops per set. Typically, a new instruction segment is built each time an IP miss occurs in the instruction segment cache. Program flow may not return to the IP that caused a miss in the segment cache or, even if it does return to the IP, the program flow may return after so much time that the instruction segment has been evicted from the segment cache in favor of newer instruction segments. In either case, the power spent in the process of building and storing the unused instruction segment is wasted without contributing to the performance of the front-end system. The techniques of the present embodiments help to ensure that power will be spent building instruction segments that are likely to be used.
[0021] [0021]FIG. 3 illustrates a front-end system 200 according to an embodiment of the present invention. This embodiment may include a segment cache 210 , an instruction cache 220 , an instruction synchronizer 230 , an instruction decoder 240 and a segment builder 250 . In this embodiment, power conservation may extend to the segment builder 250 by disabling it unless certain preconditions are met. An access filter 260 may enable or disable the segment builder 250 . Disabling the segment builder 250 , of course, conserves power.
[0022] [0022]FIG. 4 illustrates a method 1000 according to an embodiment of the present invention. According to the method, when a new IP is presented to and hits the instruction cache, the number of times that a cache line has been accessed may be counted (box 1010 ). The count is compared with a predetermined threshold to determine whether it meets or exceeds the threshold (box 1020 ). If so, then the segment builder may be enabled (box 1030 ). Enabling the segment builder may cause it to build an instruction segment by conventional techniques and to store the new instruction segment in the segment cache (boxes 1040 , 1050 ). Storing the new instruction segment may cause eviction of an old instruction segment (box 1060 ). Building of instruction segments and storage and eviction of instruction segments from a segment cache is well known. If, at box 1020 , the count did not meet or exceed the threshold, the segment builder may be maintained in a disabled state (box 1070 ).
[0023] In an embodiment of the invention, if the new IP hits the segment cache 240 the method 1000 may be aborted regardless of the value of the access count (box 1080 ). In the general case, a hit in the segment cache 240 may indicate that the segment cache 240 already stores an instruction segment responsive to the new IP. The segment builder 250 may be disabled to conserve power because the segment builder 250 could not generate a useful result in this circumstance.
[0024] A hit in the segment cache 240 , however, need not disable the method 1000 in every event. As described in the Jourdan article, the multiple-entry, single-exit architecture of extended blocks permits the beginning of an extended block to be extended to include additional uops. In this embodiment, by threshold testing the access count regardless of a hit/miss response from the segment cache 240 , the method may identify situations that are reasonably likely to cause an existing extended block to be extended. In such situations, it may be beneficial to enable the segment builder 250 . The segment builder 250 , operating according to the techniques disclosed in the above-referenced application, may enhance existing extended blocks as appropriate.
[0025] [0025]FIG. 5 is a block diagram of an instruction cache 300 having integrated functionality of an access filter according to an embodiment of the present invention. The instruction cache 300 may be populated by a plurality of cache entries 310 . 1 - 310 .N, an address decoder 320 and a comparator 330 . Each cache line may include a tag field 340 , an access count field 350 and a data field 360 . The tag field 340 may store tag data representing an address of program instructions stored in the data field 360 . The access count field 350 may store a count of the number of times data from the cache entry has been read from the cache 300 .
[0026] In response to a new IP, the address decoder 320 may cause data from one of the cache entries 310 . 1 - 310 .N to be driven on output lines. The comparator 330 may compare data from the tag field 340 to a portion of the new IP. If they match, the instruction cache 300 may register a hit. Otherwise, the IP misses the instruction cache 300 .
[0027] Typically, when the address decoder 320 selects a cache line (say, line 310 . 1 ) in response to a new IP, the contents of the data field 360 may be driven toward an output of the gate. If the comparator 330 registers a hit, the contents of the data field 360 may propagate out of the instruction cache 300 ; otherwise, they are blocked. For example, the hit/miss indicator from the comparator 330 may control a transmission gate that communicates data from the data field 360 out of the cache 300 .
[0028] In an embodiment, an access count field 350 may be provided in each cache entry 310 . 1 - 310 .N for storage of a count value. The cache may include an incrementor 370 coupled to the access count fields 350 and a second comparator 380 coupled to the incrementor. When a cache entry (say, entry 310 . 1 ) is activated by the address decoder 320 , data from the access count field 350 may be output to the incrementor 370 . As its name implies, the incrementor 370 may increment the value of the count field. The incremented value may be threshold tested by the second comparator 380 . An output of the second comparator may indicate whether the incremented count value meets or exceeds the threshold. The output may be output from the cache 300 as the enable signal.
[0029] The incremented count value may be stored back in the count field 350 of the cache entry 310 . 1 so long as the IP hits the cache. FIG. 5 illustrates a second gate 390 , controlled by the hit/miss output from the tag comparator 330 . If the incremented count value advances beyond the second gate 390 , it may propagate to write circuitry within the cache 300 (not shown for clarity) and may be written back in the cache entry 310 . 1 .
[0030] The threshold value Th may be tuned to meet design criteria of any system for which the present invention may be used. Typical threshold values are 1, 3 or 7, permitting the access count field to be one, two or three bit fields.
[0031] In an embodiment, the incrementor 370 may be provided as a saturating incrementor. If, by incrementing the access count value, it causes a carry out of the most significant bit position in that value, the access count value may be left unchanged.
[0032] In the embodiment shown in FIG. 5, the incrementor is shown provided in direct connection to the count fields 350 and the threshold comparator 380 shown coupled to the output of the incrementor 370 . Of course, the interconnection of these units may be reversed in other embodiments. The threshold comparator 370 may compare the stored count value to a threshold and, if it meets or exceeds a threshold, the comparator may generate the enable signal therefrom. In this alternate embodiment (not shown), the incrementor 370 may increment the count value and store the result back in the respective access count field 350 .
[0033] The foregoing description presents operation of the cache 300 when reading data therefrom. In an embodiment, the access counter may be cleared (e.g., set to zero) when new instructions are stored in the respective line of the instruction cache. Thus, when writing new data to a line 310 . 1 within the instruction cache 300 and possibly evicting old data therefrom, the contents of the access counter field 350 may be cleared. Techniques for writing data to an instruction cache and evicting data therefrom are well known.
[0034] The access filter need not be integrated with the instruction cache. FIG. 6 illustrates an access filter 400 according to an embodiment of the present invention. The access filter 400 may be populated by a plurality of filter entries 410 . 1 . 1 - 410 . 1 .N, an address decoder 420 , a tag comparator 430 and a write controller 440 . In this embodiment, the cache entries 410 . 1 - 410 .N may store only tag data.
[0035] During operation, when a new IP is applied to the address decoder 420 , it may cause tag data to be output from an addressed entry (say, entry 410 . 1 ). If the tag data from the entry 410 . 1 matches tag information from the new IP, then a match may be registered. Otherwise, no match occurs. When no match occurs, the tag data from the new IP may be stored in the entry 410 . 1 via the write controller 440 . The new tag data overwrites the tag data previously stored in the entry.
[0036] When a tag match occurs, it signifies that program flow has traversed a single IP twice. It also signifies that no other IP has been encountered to the same tag. Otherwise, the tag of the second IP would have overwritten the tag that caused the tag match. The hit/miss output generated by the tag comparator 730 may be used as an enable signal to control the segment builder 250 (FIG. 3).
[0037] Returning to FIG. 3, an access filter 260 may reduce the rate at which data is evicted from the segment cache. The access filter 260 may keep the segment builder 250 disabled until program flow exhibits a pattern in which it traverses a single IP multiple times. Once a pattern is exhibited, however, a new instruction segment may be stored in the segment cache 210 . Data eviction in the cache 210 is reduced by requiring the same pattern to be exhibited (directed to the same set) before a second instruction segment is created. The first instruction segment remains valid until a second instruction segment is assembled and stored in cache locations formerly occupied by the first instruction segment. Thus, the access filter 260 may improve the useful life of an instruction segment.
[0038] In this embodiment, the access filter 400 operates with a threshold value of Th=2. The first time an IP is presented to the access filter, it causes a miss with previously stored tags and is written to an entry within the cache. The second time the IP is presented, assuming the tag has not been overwritten, a tag hit occurs and the segment builder 250 (FIG. 3) is enabled. Thus, this embodiment permits a threshold comparison to be made even though the embodiment does not store an access count value within the access filter 400 .
[0039] Of course, the access filter 400 can include access count values in other embodiments. FIG. 6 illustrates in phantom access count fields 450 provided for each entry 410 . 1 - 410 .N, an incrementor 460 , a transmission gate 470 and a threshold comparator 480 . When a new IP is applied to the address decoder 420 , the count value from one of the count fields 450 may be output to the incrementor 460 . If the tag comparator 430 registers a hit, an incremented count value may pass through the gate 470 to the threshold comparator 480 . An output of the threshold comparator 480 may be output from this embodiment of the access filter 400 as an enable control signal. FIG. 6 also illustrates the incremented count value passing from the gate 470 to write controller 440 (shown in phantom to maintain clarity of presentation). Thus, the incremented count values may be stored back in the count fields 450 of the entry selected by the address decoder 420 .
[0040] In other embodiments, an instruction cache 210 (FIG. 3) may be provided as a set associative cache. Set-associative caches are known per se. They typically include several arrays of cache entries (called “ways”), one entry from each way being a member of the same set. To implement the cache 300 of FIG. 4 as a set-associative cache, the structure shown in FIG. 4 may be duplicated for each of the ways in the cache. The cache may also include a cache manager (not shown), typically provided as a state machine, to manage victim selection and other elements of the cache's eviction policy.
[0041] Embodiments of the access filter 400 of FIG. 6 also may be provided in a set-associative fashion, duplicating the structure shown into multiple ways. Although it is possible to provide in the access filter one way for every way in the instruction cache, other embodiments permit fewer ways than are provided in the associated instruction cache. One of the advantages of the access filter is that, when an instruction segment is built and stored in the segment cache 240 , it is unlikely to be evicted until program flow hits another conflicting IP repeatedly. Providing a large number of ways in the access filter 400 can cause a slow eviction rate among tags stored in the access filter which can correspondingly increase the eviction rate within the segment cache 240 .
[0042] As described above, count values are a useful basis on which to predict instruction segments that have a high likelihood of reuse. Additional embodiments of the present invention can improve the prediction by de-emphasizing count values that may not demonstrate sufficient re-use to merit an instruction segment. In one embodiment, it may be sufficient to decrement or downshift counter values of all access counters periodically in an access filter. It may occur that some instructions are infrequently used when compared with other instructions in the instruction cache. These instructions, although infrequently used, may not be evicted by other instructions. Infrequent but regular use might otherwise cause an access counter to approach the threshold value that would cause an instruction segment to be built. However, in an embodiment that periodically decrements access counters, it would be less likely that an instruction segment would be built from an infrequently used cache line.
[0043] Alternatively, decrementing or downshifting of access counters may occur individually for each cache line. FIG. 7 is a block diagram of a set-associative cache 500 according to an embodiment of the present invention. The cache 500 is shown with a plurality of ways O-N, labeled 510 - 540 , and an eviction unit (EU) 550 . Each of the ways 510 - 540 may include a count field and a data field as discussed above. For each set in the cache 500 , the EU 550 may store a pointer identifying a “victim way,” a way that is the next candidate for eviction. The pointer may be established according to a least-recently-used (LRU) algorithm or some other conventional technique that monitors IPs input to the cache and determines which of the entries in the cache are not used. According to an embodiment, when the eviction pointer changes and points to a new victim way, the access counter within the victim way may be decremented or downshifted. Thus, even if the count value within a particular entry were nearing the threshold sufficient to trigger the construction of a new instruction segment, if program flow were accessing other ways in the set with such regularity that a way became the victim way, it may indicate that the instructions within the victim way are so useful as to merit a new instruction segment.
[0044] As is known, eviction units typically include an age matrix (not shown in FIG. 7) to implement the LRU algorithm. Instead of merely reducing an access counter of a new victim way (the “oldest” way in the set), the access counter may be reduced when a way passes the median age threshold of all ways in the set. Stated alternately, a count value may be reduced when a way passes the half-way mark between the most recently used way and the least recently used way in the set. In these latter embodiments, the “age” of a cache line represents the time since the cache line was most recently used, not necessary an absolute measure of all time in which the data resided in the cache line.
[0045] [0045]FIG. 7 illustrates a controller 560 to manage count values within the cache 500 . Cache controllers 560 are known per se. Typically, they are provided as state machines. In an embodiment, a conventional cache controller 560 may be modified to integrate the functionality recited above into its overall operation.
[0046] Several embodiments of the present invention are specifically illustrated and described herein. However, it will be appreciated that modifications and variations of the present invention are covered by the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention.
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Power conservation may be achieved in a front end system by disabling a segment builder unless program flow indicates a sufficient likelihood of segment reuse. Power normally spent in collecting decoded instructions, detecting segment beginning and end conditions and storing instruction segments is conserved by disabling those circuits that perform these functions. An access filter may maintain a running count of the number of times instructions are read from an instruction cache and may enable the segment construction and storage circuits if the running count meets or exceeds a predetermined threshold.
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FIELD OF THE INVENTION
The present invention relates generally to a fan assembly, and more particularly to an electric fan with more than one operational configuration.
BACKGROUND OF THE INVENTION
A great variety of consumer fans are known in the industry. Fans of various operational capabilities have been configured for uses in different conditions and locations. For example, some fans have speed or height adjustability, or noise reduction features. Certain fans are configured as floor fans intended to circulate air in a good-sized area, such as a living room. Others are manufactured as desk fans intended for personal use. The present invention provides a method for enhancing the operational versatility of a fan and a fan having such operational versatility.
SUMMARY OF THE INVENTION
One embodiment in accordance with the present invention provides a fan assembly with two operational configurations. In one configuration, the fan body is attached to and rests on top of a support member. In another configuration, the fan body is tilted approximately 90 degrees, and operates on top of a second support member.
Preferably, the fan body comprises an elongated spinning drum having a plurality of fan blades encased in a substantially cylindrical fan housing. The fan housing includes a substantially tubular portion that is rotatable and oscillatable during operation. In the first or upright configuration, the fan generates a transversely oscillating airflow. In the second or horizontal configuration, the fan generates a vertically oscillating airflow.
In addition, the present invention discloses a method for enhancing the operational versatility of a fan. Two support members attachable to a fan are provided. One support member is used to support the fan in a first or upright position. Another support member is used to support the fan in a second or horizontal position.
Another illustrative embodiment of the present invention provides a fan assembly comprising an elongated spinning drum having a plurality of fan blades encased in a substantially cylindrical fan housing, which includes a substantially tubular portion that is rotatable. The tubular portion includes at least one grille member with varied thickness in a circumferential direction about the fan drum. Preferably, the thickness of the grille member decreases in the direction opposite to the rotation of the fan drum, creating a tapered portion for the grille member.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, aspects and advantages will be better understood from the following description of the embodiments in accordance with the present invention with reference to the accompanying drawings, in which like numerals reference like elements, and wherein:
FIG. 1 is a top, front perspective view of a fan assembly in a first operational configuration in accordance with the present invention;
FIG. 2 is an exploded, rear perspective view of the FIG. 1 fan assembly;
FIG. 3 is an enlarged view of FIG. 2 ;
FIG. 4 is a top, front perspective view of the FIG. 1 fan assembly in a second operational configuration;
FIG. 5 is an exploded, front perspective view of the FIG. 4 fan assembly;
FIG. 6 is a top, front perspective view of another embodiment of a fan assembly in a first operational configuration in accordance with the present invention;
FIG. 7 is a rear elevational view of the FIG. 6 fan assembly;
FIG. 8 is a top, front perspective view of the FIG. 6 fan assembly in a second operational configuration;
FIG. 9 is a cross-sectional view of FIG. 1 , taken along section lines A—A.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1–4 , an illustrative embodiment of a fan assembly in accordance with the present invention includes a fan body 10 , a first support member 20 , and a second support member 30 .
The fan body 10 comprises a fan (not shown), preferably an elongated spinning drum having a plurality of fan blades, situated inside a substantially cylindrical fan housing, which includes a substantially tubular portion 11 , a first end cap member 12 , a second end cap member 13 , and at least one ventilation opening 14 , preferably a grille. The substantially tubular portion 11 is preferably rotatable with respect to the end cap members 12 and 13 . The end cap members 12 and 13 define a first surface 15 and a second surface 16 substantially perpendicular to the first surface 15 .
Preferably, the end cap member 12 includes a first receiving member 17 on the first surface 15 . Similarly, the end cap members 12 and 13 each includes a second receiving member 18 on the second surface 16 . The receiving members 17 and 18 are present to enable the first and second support members 20 and 30 to be attached to the fan body 10 , respectively, which is described in further detail below. As such, the receiving members 17 and 18 may take any suitable form, including a socket, a clip, a clamp, and any other connecting, coupling or locking mechanisms. Preferably, however, the first receiving member 17 is in the form of a socket and the second receiving member 18 includes at least one clip.
In operation, a user may choose a first or upright operational configuration by attaching the fan body 10 to the first support member 20 via the first receiving member 17 and a first attaching member 21 , as illustrated in FIGS. 2 and 3 . In addition to the first attaching member 21 , the first support member 20 preferably includes a locking clip 22 , which may be spring loaded. The fan body 10 is securely attached to the first support member 20 by inserting the first attaching member 21 into the first receiving member 17 , and securing the position using the locking clip to prevent the first attaching member 21 from slipping out of the first receiving member 17 .
In this first or upright operational configuration, the substantially tubular portion 11 of the fan housing rotates circumferentially about the fan drum (not shown), and oscillates back and forth to generate a transverse airflow moving in radial directions away from a rotation axis defined by the rotations of the fan drum and the tubular portion 11 . The first support member 20 may be detached from the fan body 10 for easy storage or in preparation of operating the fan assembly in a second or horizontal configuration.
Turning now to FIGS. 4 and 5 , the second or horizontal operational configuration is formed by attaching the fan body 10 to the second support member 30 via the second receiving member 18 and a second attaching member 31 . The fan body 10 is securely attached to the second support member 30 by inserting the second attaching member 31 into the second receiving member 18 , as shown in FIG. 5 , such that the second receiving member 18 securely clips into the second attaching member 31 . Note that the relative male-to-female roles of the receiving members 17 and 18 and their corresponding attaching members 21 and 31 may be reversed without deviating from the principles of the present invention.
In the second configuration, therefore, the substantially tubular portion 11 of the fan housing rotates circumferentially about the fan drum (not shown), and oscillates back and forth to generate a vertically oscillating airflow moving in radial directions away from the rotation axis of the fan drum and the tubular portion 11 . The second support member 30 may be detached from the fan body 10 for easy storage or in preparation of operating the fan assembly in the first configuration.
Referring now to FIGS. 6–8 , another embodiment of a fan assembly in accordance with the present invention includes a fan body 40 , a first support member 50 , and a second support member 60 .
Similar to the first embodiment, the fan body 40 comprises a fan (not shown)—preferably an elongated spinning drum having a plurality of fan blades—situated inside a substantially cylindrical fan housing, which includes a substantially tubular portion 41 , a first end cap member 42 , a second end cap member 43 , and at least one ventilation opening 44 , preferably a grille. The substantially tubular portion 41 is preferably rotatable with respect to the end cap members 42 and 43 .
In this embodiment, however, the first supporting member 50 and the first end cap member 42 are one and the same. That is, the fan body 40 rests on the first end cap member 42 when the fan assembly operates in a first or vertical configuration. The fan assembly generates a transversely oscillating airflow similar to the fan assembly of the first embodiment described above.
To use the fan assembly in a second or horizontal configuration, one simply tilts the fan assembly approximately 90 degrees such that the fan assembly rests on the second support member 60 , which is preferably attached fixedly to the fan body 40 . As illustrated, the second support member 60 preferably comprises four legs 61 connected by a U-shaped tube 62 . The U-shaped tube 62 adds structural integrity to the fan assembly and is an optional feature. The second support member 60 may additionally include a handle bar 63 for easy handling. In this second configuration, the fan assembly generates a vertically oscillating airflow similar to the fan assembly of the first embodiment described above.
The uniqueness of the embodiment illustrated in FIGS. 6–8 is that the fan assembly is a whole unit, with both of the supporting members 50 and 60 already attached. As such, this embodiment is most suitably used as a personal unit on top of a desk, for example.
As shown in FIG. 9 , a fan body similar to fan bodies 10 and 40 may increase the air outflow by employing a grille member with varied thickness in a circumferential direction about the fan drum. It is believed that pockets of air currents that form small eddies or vortexes inside a traditional fan unit having a fan grille of uniform thickness are reduced by using a grille member with varied thickness. With the absence or a reduction of conflicting air currents inside the fan housing, the air outflow from a fan assembly will increase, and the fan assembly may be used more efficiently.
Referring to FIG. 9 , the thickness of a grille member 80 in accordance with the present invention decreases in a circumferential direction about the fan drum 70 opposite to the rotation of the fan drum 70 , creating a tapered portion 81 for the grille member 80 .
Although the invention herein has been described with references to particular embodiments, it is to be understood that the embodiments are merely illustrative of, and are not intended as a limitation upon, the principles and application of the present invention. It is therefore to be understood that various modifications may be made to the above mentioned embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention.
For example, the fan bodies 10 and 40 as described above may comprise a fan housing with a stationary tubular portion 11 or 41 , respectively, resulting in a constant and stationary airflow.
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An electric fan with more than one operational configuration is disclosed, comprising a fan unit, a first support element and a second support element. In one operational configuration, the fan unit rests on top of the first support element and generates a horizontally oscillating airflow. In another configuration, the fan unit rests on top of the second support element and generates a vertically oscillating airflow.
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FIELD OF THE INVENTION
The following invention relates generally to a method and apparatus for building up material on an outer surface of a hollow toroidal shaped object. More specifically, the instant invention is directed to an apparatus and method for recapping vehicular tires.
BACKGROUND OF THE INVENTION
Despite the ongoing efforts in modern society to recycle, the efforts towards recycling tires has curiously remained a difficult problem to solve. This problems persists today because the technology for manufacturing new tires--radial tire technology--has virtually made obsolete the technology for recapping tires. As a result, the industry for recapping tires has all but vanished in recent years. In its place, huge mountains of spent tires are being stockpiled at dump sites where they constitute a waste of space, an ongoing eye sore and danger should they be ignited. Reports occur of mountains of spent tires having caught fire. These fires often burn unchecked until all of the stockpiled tires have been consumed, an event that can takes months, if not years. During the uncontrolled burning, the atmosphere is polluted and the ground contaminated by rivers of molten petroleum products released from the burning tires. Damages are incalculable.
Once, recapping tire casings was a thriving, established industry. The industry still survives today, if only for applications directed substantially toward industrial and commercial vehicle tires. Even so, the industry still suffers from a wide variety of problems. The most prevalent problem is the dislodgment of the annular band defining the recap from the spent tire casing. The primary reason that the recap band becomes disassociated from the tire casing is poor adhesion. High vehicular speeds create extreme heat which causes separation along the interface between the tire casing and recap band. Variances in the recap band shape exacerbate this problem. This separation contributes to the frequent failure of recapped tires. This failure has been the principal reason most retail consumers are biased against retreads. Yet, economics still support the retread business for commercial and industrial tires (because of the high cost of these tires). Thus, tire sales to commercial fleet companies still remain commonplace.
Until the advent of the radial tire, the predominate method for recapping spent tire casings was the hot capping method. With this method, a spent tire casing (also called a carcass or tire carcass) was prepared, and then a recap band of uncured rubber was introduced along the outside periphery of the tire casing. The tire casing was stretched and under high temperature and pressure, typically 160 psi and 305° F.; the band of uncured rubber was adhered, as it cured, to the tire casing creating a sturdy and robust retread by creating a fairly strong bond between the new and the old rubber. However, with radial tires, traditional methods for recapping could not be used. Although the new radial tire technology provided a much stronger tire initially, when the radial tire wore out, the prospects for retread were dismal. The known hot capping technology could not be used for radial tires. The primary difficulty with retreading of radial tires is that a radial tire cannot be stretched. The radial cords imbedded in the tire rubber prevent the stretching of the tire casing--a necessary and integral procedure for the manufacturing of retreads using the prior hot capping method.
Because of the inability to stretch the spent radial tire casings under high temperature and pressure, alternative procedures were developed without stretching, using lower temperatures and pressures. The alternative procedures were inferior. The alternative procedures provided for application of the uncured rubber to the spent radial tire at much lower temperatures and pressures. Typically, heated, highly pressurized air, or gas, was used to provide both the heat and pressure needed for the process. Curing times were longer, which substantially lengthened manufacturing time. Moreover, without high temperatures and pressures, the strength of the recap rubber was compromised resulting in an inability to obtain the stronger recap band of previous retreads. As a consequence, the life of the retread tire was shortened, and its economic value diminished. Further, because of the use of highly pressurized air, safety risks to manufacturing process operators were substantial. When the pressurized air system failed during the manufacturing process, the instantaneous pneumatic expansion--a violent explosion--could, and did, cause severe injury and death.
Cold capping of retread tires was developed as an alternative to the hot capping method. With cold capping, the recap band was precured prior to attaching it to the tire casing. Typically, the recap band was cured at the desirable higher temperatures and pressures as a flat piece of rubber. The precured recap band was later attached with adhesive to the perimeter of the tire casing. Although the precured recap band had the superior qualities of the hot cap recap band manufactured using high pressure and temperature, because precured rubber has a "memory" of the shape in which it was originally cured, the precured flat recap band tried to return to its original shape after it was adhered to the tire casing. That is, with cold capping, the memory of the precured flat recap band resists the curved shape of the tire casing perimeter, fighting the adhesive which attaches it to the tire casing. Because the memory of the recap band opposed the adhesive, the life of the adhesive was diminished. Yet curing the recap band in a curved shape to match the tire casing perimeter is so costly as to make it an unattractive and commercially undesirable alternative to the precured flat recap band. The aesthetic of the retread manufactured by the cold capping process also diminished it's commercial success with the retail consumer as the cold cap retread was considered unattractive.
With the radial tire causing the retread manufactured by the hot capping process to be of substantially diminished quality, and the retread manufactured by the cold capping process to also be undesirable, the retread business has sharply fallen off in recent years. It is only in the commercial and industrial vehicle market, where new tire costs is substantially higher, that the retread business has managed to survive. The retail consumer tires of today are just not retread--instead spent tires are retired to the unsightly, and ever expanding, stockpiles of local waste sites.
The following documents further reflect the state of the art of which applicant is aware and have been included herewith to discharge applicant's acknowledged duty to disclose relevant prior art. It is stipulated, however, that none of the prior art teach singly nor render obvious when considered in any conceivable combination the nexus of the instant invention as set forth hereinafter and as especially claimed.
______________________________________INVENTOR ISSUE DATE U.S. PAT. NO.______________________________________Fetter October 31, 1933 1,932,692Freeman December 29, 1936 2,066,265Leguillon, et al. October 2, 1951 2,569,935Ostling November 22, 1955 2,724,425White May 14, 1957 2,791,805White May 27, 1958 2,835,921Barefoot October 14, 1958 2,855,629Pfeiffer February 6, 1962 3,020,190Keefe October 4, 1966 3,276,930Ireland, et al. November 6, 1973 3,770,858Fredericks, et al. February 19, 1974 3,793,420Barefoot June 11, 1974 3,816,217MacMillan November 12, 1974 3,847,631Barefoot December 10, 1974 3,853,666Foegelle July 13, 1976 3,969,179Batchelor, et al. March 21, 1978 4,080,230Baatz May 23, 1978 4,090,901Cole, et al. June 27, 1978 4,097,565Logan August 23, 1983 4,400,342Mattson May 1, 1984 4,446,093Mattson, et al. December 25, 1984 4,490,325Fike, et al. March 11, 1986 4,575,438Greenwood, et al. August 5, 1986 4,604,256Greenwood, et al. December 29, 1987 4,715,577Mattson March 28, 1989 4,816,198Seiberling July 25, 1989 4,851,063Majerus August 15, 1989 4,857,122Lindsay, et al. October 8, 1991 5,055,148Trethowan July 7, 1992 5,127,811Lindsay, et al. September 29, 1992 5,151,148______________________________________
The patent to Baatz teaches the use of a recapping method for tires using a flat precured recap band. The tire to be recapped is placed within an envelope with the precured recap band thereabout. A hose runs from inside the envelope to outside the tank in which the tire is placed. Hot water is pumped into the airtight tank. The rising air and water pressure force the air out of the envelope and press the envelope firmly against the recapped tire to hold the recap band securely in place.
The two patents to Lindsay, et al. (U.S. Pat. Nos. 5,055,148 and 5,151,148) teach the use of a method and system for retreading spent tires with precured treads utilizing time and temperature in conjunction with an envelope pressure system. A precured rubber tread is applied to a tire casing having a cushion gum disposed therebetween. An envelope system is placed over the tread/tire casing and this assembly is placed within a pressure chamber. Heat and fluid pressure are then supplied to the chamber. Fluid pressure is then supplied to the chamber after both a predetermined length of time and after a predetermined temperature of the chamber has been reached.
The patent to Seiberling teaches the use of a radiation cure of tire plies. In a continuous operation, steam or hot water is led into the mold through a pipe and provides sufficient pressure within the tire to force it against the mold to groove the tread and form any desired identification and indicia marks desired on the tire surface. The tire is cured at usual temperatures, and steam or hot water is used in the usual manner, but without an air bag or bladder.
The patent to Foegelle teaches the use of a curing apparatus which may be used for vulcanizing a pre-cured tread onto a suitably prepared tire casing. The apparatus provides a mold defining a chamber in which the tire casing and adhesively attached pre-cured tread are placed and includes means for establishing pressurized fluid, such as steam or air, within the interior of the tire casing and pressurized fluid, such as steam, in the annular space between the casing and the inside peripheral surface of the chamber.
The patent to Trethowan teaches the use of a bladderless tire mold press for tires, including lower and upper platens and a mechanism for moving the platens relatively toward one another from an open position to a closed molding position. Each of the platens further includes a mechanism for molding tire beads. Note column 4, from line 26. The curing medium may be steam or hot water. The effect of this is to expand the green tire so as to properly engage with the various molds surrounding it.
The patent to Majerus teaches the use of a process for injection molding tire treads. Note the discussion of operation starting at column 4, line 16 through column 5, line 17, which utilizes a first low pressure on the interior of the tire casing to position the tire casing until the injection of tread material is complete and then uses a second higher pressure for curing.
The remaining citations not specifically discussed diverge even further from the focal point of patentable novelty as set forth hereinbelow.
SUMMARY OF THE INVENTION
The present invention is distinguished over the known prior art in a plurality of ways. Most significantly, the present invention is distinguished over the known prior art in that the tread portion which circumscribes a tire casing is adhered in a manner which achieves all possible benefits. Thus, the present invention provides for the manufacturing of retreads especially solving the radial tire problem, in a far more effective manner than heretofore.
Another facet of the instant invention involves the manner in which the instant invention addresses manufacturing protocols for the purpose of not only increasing the degree to which the tread adheres to the tire casing, but also the amount of time required in fabricating an improved recap. The instant invention greatly decreases recapping cycle time.
More specifically, the present invention is distinguished over the known prior art, inter alia, in that the invention relies upon the utilization of uncured tire compounds as the preferred material which overlies and bonds with the tire casing. By using uncured material, the subsequent step of curing and adhering increases the degree, depth and quality of adherence of the new tread to the tire casing.
A further benefit to the use of uncured tire compounds, and curing in situ, is that recap band's memory recalls the shape of the tire it is adhered to an not and arbitrary or flat shape (such as that used for a precured recap band).
Another component involves the utilization of hot water directly on the interior surface of the tire casing. An exterior overlying, enveloping matrix serves as a form which holds the tire casing, receives the injected tire compound defining the recap band and defines a tread which is to be disposed on the recap band. As a general rule, thermal conductivity is greater through a liquid than through a gas. By admitting extremely hot water, or other heated incompressible liquid to the interior of the tire casing, the rate of thermal transfer is improved to both cure and bond the uncured composition to the tire casing. With both the matrix heated, and the interior of tire casing heated, the heat migration across the tire compound occurs much faster than just the heating of the matrix alone. Using water or other incompressible fluid on the inside of the tire casing has the added benefit of exerting pressure on the interior of the tire casing outwardly in response to the forces exerted by the matrix and through the uncured material onto the tire casing.
Thus, the combination of injected uncured material with high temperature incompressible fluid at high pressure (hydraulic pressure) improves the chemical and mechanical bonding between the tire casing and the material. It also increases the strength and life of the recap tire band because the temperatures and pressures used for curing are well in excess of those previously used, thereby creating a stronger, tougher recap band.
Additional benefits to the foregoing involve the adherence and appearance of the retread so formed. The uncured tire compound is adhesively molded to the contour of the tire casing, that is, the cracks and crevasses of the tire casing surface are penetrated by the uncured tire compound and become the adhesion surface (when the tire compound of the recap band is applied under heat and pressure). Good adhesion results and the recap band appears integral with the tire casing, taking on the appearance of a new tire. Moreover, because the tire compound of the recap band is injected and its shape closely controlled, the tire is not caused to be deformed in any way.
In the past, many spent tires could not be retreaded because of broken tire shoulders and/or broken tire belts and/or punctures. With the present invention, there is a much greater tolerance for acceptance of spent tires for retread because the uncured tire compound is able to build up broken shoulders and/or fill holes and/or adhere to areas having broken tire belts.
With regard to the manufacturing process safety risk, the potential for an explosion is substantially diminished. Because the present invention uses hydraulic pressure rather than pneumatic pressure, there is no risk of an explosion caused by a pneumatic failure. Thus, the safety of the process is greatly improved.
An ancillary benefit from the foregoing involves an increase in productivity in forming a recap. The amount of time when a tire casing must be disposed within an enveloping matrix is reduced because of the improved thermal conductivity, pressure and adherence that occurs thereby shortening the amount of time required to form a retread. Because the retread has superior bonding characteristics to the tire casing, the retread exhibits greater properties in the intended operating environment, on the road.
OBJECTS OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a new and novel apparatus for forming recapped tires, a method associated therewith and the article of manufacture formed thereby.
It is a further object of the present invention to provide a system as characterized hereinabove which reduces the amount of time required to fabricate a recapped tire.
A further object of the present invention is to provide a system as characterized above where the properties of adhesion, between the recap band and the tire casing, are improved when compared with prior art teachings.
Yet another object of the present invention is to provide a system as characterized above where the wear properties of the recapped are improved so as to extend the life of the recapped tire.
A further object of the present invention is to provide a system as characterized above which exhibits greater safety on the road than has been known heretofore.
A still further object of the present invention is to provide a system characterized by its ability to accept for retread tires which would normally not be considered, such a those spent tires with broken shoulders, broken belts, or holes.
A further object of the present invention is to provide a system as characterized above which lends itself to mass production techniques.
A further object of the present invention is to provide a system as characterized above which benefits from the properties of using uncured tire compound when first introduced to the tire casing so that subsequently, upon curing by use of heat and pressure, an improved bond will be evidenced between the tire casing and the uncured rubber compound.
A further object of the present invention is to provide a device as characterized above which exhibits greater safety during the fabrication process.
Viewed from a first vantage point, it is an object of the present invention to provide a process for retreading a spent tire, comprising, in combination: providing a buffed tire casing ready to receive uncured tire compound for the recap band; placing the tire casing into a mold cavity which has a tire compound entry point; rotating the tire casing within the mold cavity past the entry point while injecting uncured tire compound into a space between the tire casing and interior cavity walls of the mold cavity; pressurizing an interior of the tire casing by injecting heated fluid into the interior of the tire casing to resist forces on an exterior of the tire casing due to injecting the tire compound; forming a tread pattern onto the tire compound; curing the tire compound to the tire casing thereby creating the recap band; and removing the thus formed retreaded tire from the mold cavity.
Viewed from a second vantage point, it is a further object of the present invention to provide an apparatus for retreading a spent tire, comprising, in combination: means for defining a generally annular chamber adapted to receive both a tire casing and injected, uncured tire compound; means for seating tire casing beads on a tire rim within the annular chamber; means for pressurizing an interior of the tire casing with heated fluid; means for injecting uncured tire compound into the annular chamber outside of the tire casing; and means to pressurize and cure the uncured tire compound thereby forming the recap band.
Viewed from a third vantage point, it is a further object of the present invention to provide a method of recapping a tire, comprising the steps of: placing the tire in a matrix; seating the tire on a tire rim with air pressure; closing the matrix; rotating the tire; forcing tire compound into the matrix and onto a periphery of the tire as the tire is rotated; replacing the air within the tire by forcing an incompressible fluid into an interior of the tire; maintaining a pressure differential between the tire compound and the interior of the tire until the tire compound is cured; evacuating the fluid from the tire; opening the matrix; and removing the tire.
Viewed from a fourth vantage point, it is a further object of the present invention to provide a tire, comprising, in combination: a tire casing; a buffed periphery circumscribing the tire casing; and a band of rubber bound to the buffed periphery.
Viewed from a fifth vantage point, it is a further object of the present invention to provide an apparatus for recapping a tire formed from a tire casing, comprising, in combination: means for buffing the periphery circumscribing the tire casing; means for applying a band of uncured rubber coated on the periphery; and means for curing the band of uncured rubber.
Viewed from a sixth vantage point, it is an object of the present invention to provide a method of recapping a tire, comprising the steps of: placing the tire in a full circumferential matrix; seating the tire on a tire rim with air pressure; closing the matrix; rotating the tire; forcing tire compound into the matrix and onto a periphery of the tire as the tire is rotated; replacing the air within the tire by forcing an incompressible fluid into an interior of the tire; maintaining a pressure differential between the tire compound and the interior of the tire until the tire compound is cured; evacuating the fluid from the tire; opening the matrix; removing the tire; and injecting water initially at less than 40 psi into the tire prior to rotating the tire.
Viewed from a seventh vantage point, it is an object of the present invention to provide a method of recapping a tire, comprising the steps of: placing the tire in a full circumferential matrix; seating the tire on a tire rim with air pressure; closing the matrix; rotating the tire; forcing tire compound into the matrix and onto a periphery of the tire as the tire is rotated; replacing the air within the tire by forcing an incompressible fluid into an interior of the tire; maintaining a pressure differential between the tire compound and the interior of the tire until the tire compound is cured; evacuating the fluid from the tire; opening the matrix; removing the tire; and forcing the tire compound in an uncured state at a pressure less than 600 pounds per square inch.
Viewed from an eighth vantage point, it is an object of the present invention to provide a method of recapping a tire, comprising the steps of: placing the tire in a full circumferential matrix; seating the tire on a tire rim with air pressure; closing the matrix; rotating the tire; forcing tire compound into the matrix and onto a periphery of the tire as the tire is rotated; replacing the air within the tire by forcing an incompressible fluid into an interior of the tire; maintaining a pressure differential between the tire compound and the interior of the tire until the tire compound is cured; evacuating the fluid from the tire; opening the matrix; removing the tire; and increasing fluidic pressure inside the tire when filled with heated water to 560 psi, while increasing delivery pressure on the tire compound to 600 psi, whereby the tire compound is rapidly cured.
These and other objects will be made manifest when considering the following detailed specification when taken in conjunction with the appended drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction from a side view thereof of the rough shaping step of the shaping station according to the present invention.
FIG. 1A is a perspective depiction of a tire casing having been roughly shaped.
FIG. 2 is a schematic depiction from a side view thereof of the buffing step of the shaping station according to the present invention.
FIG. 2A is a perspective view of the FIG. 1A prepared tire casing having been buffed and in suitable form for use in the recapping process.
FIG. 2B is an alternate view of the buffing step of the shaping station, depicted as a sectional view showing the buffing wheel used in the buffing step of the shaping station.
FIG. 3 is a side view of a recapping matrix according to the present invention.
FIG. 4 is a partial sectional view taken along a vertical, longitudinal section line of FIG. 3 showing the matrix in an open position with a tire casing inserted therein.
FIG. 5 is similar to FIG. 4 showing the mold matrix in a stage of closing in on a tire casing to be recapped.
FIG. 6 is a view similar to FIGS. 4 and 5 showing the mold matrix partially open and receiving a band of uncured tire compound to circumscribe a periphery of the tire casing.
FIG. 7 shows the tire after having received the band of uncured tire compound and being further closed.
FIG. 8 shows the matrix in a closed position substantially ready to receive the tire compound once a safety band has been latched thereabout.
FIG. 9 is a side view of FIG. 8 showing the safety band in an undeployed position ready for cinching.
FIG. 10 shows the safety band cinched about the closed mold, ready for the tire compound to be injected therein.
FIG. 11 shows the tire compound being injected therein.
FIG. 12 shows a sectional view along lines 12--12 of FIG. 3.
FIG. 13 shows the tire being partially deformed during the injection process and being resisted by fluidic pressure.
FIG. 14 shows a tire finished according to the present invention.
FIG. 15 is a sectional view taken along lines 15--15 of FIG. 14.
FIG. 16 shows one preferred system by which the tire of FIG. 14 will have been fabricated.
FIG. 17 is a view of the injector shown in FIG. 16.
DESCRIPTION OF PREFERRED EMBODIMENTS
Considering the drawings, wherein like reference numerals denote like parts throughout, reference numeral 10 is directed to a matrix according to the present invention; reference numeral 100 is directed to an injector according to the present invention; and reference numeral 1000 is directed to the system (FIG. 16) according to the present invention.
In its essence, and as shown in FIG. 16, a plurality of matrices 10 all communicate with an air inlet 2 and a water inlet 4 as well as an air outlet 6 and a water outlet 8 emanating from a communal trunk 200 and removably attached thereto by detachable couplings C. Further, each matrix can couple to an AC outlet W/S via an AC cord 301 which communicates with a resistive heating element 302 contained in the matrix. When decoupled from the trunk, the matrices 10 move in the direction of the double ended arrows B and communicate with the injector 100. The injector 100 preferably moves in a direction perpendicular to the direction of the arrow B, along arrow D. The injector receives a supply of air along arrow A and a supply of uncured tire compound U as indicated diagramatically in FIG. 16 by arrow U. Thus, as the injector 100 moves along the direction of the double ended arrow D, it receives one matrix which has been removed from the trunk 200. First a finished cured tire is removed from the matrix and next an abraded tire casing is mounted in that matrix for building a tread pattern thereabout as to be described. Once the rubber or compound has been placed on the prepared tire casing, the matrix 10 is recoupled to the trunk system for treatment with hot water and air therewithin to allow the tire to cure. In this way, a single injector 100 can service a multiplicity of matrices 10 to maximize the number of tires made from one injector 100.
More particularly, and with respect to FIGS. 1, 1A, 2, 2A and 2B the tire casing of an old tire T is shown as being prepared for the retread process. As shown in FIGS. 1 and 1A, a tire T is mounted on a wheel W adapted to be driven by a shaft S. The tire T is contacted with a coarse grinder G so that any out-of-round condition for the tire can be rectified. In this manner, the FIG. 1A tire will have portions removed defining eccentricities or out-of-round conditions.
Subsequently, the roughly shaped tire T is shown in FIG. 2 as being mounted on another wheel W driven by a shaft S in operative engagement with a buffer R which provides a buffed surface on the tire as shown in FIG. 2A. The buffed surface actually has a fiber-like "hill and valley" texture which provides an enhanced gripping area when the tire compound is applied thereto. As further shown in FIG. 2B, a carbide wheel may be also used as a buffer R' to render the side surfaces of the wheel W prepared for the retreading process. In view of FIG. 2B, it is demonstrated that the surface to be prepared can be from bead to bead, wing to wing, shoulder to shoulder, or any point in between depending on the desired area to be covered by the recap band, according to the present invention. With the surface to be prepared identified, the carbide wheel R is then moved across the surface of the wheel W, buffing it and preparing it for the retreading process.
FIG. 3 is a side view of the matrix shown in FIGS. 4 through 13. In essence, the matrix 10 is supported above the ground by four castor-type wheels 12. One pair of wheels is shown in FIG. 3 and a second parallel set extends on an opposite side as shown in FIG. 9. The castors support four legs 14 extending upwardly therefrom. The legs 14 of FIG. 3 are interconnected by a transverse brace 16a having a spaced parallel horizontal counterpart 18a located at a topmost portion of the matrix. Braces 16a and 18a are interconnected by vertical braces 20a and 22a at distal extremities of each of the braces 16a, 18a, collectively defining a first rectangular frame. The vertical braces 20a and 22a are coaxial with the legs 14 of FIG. 3.
FIG. 4 shows that the intersection of vertical brace 22a and horizontal lower brace 16a conjoin with another lower brace 24 that extends between the two wheels 12 of FIG. 4 which share a common axis of rotation. The wheel exposed in FIG. 4, but occluded in FIG. 3 is inboard from the right hand extremity of the matrix 10. Brace 24 has a necked-down portion 26 that begins directly above the last named wheel. The necked-down portion 26 includes a top surface 28 which supports a vertical brace 22b on a side of the matrix opposite from, but parallel to the vertical brace 22a. Similarly, braces 16a, 18a and 20a have counterparts 16b, 18b and 20b shown in FIG. 9 which define a second rectangular frame. Comparing FIGS. 4 and 13, for example, it is seen that the vertical brace 22b moves along arrow F from an extreme position outboard the brace 24 to an inboard position immediately adjacent the area where the brace 24 is necked-down at 26. This defines a position where the matrix is closed. Thus, the matrix is defined as first and second substantially rectangular frame members spaced apart by an area adapted to open and close, within which a mold cavity is disposed for receiving a recap tire. The mold cavity will be described later.
At the intersection of the horizontal and vertical braces, the rectangular frames have screw threads extending therebetween. By having four screw threads 34 at the extremities, the matrix can move from the open and closed positions along arrow F to be described. The screw threads 34 are advanced and retracted by means of a plurality of gear trains connected to a common motor 36. The motor 36 (FIG. 3) includes a first sprocket 38 which communicates with a chain 40 that passes over a lower left hand sprocket 42. Another sprocket 44, also driven directly by the motor 36, extends to an upper right hand corner of the frame via chain 46. It loops over a double sprocket 48 which in turn drives a lower right hand corner sprocket 52 by means of chain 50. In this way, all four threaded shafts 34 move in synchrony.
As mentioned, each half of the frame of the matrix 10 supports one half of a mold cavity. As shown in FIG. 5, one mold cavity half 54 is located on the first frame half immediately adjacent the motor 36 while another mold cavity half 56 is located adjacent free ends of the threaded shafts 34 on the second frame half. The mold halves move along the direction of the double ended arrows E to go from an open position as shown in FIG. 4 to a closed position as shown in FIG. 13. The mold cavity halves 54, 56 when closed have the general inner contour of the outer periphery of a finished tire as shown in FIGS. 14 and 15.
A central core of the mold cavities 54 and 56 include a space for accommodating a rim 58 for supporting the tire T. In a preferred form of the invention, the rim is formed from two parts. FIG. 12 shows detail of one of the rim halves 60 and its operating geometry. The second rim half 62 parallels the following discussion of FIG. 12. Each half of the rim 60, 62 is adapted to reciprocate along the direction of the double ended arrows G. The reciprocation is caused by means of a pneumatic air drive where the matrix 10 receives air from an input A on injector 100 of FIG. 16 and leads to conduits 64 and 66 of FIG. 16 adapted to couple with conduits 68 and 70 of FIG. 12. A quick coupler C, FIG. 16, facilitates the coupling and uncoupling with a complementally formed coupler C of FIG. 12. Air forced into inlet 68 communicates with a hollow 72 disposed within a substantially cylindrically shaped housing 74 that is mounted on a side of the matrix 10. The cylindrical housing 74 has an end wall 76 which receives the air conduits 68 and 70. The conduit 68 communicates through the end wall 76 via passageway 78 allowing access to the interior 72. Air enters along the direction of the arrow I and causes the chamber to fill with fluidic pressure. A piston 80 having a connecting rod 82 moves from left to right as shown in FIG. 12. The piston 80 causes the rim 60 to engage an annular bead that is located on a tire casing of the tire as suggested in FIG. 5, with contact just having been made. In one form of the invention, the rim is configured as a frusto-conical solid with a smaller diameter frustum nearest a center of the tire casing.
When the rim 60 is to be disengaged from the annular bead of the tire casing, a negative pressure can be applied via conduit 68 providing a "pull" effect or further pressure can be positively provided via conduit 70 communicating with interior passageway 84 which pushes against a back face 86 of the piston by providing air in a chamber 88 on a side of the cylindrical sleeve remote from the interior 72 to move the piston in an opposite direction (i.e. from right to left of FIG. 12). This corresponds with the release of the tire casing from the rims 60, 62. Besides a "pull" system or "push" system, a hybrid "push-pull" system, could be used for rapid motion of rims 60, 62 for opening and closing (using both conduits 68, 70).
The cylindrical housing 74 is mounted within the matrix 10 by means of a bearing 90. This allows for the housing 74 to rotate along the arrow J and therefore cause the rim 60 to also rotate about the arrow J. Since the annular bead on the tire is secured to the rims 60 and 62, the tire also rotates about the arrow J. Rotation is imparted to the cylindrical housing 74 by means of a sprocket 92 which is driven as shown in FIG. 3. More specifically, the sprocket 92 cooperates with a chain 94 to be driven by a complemental sprocket 96 and in turn driven by motor 98.
Each rim, 60 and 62, includes a center core 102 (FIG. 12) provided with a first conduit 104 and a second conduit 106. These conduits communicate from an exterior of the rims 60, 62 with conduit leads 108 and 112. These conduits 108 and 112 are isolated from the core 102 and its rotation about the arrow J and explained infra by means of a further bearing assembly 110.
With the foregoing structure in mind, the sequence of operations reflected in FIGS. 4 through 13 can now be appreciated. As mentioned above, after a completed cured recapped tire has been removed from the matrix 10, an uncured tire casing is placed within the center of the matrix 10 as suggested in FIG. 4. The mold cavities 54 and 56 are then closed along the direction of the double ended arrow E as suggested in FIG. 5.
When the mold is almost closed, in some instances it is desirable to provide an intermediate band of uncured tire compound as a build-up onto the tire casing prior to the injection of more tire compound. When this is desired, the step in FIG. 6 is utilized. A machine 113 which extrudes uncured tire compound for the recap band in the form of an elongate ribbon 114 is oriented such that the width of the ribbon of uncured tire compound is allowed to circumscribe the outer periphery of the tire casing as shown in FIG. 6. The width of the ribbon of uncured tire compound may be from bead to bead, wing to wing, shoulder to shoulder, or any point therebetween depending on the desired width of the recap band which circumscribes the tire casing. Rotation of the rims 60, 62 along the direction of the arrow J allows the ribbon 114 of uncured tire compound to be wrapped around the tire casing of the tire. This step is not needed in all tires, but preferably can be used when more than twenty pounds of uncured tire compound is to be added around the outer periphery of any tire.
In any event, FIG. 7 reflects detail where the mold is being further closed such that the FIG. 8 configuration of a closed mold will be effected with the exception of the locking clamp 116 shown in FIGS. 8 and 9.
The locking clamp 116 has a hinge 118 at its lowermost extremity and divides the locking clamp into a first portion 116a and a second portion 116b. An opposite side of the clamp remote from the hinge 118 includes a hydraulic actuator 120 having an extensible arm 122 such that the hydraulic actuator 120 is fixed on the rectangular frame housing and locates with a half of the clamp 116b while the hydraulic rod 122 couples to the other half of the clamp 116a whereby rotation and locking of the clamp is possible by linear reciprocation of the hydraulic rod 122 within the sleeve 120 along the direction of the double ended arrows K. A tab 124 connecting to a free end of the hydraulic rod 122 and clamp half 116b assists the safety clamp 116 in circumscribing the first and second halves of the molds 54 and 56 for safety during the high temperature, high pressure operation. As shown in FIG. 8, the closed molds 54, 56 are oriented such that an injector 130 is in line with an injection orifice 132 to allow the liquid tire compound to be added into the mold cavity interior.
With respect to FIG. 11, the injector 130 from the injection station 100 is in communication with the inlet 132 and exposed to an interior of the mold cavities 54 and 56. Notice also in FIG. 10 that an interior of the tire casing is to be filled with an incompressible fluid 134, preferably extremely hot water and preferably less than 100° C. The water enters into the interior of the tire casing via the conduit openings 104. Subsequently, the hot water is allowed to exit via a complemental outlet 106 on the half of the rim 62. As the liquid or viscous tire compound is injected along an outer periphery of the tire, (preferably at less than 340° F. or a temperature which prevents flash curing of the tire compound used) the tire is rotated about the arrow J (FIG. 10) so that a uniform coating of the tire compound extends between the exterior surface of the tire casing and the interior surface of the mold cavities 54 and 56. The interior of the cavity also includes a pattern which when completed parallels the tread pattern shown in FIGS. 14 and 15 so that subsequent surface finishing of the tire is not required. The effect of the hot water 134 is two fold. The first purpose is to resist the deformation of the tire which would normally occur as hydrostatic pressure increases because of injecting the tire compound into the mold cavity. Thus, with incompressible fluid in the interior cavity, higher operating pressures both inside and outside the tire casing are now possible. These higher operating pressures yield a much better quality of retread by providing a recap band with the superior properties heretofore found only with precured tread. A second advantage is that with high water temperature (and with increasing hydrostatic pressure) the curing time of the uncured tire compound is accelerated.
FIG. 13 is a view similar to FIG. 10 with the exception that the intervening layer of a strip of uncured material discussed infra with respect to FIG. 6 has been avoided.
By way of definition, it is important to note that by "uncured tire compound" it is traditionally meant unvulcanized rubber in its conventional sense. However, rubber formulations and rubber chemistry in the art of tire making is extremely complex in modern times and most tire compounds are not one hundred percent pure rubber. Yet, presently there is still a clear line of demarcation between cured and uncured tire compounds. A tire compound that has already been subjected to considerable heat and pressure is cured, and therefore is "preset." Most cold capping processes typically use precured recap bands which are cured flat, and therefore retain a memory of their flat shape. Most recaps today use cold capping and require the use of cured tire compounds. Because the cold capping process puts a cured recap band (with a memory of a flat shape) on top of a rounded tire casing, the recap band does not readily adopt to its new shape. This is the problem with prior art recaps. The present invention has as one hallmark the utilization of uncured tire compound. Upon subsequent application of heat and pressure, the uncured tire compound cures as it adheres to the shape of the tire casing, thus optimizing the vulcanization of the uncured tire compound and beneficially affecting the bond with the tire casing. This memory forming on the tire characterizes one hallmark of the instant invention.
FIG. 11 reflects a stage where the rubber is filled within the cavity of the mold halves so that the matrix 10 can be removed from the injection mold machine 100 and thereafter allowed to cure as shown in FIG. 16 where the matrix is reconnected to hot air or hot water to facilitate the cure process. FIG. 11 further suggests that the remaining liquid has been removed from the matrix 10 and is communicated with the trunk line prior to the injector 130 being withdrawn.
FIG. 17 shows the injector 100. The injector is coupled to the matrix 10. Strip stock 101 is fed to an extruder 103 configured as an auger powered by a motor 105. A head gate 107 allows the uncured tire compound strip stock 101 to pass therebeyond, into an injection cavity 109. An injection cylinder 111 receives a double acting piston 113 therewithin which drives the strip stock 101 through the injector nozzle 130. The injector 100 is supported on wheels 115 to allow translation along arrow "D" of FIG. 16.
Moreover, having thus described the invention, it should be apparent that numerous structural modifications and adaptations may be resorted to without departing from the scope and fair meaning of the instant invention as set forth hereinabove and as described hereinbelow by the claims.
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A method, apparatus and article of manufacture for tires in order to salvage used tire casings of tires and recap them with a better mechanical and chemical bond involving the use of hot water to accelerate the cure rate and uncured tire compound placed on the tire casing subjected subsequently to heat and pressure.
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CLAIM OF PRIORITY
[0001] This application claims benefit to non-provisional application Ser. No. 10/984,182, filed Nov. 8, 2004, entitled “Catch Basin for Salt Water Sand”, which further claims benefit to provisional application 60/589,720, filed on Jul. 21, 2004 entitled “Catch Basin for Salt Water Sand”, which are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates to an apparatus and method for preventing the formation of sandbars caused by current or tidal flow at passages such as the inlets to harbors, basins and estuaries.
BACKGROUND OF THE INVENTION
[0003] Sand and sediment tends to accumulate in locations such as the entrances to harbors due to the deposit of sand and sediment by tidal flow of water. The existence of sandbars can create serious environmental and navigational hazards. Such accumulations require at least periodic dredging at great expense and disruption of water traffic.
[0004] The present invention is directed to a novel system which eliminates the accumulation of the sand or sediment that would normally be deposited on the bottom of an inlet, into a permanently located catch basin from which the sand/sediment can be continuously or periodically removed by water pumps capable of moving water and sand.
[0005] A number of U.S. patents have been devoted to the problem of preventing beach erosion and the like. U.S. Pat. No. 4,498,806 discloses a beach erosion jetty configuration wherein the jetties are curved to stop or prevent a vacuum effect which causes beach erosion. Swift currents running in or out of inlets create a Venturi effect that pulls sand-laden waters from nearby and sometimes distant shorelines. In accordance with the present invention, jetties are provided with curved ends that negate the loss of precious sand. Such curved jetties function as erosion control devices and actually stop and prevent erosion.
[0006] U.S. Pat. No. 4,023,369 discloses an apparatus and method carried out thereby for preventing formation of sand bars from sand or silt at the outlet of a body of water emptying from inland into another body of water, such as a lake or the sea and the like. At least one elongated gutter is provided at the outlet of a body of water from inland to another or receiving body of water, such as a lake or the sea. The gutter is disposed above the level of the water in the outlet and may or may not extend through the mouth of the outlet into the receiving body of water. Water is pumped into the gutter to an overflow condition so that it spills over the edges, and by gravity falls and creates a splash erosion condition.
[0007] U.S. Pat. No. 4,031,009 discloses a pre-cast reinforced concrete catch-basin of larger than conventional catch-basin dimensions, which includes a solid horizontal bottom wall with a solid, hollow, cylindrical side wall upstanding therefrom to about half the height of the catch-basin. The lower half thus forms a sealed, unapertured, undrained sump receptacle for collecting drain water and silt and allowing sand to settle out. The hollow, cylindrical, upper half contains leaching openings which extend through from the inside to the outside of the wall, from top to bottom, for discharging cleared water to the surrounding, stone-lined earth without plugging or clogging and without polluting nearby wells, brooks, etc.
[0008] U.S. Pat. No. 6,481,926 discloses a method and apparatus for land reclamation which includes utilizing groyne-like structures, including spaced stanchions to which are mounted porous screens and wherein the screens are vertically adjustable as material is deposited during the reclamation process. In some embodiments, the screens are carried by sleeves slidable on spaced stanchions. In other embodiments, the screens may be sectional and carried by multiple sleeves.
[0009] U.S. Pat. No. 5,174,681 discloses a permeable breakwater for submerged offshore or seawall retentive installation that includes a base and permeable opposed sides terminating at an upwardly projecting permeable wave wall. The breakwater is located offshore to cause moderate to heavy waves to break further offshore, thereby dissipating their energy before reaching the beach.
[0010] U.S. Pat. No. 5,888,020 discloses a sub-tidal platform adapted to be placed under water in front of a beach comprising a support structure having at least two upwardly extending, spaced-apart side walls extending along vertical planes. Each side wall has a bottom adapted to rest on a generally horizontal surface and a sloping, upwardly extending edge which is at an acute angle with respect to the bottom. A plurality of interconnecting members extends between the side walls for maintaining them in an upright position. The interconnecting members are positioned adjacent to the sloping edge of the side walls. A plurality of gates are pivotally connected to the interconnecting members of the support structure for controlling fluid flow through the space between the side walls. The gates open in response to incoming fluid flow through the gates and close in response to outgoing fluid flow in the opposite direction. The gates, when in their closed position, combine to form a sloping wall which substantially blocks the flow of fluid through the space between the side walls and deposits fluid-carried material in the space formed by the side walls and the sloped wall.
[0011] While there have been a number of prior art systems directed toward preventing beach erosion, there has not been a systems that adequately addresses the problem of preventing sand bar creation in inlets. There has not been a system that provides a simple, yet inventive basin which accumulates sand and sediment.
[0012] It is therefore an object of the present invention to provide a system which functions to prevent the accumulation of sediment in inlets and the like.
[0013] It is a further object of the present invention to provide a system for collecting sand and sediment, comprising singular or multi-piece casing.
[0014] It is an object of the present invention to provide a system which permits the removal of sand and sediment by means of a pump and piping.
[0015] These and other objects of the present invention will become apparent from the detailed description which follows.
SUMMARY OF THE INVENTION
[0016] In a preferred embodiment, the invention is a system for collecting the flow of sand or sediment in a current comprising a catch basin with a base structure having a bottom and a plurality of angled side walls, said bottom having at least one aperture, an external pipe affixed at a first end to the at least one aperture, at least two guides affixed to one or more ends of the catch basin to direct sand and sediment into the catch basin, each of said guides comprising a chute with curved sidewalls extending substantially parallel to the flow of current, and a pumping system affixed to the second end of the external pipe to remove the sediment or sand from the basin.
[0017] In a further embodiment, the invention is a system for collecting the flow of sand or sediment comprising a catch basin, further comprising a plurality of angled side walls which converge with a bottom wall, said catch basin being placed at a predetermined location within a waterway to collect sediment or sand, a plurality of apertures on the bottom wall of the catch basin to permit the removal of sediment or sand from the basin, a plurality of external pipes each affixed at a first end to an aperture, one or more pumping systems affixed to the second ends of the pipes to remove the sediment or sand from the catch basin, a screen affixed over the top of the basin to block debris and prevent the intrusion of sea life, and at least two guides affixed to one or more ends of the catch basin to direct sand and sediment into the catch basin, each of said guides comprising a chute with curved sidewalls extending substantially parallel to the flow of the current.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of the catch basin forming part of the apparatus used in carrying out the method of the invention.
[0019] FIG. 2 is a cross-sectional view of the catch basin shown in FIG. 1 .
[0020] FIG. 3 is a longitudinal cross-sectional view of the catch basin of the present invention.
[0021] FIG. 4 is a diagrammatic view showing an example of the installation of the catch basin for the purpose of carrying out the method of the invention.
[0022] FIGS. 5 through 7 are further embodiments of the invention.
[0023] FIGS. 8 through 11 illustrate an embodiment of the invention which is constructed from panels.
[0024] FIG. 12 illustrates a guide mechanism for use with the invention.
[0025] FIG. 13 is an alternative guide mechanism for use with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention is described with reference to the attached Figures. As shown in FIGS. 1 through 4 , the apparatus of the invention which prevents sand bar formation includes a catch basin 10 which may be constructed from a pre-cast concrete or other composite material. The base is floated into position, or may be fabricated in sections and erected in the desired location.
[0027] The catch basin 10 , in accordance with the invention, will be constructed to have a length substantially equal to the width of the stream of water which creates the sand bars. This may be freely adjusted according to the situation. Alternatively, one or more catch basins 10 , in accordance with the invention, may be placed end to end to form a continuous chain of catch basins for wider inlets. As shown in FIG. 4 , the basin may be repositioned as deemed necessary by location in order to attract the greatest amount of current and sediment.
[0028] The catch basin 10 of the invention will typically have a width of twenty or more feet at its top with the sidewalls 12 tapering down and converging toward each other at an angle of approximately forty-five degrees. Similarly the end walls 14 converge toward each other. The converging walls 12 and 14 merge with a bottom portion 16 , which is approximately two feet wide. The over all depth of the catch basin is preferably approximately ten feet. Both dimensions may be freely adjusted according to the need and usage.
[0029] The catch basin 10 can be constructed from concrete reinforced with glass fiber mesh or other appropriate composite material. The catch basin 10 can be pre-cast in one unitary body and floated to its desired position for installation. Alternatively, the basin may be constructed from layers, in layers or segments as illustrated in FIGS. 2 and 3 in which the various segments or layers 10 a, 10 b, 10 c, 10 d, and 10 e can be positioned relative to each other and cemented into a permanent structure.
[0030] Whether the catch basin 10 is formed as a unitary structure or of separate sections and cemented together, the location in the inlet would be below the desired bottom level of the inlet as illustrated in FIG. 2 . In one embodiment, the depth could be at a depth of approximately ten feet below the mean water level indicated at 19 to ensure that vessels with no more than that draft could make passageway in the inlet. This may be adjusted according to need and usage.
[0031] With the basin 10 disposed as illustrated in FIGS. 2 and 3 , the tidal flow indicated by arrow 28 would cross the catch basin 10 and the sand carried by the tidal water would tend to be deposited into the catch basin rather than on the normal bottom of the passageway or inlet 20 . The sand or sediment, thus accumulated, can be periodically removed by pumps 30 and pipes 32 , which could be permanently connected to openings 34 in the bottom of the basin 10 as illustrated in FIG. 2 or temporarily as illustrated diagrammatically in FIG. 3 . The number and nature of the parts will be determined according to the size and volume of the sediment addressed.
[0032] The catch basin 10 is preferably formed so that its interior walls are substantially smooth. This permits the movement of accumulated sand and sediment toward the bottom of the catch basin 10 .
[0033] It is anticipated that the catch basin 10 can be located in various locations such as the outlets of rivers or wherever sand bars tend to form so that the sand and sediment that otherwise would be deposited from the current to the bottom of the water is accumulated in a predetermined position from which it can be pumped to locations on the upland and permitted to dry.
[0034] From its fixed location, the sand and sediment can be transported to other locations such as beach replenishment areas or land fill areas. An example of such an installation is shown in FIG. 4 in which an inlet 20 opens to the sea 22 and forms a passage of water between the sea 22 and a bay or the like, not shown. Jetties 26 located at opposite sides of the inlet 20 can be formed of stone and concrete. Tidal flow would thus be directed in both directions within the inlet 20 . The flowing water at least from the sea will have sand or silt in suspension so that as the velocity of the water flow decreases at slack tide, the sand or sediment suspended within the water tends to be deposited in the outlet creating a sand bar. To avoid this problem the catch basin 10 is shown in position between the jetties 16 , disposed transversely to the current flow indicated by the arrow 28 .
[0035] As noted, the apparatus of the invention includes the catch basin 10 and accompanying conduits or pipes 32 which remove the accumulated sand and sediment by the use of pumps 30 capable of transporting such materials. The function of this invention is the disposition of the catch basin 10 in the particular location that is subject to the formation of sand bars to that the flowing current carrying sand and sediment tends to deposit the sand or sediment into the catch basin rather than on to the bottom of the inlet or area where the sand bar typically forms. The accumulated sand can be removed periodically as the catch basin 10 fills as noted above.
[0036] It is to be appreciated that the inclination angles of the basin walls in correlation to the basin bottom are preferably determined by the volume of current and level sediment through the area being covered (inlet, estuary, etc.). This positioning (and angles) of walls, the size of the basin, the depth of basin, and physical anchoring position of basin for usage shall be determined by professional engineers associated with each project.
[0037] A dimensional diagram of the basin is provided in FIGS. 5, 6 and 7 , where examples are given as to approximate dimensions and angles of said basin which is shown as 10 feet wide by 20 feet long. These angles and dimensional sizes may be adjusted accordingly to take into account the different required sizes of basins for appropriate usages of each project. The thickness of walls shall vary based on needed structural support required by flow of current and volume of sediment, as well as composition of the materials used.
[0038] Referring to FIGS. 8 to 11 , the invention is shown as being fabricated with the use of panels 40 for larger basins. The basin 10 may have unlimited size and shape usage in such application but the basic basin concept defined herewith remains applicable. Because of structural size increases, bracing and/or brackets 42 may be required (as illustrated) to support the additional span openings as illustrated in 9 and 11 .
[0039] FIG. 10 illustrates the positioning of ports/openings in the bottom of the sectional basin for the direct pumping of sediment and sand below the positioned basin on a permanent basis, if required.
[0040] In one embodiment, as shown in FIG. 7 , a screen 42 may be placed over the basin to prevent the intrusion of sea life and larger debris, which would be detrimental to the operation of the system and also to protect animal life in the area. Also, an adapter may be placed at appropriate ends of the basin to assist and guide the flow of sand and sediment into the catch basin. See illustration 12 for an example of said guide.
[0041] FIGS. 12 and 13 illustrate a guide 52 to guide sand and sediment into the basin. The guide 52 is attached to both ends of its basin. FIG. 13 is an alternative guide mechanism.
[0042] The guide 52 in a most preferred embodiment comprises one or more angled chutes 54 with curved sidewalls. The cutes 54 , in one embodiment, comprise semi-circular members which lie substantially parallel to the direction of flow of the water. As shown in FIG. 13 the chutes 54 may be angled toward the center of the basin and include a frame support structure 56 . FIG. 12 shows an embodiment in which the chutes attach at the ends of the basin. While the chutes 54 are shown as being semi-circular, other geometric shapes will work as well.
[0043] The present invention has been described with reference to the enclosed detailed description. It is to be appreciated that the true nature and scope of the invention is to be determined with reference to the appended claims.
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A system for collecting the flow of sand or sediment in a current comprising a catch basin, comprising a base structure having a bottom and a plurality of angled side walls, said bottom having at least one aperture, an external pipe affixed at a first end to the at least one aperture, at least two guides affixed to one or more ends of the catch basin to direct sand and sediment into the catch basin, each of said guides comprising a chute with curved sidewalls extending substantially parallel to the flow of current and a pumping system affixed to the second end of the external pipe to remove the sediment or sand from the basin.
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BACKGROUND OF THE INVENTION
The invention relates to a home appliance door, for example a home chiller appliance door, and to a method for assembly of a home appliance door.
From the prior art a home appliance door is already known. The home appliance door comprises a door unit having an inner wall and an outer wall. A decor panel is located on the inner wall, in an assembled state. The main function of the decor panel is to improve the design of the inner wall of the door unit.
SUMMARY OF THE INVENTION
An objective of the invention is, in particular, to provide a home appliance device with improved characteristics regarding a user convenience. This objective is achieved, according to the invention, while further implementations and further developments of the invention may be gathered from the dependent claims.
A home appliance door, for example a home chiller appliance door, is proposed, comprising: at least one door unit having an outer wall and an inner wall which in particular encompass at least one interior space which is at least partly and preferably at least mostly filled with insulation material; and at least one covering element which at least partly or at least mostly or by considering tolerances completely covers at least one feature of the inner wall.
By a “home appliance door” is in particular to be understood a door of a home appliance device and/or of a home appliance. By a “home appliance device” is in particular to be understood at least a portion, preferably a sub-assembly group, of a home appliance. The home appliance is in particular provided for storing and preferably tempering victuals such as beverages, meat, fish, vegetables, fruits, milk and/or dairy products in at least one operating state, advantageously for the purpose of enhancing a keepability of the stored victuals. For example, the home appliance is embodied as a home chiller appliance, which is in at least one operating state configured for cooling victuals. The home chiller appliance could in particular be embodied as a climate cabinet, an ice-box, a refrigerator, a freezer, a refrigerator-freezer combination and/or a wine cooler. However, the home appliance could also be embodied as a home appliance for warming and in particular for cooking victuals, e.g. an oven and/or a steamer and/or a microwave. Alternatively, the home appliance could also be embodied as a home appliance for cleaning, e.g. a washing machine and/or a dryer and/or a dishwasher. The home appliance may in particular comprise at least two, in particular at least three and preferably at least four home appliance devices.
A “door unit” is in particular to be understood as a unit which is, in at least one assembled state, connected to an appliance body in a movable and in particular swiveling fashion and which at least partly defines, in at least one operating state, at least one storage space. In at least one operating state the door unit in particular defines the storage space together with the appliance body. The door unit in particular comprises at least one seal, which is in particular provided for sealing at least one gap between the inner wall and the appliance body in at least one operating state. The door unit itself, in particular without the covering element, is in particular sufficient for closing at least one storage space and/or for sealing at least one gap between the inner wall and the appliance body. The door unit can, for example, at least partly comprise at least one stamped part and/or at least one stamped portion. Alternatively and/or additionally, the door unit can for example comprise at least partly one thermoforming part and/or at least one thermoforming portion.
The appliance body is in particular part of a home appliance device, which in particular also comprises the home appliance door. An “appliance body” is in particular to be understood as a unit at least partly defining at least one storage space and in particular defining the storage space at least substantially together with at least one home appliance door. In particular, the home appliance device comprises, in at least one operating state, the home appliance door. The appliance body and the home appliance in particular define the storage space in at least one operating state at least substantially and preferably by considering tolerances completely. The appliance body in particular comprises at least two, in particular at least four and preferably at least five walls. The walls in particular delimit the storage space. The walls may in particular be embodied as a lateral wall and/or as a rear wall and/or as a bottom wall and/or as a top wall. The appliance body in particular has two lateral walls, preferably opposite each other, one rear wall, one bottom wall and one top wall, which is preferably situated opposite the bottom wall.
In at least one operating state, the inner wall of the door unit is in particular located facing the storage space and/or the appliance body, in particular the rear wall of the appliance body. In at least one operating state, the outer wall is in particular located facing a user. In at least one assembled state, the inner wall and the outer wall are connected and/or fixed to one another, thereby in particular defining at least one interior space. The interior space is, in at least one assembled state, in particular at least partly and preferably at least mostly filled with insulation material. The inner wall and/or the outer wall can for example be in particular at least partly thermoforming parts/a thermoforming part.
The term “at least mostly” with reference to an object is in particular to mean by more than 50% or more than 65% or by more than 80% or by more than 95% of that object, in particular of a surface area and/or of a volume and/or of a mass of the object. An “operating state” is in particular to be understood as a state in which the storage space is closed and an access to the storage space is prevented, in particular by the door unit. In the operating state, the door unit and the appliance body are in particular located with respect to one another in a manner with a maximum contact area.
A “covering element” is in particular to be understood as an element having the main function of covering at least one feature of the inner wall. For example, the covering element can in particular have at least one further function which is of less priority than the main function. The main function of the covering element is in particular the reason for using the covering element. An element covering at least one feature of the inner wall and having a main function that differs from covering at least one feature of the inner wall is in particular not to be understood as a covering element. The covering element can for example be in particular at least partly a stamped part. In particular, the covering element differs from at least one door bin and/or shelf.
The term that the covering element “at least partly” covers at least one feature of the inner wall is in particular to mean that the covering element covers more than 50% or by more than 65% or by more than 75% or by more than 85% of the feature of the inner wall.
In this context, “configured” is in particular to mean specifically programmed, designed and/or equipped. By an object being configured for a certain function is in particular to be understood that the object implements and/or fulfills said certain function in at least one application state and/or operating state.
By means of the invention, in particular a high level of convenience for a user can be provided. Features of the inner wall and/or located on the inner wall can in particular be covered in an easy and/or cost-saving manner. The home appliance door and in particular the covering element can in particular be used for several and preferably for any brands. It is in particular possible to change the design of the covering element in an easy manner, in particular just using different types of material and/or coloring, thereby in particular creating different designs for different brands and/or types of home appliance doors.
Further, it is proposed that the covering element is embodied as a covering plate. The covering element has in particular at least one longitudinal extension and at least one transverse extension, which are at least 5 times or at least 10 times or at least 20 times or at least 50 times larger than at least one thickness of the covering element. In this context, a “longitudinal extension” of an object is in particular to be understood as an extension of the longest side of an imaginary smallest rectangular cuboid just still entirely encompassing the object. In this context, a “transverse extension” of an object is in particular to be understood as an extension of the second-longest side of an imaginary smallest rectangular cuboid just still entirely encompassing the object. In this context, a “thickness” of an object is in particular to be understood as an extension of the shortest side of an imaginary smallest rectangular cuboid just still entirely encompassing the object. In particular, the longitudinal extension and the transverse extension and the thickness are perpendicular to one another, respectively. On account of this, the covering element can in particular be produced and/or manufactured in an easy and/or fast manner.
Further, it is proposed that the covering element is fixed to the inner wall. As a result of this, a high stability can in particular be provided.
The covering element can in particular be fixed to the inner wall by means of a friction-fit connection and/or by means of a form-fit connection. Preferably the covering element is fixed to the inner wall by means of an adhesive bond. For example, the covering element can be fixed to the inner wall by means of a tape and/or double-sided tape. In this way, in particular a stable and/or cost-saving implementation can be provided. A usage of screws can in particular be avoided, thus in particular reducing the number of parts used.
The feature of the inner wall and/or located on the inner wall which may be covered by the cover element can in particular comprise quality problems, such as in particular a usage of too many parts and/or at least one gap located on the inner wall and/or at least one scratch located on the inner wall. Additionally and/or alternatively, the feature can in particular comprise mechanical parts, such as in particular at least one rail and/or at least one screw and/or at least one air duct and/or at least one elbow and/or mechanical details. Preferably, the feature comprises at least one re-enforcing element and/or at least one air duct and/or at least one rail of the inner wall. The re-enforcing element strengthens and/or reinforces in particular the inner wall and/or the door unit. In at least one assembled state, the rail is in particular provided for mounting of at least one door bin in particular of the home appliance door. As a result of this, a high-grade convenience for a user can in particular be provided.
In an exemplary implementation of the invention it is proposed that the home appliance door further comprises at least one rail. For example, the rail and the covering element can in particular be connected to each other, wherein the rail can in particular be connected to a surface of the covering element. Alternatively, the rail and the covering element can in particular be made of one piece. The rail can in particular be embodied as a projection of the covering element. Preferably the rail and the door unit are in particular connected to each other, wherein the rail is in particular connected to the inner wall of the door unit. For example, the covering element can comprise at least one recess through which the rail projects. The rail and the recess of the covering element can in particular be adapted to one another, in particular in size and/or form and/or location. In particular, the rail and the recess can be located correspondingly to one another. It is also proposed that the rail may be located at least completely behind the covering element. The covering element defines at least one plane behind which the rail is located. For example, the rail can be covered by the covering element. The covering element may comprise at least one recess through which the rail can be seen in a front view. This allows, in particular, providing a compact implementation.
Further, it is proposed that the home appliance door may further comprise at least one door bin and that the covering element comprises at least one recess through which the door bin may be fixed to the rail. In particular, the door bin may be provided for storing victuals to be cooled and/or tempered, for example bottles and/or milk and/or juice and/or butter and/or food and/or groceries. The door bin can for example be fixed to the rail in a permanent fashion. Alternatively, the door bin may be fixed to the rail in a releasable fashion. As a result of this, a high convenience for a user can in particular be provided.
Additionally, it is proposed that the inner wall comprises at least one groove, in which the rail is located. In particular, the inner wall comprises at least one delimiting element which in particular delimits and/or defines the groove. In this context, a “delimiting element” is in particular to be understood as a portion of the inner wall, defining and/or bordering the groove. The groove can in particular be a ridge of the inner wall. In particular, the groove is opened towards the covering element. This allows, in particular, providing a compact implementation.
Additionally, it is proposed that the home appliance door further comprises at least one support element located between the inner wall and the outer wall and attached to a rear side of at least one delimiting element of the inner wall, which delimits the groove. In this context, a “support element” is in particular to be understood as an element, being separate from the inner wall and supporting and/or reinforcing the groove and/or the delimiting element and/or the inner wall. In at least one mounted state, the support element is in particular located within the interior space in particular defined by the outer wall and the inner wall. In particular, the rail is fixed to the support element in at least one mounted state, in particular by means of at least one fixing element. The door unit in particular comprises at least one fixing element, which in particular fixes the rail to the support element in at least one mounted state. For example, the fixing element can be a latching element. The fixing element may also be a screw. The support element in particular is embodied at least mostly of metal. The support element may have at least one at least essentially U-shaped region which is in particular attached to the rear side of the delimiting element. The support element may have at least one further region contacting a rear side of the inner wall beside the groove. Alternatively and/or additionally, the support element may have at least one further region extending into the interior space without contacting the inner wall and the outer wall. As a result of this, an improved fixation of the support element by at least one solidified insulation material, located within the interior space, can in particular be provided. For example, the home appliance door can comprise several support elements, being arranged along a height direction of the door unit. Alternatively, the home appliance door can comprise exactly one support element for each delimiting element of the inner wall, e.g. two support elements in total. The support element can for example be an extruded part. In this way, the rail is in particular fixed to the inner wall and/or to the solidified insulation material and/or to the support element. The rail may not be fixed to the covering element. As a result of this, no forces acting on the rail are transmitted onto the covering element.
In addition, it is proposed that the covering element comprises at least one air recess, which is located correspondingly to at least one air duct of the inner wall. The home appliance door can in particular comprise at least one ventilation which in particular leads to the air duct of the inner wall. On account of this, a storage time of victuals to be cooled and/or tempered which are stored in the storage space can in particular be prolonged.
For example, the covering element can in particular be mounted to an in particular flat surface of the inner wall. For example, the inner wall may comprise at least one flange on which the covering element is mounted. As a result of this, a high stability can in particular be provided.
Furthermore, it is proposed that the covering element and at least one portion of the inner wall may be arranged flush with each other. The term that the covering element and at least one portion of the inner wall are arranged “flush” with each other is in particular to mean that a small offset and/or tolerances are admissible and/or allowed. On account of this, a compact implementation can in particular be provided. In particular, requirements of a flat door concept can be fulfilled. The at least one portion of the inner wall may surround one, two or all edges of the covering element.
It is also proposed that the covering element is at least mostly made of metal, e.g. sheet metal. For example, the covering element can in particular be at least mostly made of aluminum and/or stainless steel and/or galvanized steel. The covering element can in particular be painted and/or varnished. As a result of this, a high stability can in particular be provided.
A convenience for a user can in particular be enhanced by a home appliance device, in particular a home chiller appliance device, comprising at least one home appliance door according to the invention.
A convenience for a user can in particular be further improved by a home appliance, in particular a home chiller appliance, comprising at least one home appliance device, in particular at least one home chiller appliance device, according to the invention.
A comfortable and/or convenient solution can in particular be provided by a method for assembly of a home appliance door, in particular a home chiller appliance door, according to the invention; the home appliance door comprising: at least one door unit having an outer wall and an inner wall; at least one feature of the inner wall being at least partly covered.
Herein the home appliance door and/or the home appliance device is not to be limited to the application and implementation described above. In particular, for the purpose of fulfilling a functionality herein described, the home appliance door and/or the home appliance device may comprise a number of respective elements, structural components and units that differs from the number mentioned herein. Furthermore, regarding the value ranges mentioned in this disclosure, values within the limits mentioned are to be understood to be also disclosed and to be used as applicable.
Further advantages may become apparent from the following description of the drawing. In the drawing an exemplary embodiment of the invention is shown. The drawing, the description and the claims contain a plurality of features in combination. The person having ordinary skill in the art will purposefully also consider the features separately and will find further expedient combinations.
If there is more than one specimen of a certain object, only one of these is given a reference numeral in the figures and in the description. The description of this specimen may be correspondingly transferred to the other specimens of the object.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 a home appliance comprising a home appliance device which comprises a home appliance door in an operating state, in a schematic front view,
FIG. 2 a home appliance comprising a home appliance device, which comprises a home appliance door in an opened state, in a schematic front view,
FIG. 3 a door unit, a rail and a covering element of the home appliance door, in a schematic exploded view,
FIG. 4 a portion of the door unit, the rail and the covering element in an assembled state, in a schematic view,
FIG. 5 a portion of an inner wall of the door unit and the covering element in an assembled state, in a schematic sectional view and
FIG. 6 a cross-section along line VI-VI in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a home appliance 34 comprising a home appliance device 10 , in a schematic perspective view. The home appliance 34 is embodied as a home chiller appliance. The home appliance device 10 is embodied as a home chiller appliance device.
In the present embodiment the home appliance 34 is embodied as a refrigerator. The home appliance 34 could further be embodied in particular as a wine cooler, a climate cabinet, an ice-box, a freezer and/or a refrigerator-freezer combination.
In FIG. 1 the home appliance device 10 is shown in an installation position. The home appliance device 10 is installed on a base 38 . The base 38 defines a substantially horizontal plane.
The home appliance device 10 comprises an appliance body 40 . The appliance body 40 partly defines an appliance housing. The appliance body 40 is installed on the base 38 substantially upright.
The appliance body 40 partly defines a storage space 42 . The appliance body 40 comprises walls 44 , 46 , 48 , 50 . The walls 44 , 46 , 48 , 50 delimit the storage space 42 . The appliance body 40 comprises two lateral walls 44 , preferably opposite each other. The appliance body 40 comprises a rear wall 46 . The appliance body 40 comprises a bottom wall 48 . The appliance body 40 comprises a top wall 50 , preferably opposite the bottom wall 48 .
The home appliance device 10 comprises at least one insert 52 . In the present case the home appliance device 10 comprises six inserts 52 . It is conceivable that the home appliance device 10 may comprise a differing number of inserts 52 as is deemed advantageous by someone skilled in the art. The home appliance device 10 may preferably comprise a combination of different embodiments of inserts 52 , for example at least one insert 52 embodied as a shelf and at least one further insert 52 embodied as a bottle holder. For the sake of clarity, in the following only one insert 52 is given a reference numeral and is described in detail. The following description may be transferred to further inserts 52 accordingly.
The home appliance device 10 comprises a home appliance door 12 . The home appliance door 12 is connected to the appliance body 40 . In a mounted state, the home appliance door 12 is rotatably connected to the appliance body 40 .
The home appliance door 12 comprises a door unit 14 . The door unit 14 has an outer wall 16 and an inner wall 18 . In an assembled state, the inner wall 18 and the outer wall 16 are connected to one another. The inner wall 18 and the outer wall 16 define an interior space 58 (compare FIGS. 5 and 6 ). The interior space 58 is, in an assembled state, mostly filled with insulation material.
The home appliance door 12 comprises a covering element 20 . In an assembled state, the covering element 20 covers several features 22 of the inner wall 18 . The covering element 20 is, in the present embodiment, mostly made of metal. The covering element 20 is embodied as a covering plate.
The home appliance door 12 comprises at least one re-enforcing element 24 . In the present embodiment, the home appliance door 12 comprises eight re-enforcing elements 24 . For the sake of clarity, in the following only one re-enforcing element 24 is given a reference numeral and is described in detail. The following description may be transferred to further re-enforcing elements 24 accordingly.
The re-enforcing element 24 is located on the inner wall 18 . In an assembled state, the re-enforcing element 24 is connected to the inner wall 18 . For example, the re-enforcing element 24 and the inner wall 18 can be made in one piece. The feature 22 comprises the re-enforcing element 24 .
The home appliance door 12 comprises an air duct 26 . In an alternate embodiment, the home appliance door 12 may comprise more than one air duct 26 .
The air duct 26 comprises an air duct inlet 62 . The air duct inlet 62 is located in a bottom part of the home appliance door 12 . The air duct 26 comprises an air duct outlet 64 . The air duct outlet 64 is located in a top part of the appliance door 12 .
The air duct 26 is located on the inner wall 18 . In an assembled state, the air duct 26 and the inner wall 18 are made in one piece. The feature 22 comprises the air duct 26 .
The home appliance door 12 comprises at least one rail 28 . In the present embodiment, the home appliance door 12 comprises two rails 28 . For the sake of clarity, in the following only one rail 28 is given a reference numeral and is described in detail. The following description may be transferred to the further rail 28 accordingly.
The rail 28 is located on the inner wall 18 . In an assembled state, the rail 28 is connected to the inner wall 18 . For example, the rail 28 and the inner wall 18 can be made in one piece. The feature 22 partly comprises the rail 28 , which means that in particular only a portion of the rail 28 is part of the feature 22 .
The inner wall 18 comprises a groove 66 . In an assembled state, the rail 28 is located in the groove 66 . The inner wall 18 comprises a delimiting element 70 . The delimiting element 70 delimits the groove 66 .
The home appliance door 12 comprises a support element 68 . In an assembled state, the support element 68 is located between the inner wall 18 and the outer wall 16 . The support element 68 is located in the interior space 58 , in an assembled state. In an assembled state, the support element 68 is attached to a rear side of the delimiting element 70 by means of a fixing element 72 . In the present embodiment the fixing element 72 is a screw.
In an assembled state, the covering element 20 is fixed to the inner wall 18 . In the present embodiment, the covering element 20 is fixed to the inner wall 18 by means of adhesive bonding.
The inner wall 18 comprises a flange 54 . In an alternative embodiment, the inner wall 18 can comprise a greater number of flanges 54 , for example at least one flange 54 per side of the inner wall 18 . The covering element 20 is, in an assembled state, mounted on the flange 54 .
The flange 54 is in the present embodiment curved in a direction towards the outer wall 16 . In an assembled state, the covering element 20 and a portion 56 of the inner wall 18 are arranged flush with each other. The portion 56 of the inner wall 18 is part of a frame 60 of the inner wall 18 .
The home appliance door 12 comprises at least one frame 60 . The frame 60 is located on the inner wall 18 . In an assembled state, the frame 60 is connected to the inner wall 18 . For example, the frame 60 and the inner wall 18 can be made in one piece. The frame 60 projects over a surface of a base body of the inner wall 18 .
The covering element 20 is, in an assembled state, located in front of the rail 28 . In an assembled state, the rail 28 is located completely behind the covering element 20 .
In the present embodiment, the home appliance door 12 comprises four door bins 32 . For the sake of clarity, in the following only one door bin 32 is given a reference numeral and is described in detail. The following description may be transferred to the further door bin 32 accordingly.
In the present embodiment, the covering element 20 comprises two recesses 30 . For the sake of clarity, in the following only one recess 30 is given a reference numeral and is described in detail. The following description may be transferred to the further recess 30 accordingly.
In an assembled state, the recess 30 is located correspondingly to the rail 28 . In an assembled state, the door bin 32 is fixed to the rail 28 through the recess 30 .
In an assembled state, the covering element 20 is located between a base body of the inner wall 18 and the door bin 32 . In an operating state, the door bin 32 is located inside the storage space 42 .
In the present embodiment, the covering element 20 comprises two air recesses 36 . For the sake of clarity, in the following only one air recess 36 is given a reference numeral and is described in detail. The following description may be transferred to the further air recess 36 accordingly. In an assembled state, the air recess 36 is located correspondingly to the air duct 26 .
In a method for assembly of the home appliance door 12 several features 22 of the inner wall 18 are partly covered.
The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
10 Home appliance device 12 Home appliance door 14 Door unit 16 Outer wall 18 Inner wall 20 Covering element 22 Feature 24 Re-enforcing element 26 Air duct 28 Rail 30 Recess 32 Door bin 34 Home appliance 36 Air recess 38 Base 40 Appliance body 42 Storage space 44 Wall 46 Wall 48 Wall 50 Wall 52 Insert 54 Flange 56 Portion 58 Interior space 60 Frame 62 Air duct inlet 64 Air duct outlet 66 Groove 68 Support element 70 Delimiting element 72 Fixing element
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For the purpose of providing a home appliance device with improved characteristics regarding a user convenience, a home appliance door, in particular a home chiller appliance door, is proposed: The home appliance door has at least one door unit with an outer wall and an inner wall; and at least one covering element which at least partly covers at least one feature of the inner wall.
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[0001] Reference: U.S. 60/749,438 Provisional application Dec. 13, 2005
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention relates to a portable exercise device with a sliding platform moving on a base board, that can provide passive, active and resisted movement in weight or non weight bearing exercises for the upper and lower extremities. This invention relates particularly to a sliding foot/hand plate moving on a base board where the device can be used for weight and non weight bearing active, passive, and resisted exercise to be performed for upper and lower extremities.
[0004] The device can be used to allow active range of motion exercises for the ankle, knee, hip and lower trunk in addition to the elbow, shoulder and upper trunk in either weight or non weight bearing situations. Passive exercises can be performed to the knee, hip, elbow and shoulder. Resisted exercises for the ankle, knee, hip and lower trunk in addition to the wrist, elbow, shoulder and upper trunk in either weight or non weight bearing situations.
[0005] There are many conditions of the musculo-skeletal system that require passive, active, and/or resisted exercises as part of their rehabilitation. The exercises can be either performed in weight bearing or non-weight bearing. Exercises that are performed non-weight bearing where there is no fixation of the distal end of the limb are defined as ‘open chain’. Sitting on the edge of the treatment table with a weight on the ankle and straightening the knee is an example of an ‘open chain’ exercise, as is performing a biceps curl in the upper arm. When the exercise is performed weight bearing, with the distal end of the limb being stabilized, it is defined as being closed chain. Performing a squat or deep knee band is an example of a lower extremity closed chain exercise as a ‘press up’ is an upper extremity example. Closed chain exercises promote different muscle actions of the limbs and are more appropriate in some rehabilitation situations than ‘open chain exercises. The device can be used for both. The device is portable and can be used in the home, gym or rehabilitation clinic. The device can be adapted to the needs of the patient. Passive movement is applied by loading the sliding foot/hand plate so when a limb is placed on the plate, the loaded plate will passively move the limb to the extent of the resistance bands. Closed chain exercise are performed by standing with one foot on the foot/hand plate for the lower extremity or the hand on the foot/hand plate while placing weight on the limb down the arm for example in a kneeling position of all fours. The larger version uses the patients other foot to fixate the board by placing the weight on the lid. The smaller version uses an anti skid friction surface on the under side.
[0006] 2. Description of Prior Art
[0007] Various kinds of muscle training apparatus and other exercising devices are well known. One of the known apparatus is U.S. Pat. No. 4,911,430 issued to Jean Marie Flament on Mar. 27, 1990 comprising of an apparatus allowing the user to exercise particularly his lower limbs as for training in sliding sports such as snow or water skiing, includes a base adapted to be anchored on a reference surface, the base having a accurate shaped track formed of two concentric paths, each path having a curved concentric rail, and a pair of movable carriages, each having grooved wheels for bearing on the concentric rails. Each carriage has a shoe connected to its upper part for articulation, the shoe being adapted to receive the foot of the user and to rotate about an axis parallel to a simulated direction of a ski. Each shoe includes a brake for blocking movement of the carriage over the track so as to a simulate an edge taking skiing technique by placing the user in a position corresponding to that actually taken during skiing.
[0008] Another known lower muscle training device is US2005/0272563 A1 published on Dec. 8, 2005 comprising a training device includes a base, and a foot support having an intermediate portion pivotally coupled to the base with a pivot shaft and having one or more foot pedals for supporting users. The foot pedals and the foot support may be rotatable relative to the base about the pivot shaft by the users, to train and exercise lower muscle groups of the users. The base includes a front pad and a rear stop to cushion the foot support. The stop may be used to adjust an inclination or tilting angle of the foot support relative to the base. A resistive device may be coupled between the foot support and the base, to apply a resistive force against the foot support and to the users.
[0009] Another known lower muscle training device is US2006/0058719 A1 published on Mar. 16, 2006 comprising an apparatus for anterior and posterior mobilization of the human talocrural joints for rehabilitation and/or therapeutic utilization. A patient's foot is secured in an apparatus and an Ankle Mortise Strap is looped around the mortise of an ankle of the foot A force strap is attached to the ends of the Ankle Mortise Strap. Anterior mobilization is achieved by moving the force strap ventrally from the foot so that the foot including the talus remains stationary while the tibia and fibula glide anteriorly. Posterior mobilizations are achieved by securing the foot, and looping an Ankle Mortise Strap around the front of the ankle. A force strap is attached to the ends of the Ankle Mortise Strap. Posterior mobilization is achieved by moving the force strap dorsally from the foot so that the foot including the talus remains stationary while the tibia and fibula glide posteriorly.
[0010] Another of the known apparatus is U.S. Pat. No. 6,616,583 B1 by Louis Stack dated Sep. 9, 2003 comprising of an exercise board for accommodating the foot or feet of a balancing user during exercise movement has an elongated flat platform with opposite, typically upturned ends, similar to a skateboard. The board defines an upper facing side dimensioned to receive the foot or feet of the balancing user and a lower facing side. Resilient rocker-mounting ends are mounted to the lower facing side at either end of the elongated flat platform. Each resilient rocker-mounting end includes a rigid floor contacting rocker section and an elastic column. The floor contacting rocker section has a rounded floor-contacting surface. The elastic column is mounted to the elongated flat platform at the upper end, mounted to the floor contacting rocker at the lower end, and bendable both longitudinally and in torque responsive to shifting weight of a balancing user on the upper facing side of the elongate platform.
[0011] None of the known muscle training or exercising devices are suitable to effectively allow weight and non weight bearing active, passive, and resisted exercise to be performed for upper and lower extremities at home, gymnasium or rehabilitation clinic that are required in many conditions of musculo-skeletal system, as part of their rehabilitation.
OBJECTS OF THE INVENTION
[0012] The main object and purpose of the invention is to provide an exercising device that allows to perform passive, active, and/or resisted exercises required in many conditions of musculo-skeletal systems as part of the patients rehabilitation.
[0013] Another object of the invention is to provide portable exercise device for passive, active, and/or resisted exercises to be performed at home, gymnasium or rehabilitation clinic.
[0014] Another object of the present invention is to provide an exercise device which is suitable for both weight bearing/close chain or non weight bearing/open chain exercises to be performed for upper and lower extremities.
[0015] A further object of the present invention is to provide an exercise device for passive, active, and/or resisted exercises of the upper and lower extremities having a resistance mechanism installed which is easily adjustable according to the degree of resistance needed.
SUMMARY OF THE INVENTION
[0016] According to the present invention, there is provided a sliding exercise device comprising of a base board on which is mounted a sliding platform movable fro one end of the board to the other in a controlled fashion and a resistance mechanism to provide resistance to the movement of the platform with respect to the board. The base board is sufficiently thick to hold a sliding board and wide enough to fit a large foot. It can have a non-slip surface on the underside. This base board is the foundation of the device.
[0017] The platform is further guided by a slide runner or groves or rails or any other such system that ensure its movement from one end of the base board to the other in a controlled fashion. The platform is made of aluminum or any other material that is strong enough to cope with the weight that will be applied.
[0018] The sliding platform can consist a hand/foot plate mounted on wheel frame having wheels for movement along the base board. The said plate is bent at at least one end to allow the plate to be pulled or pushed and thus providing a grip.
[0019] The plate can be further provided with a covering made of plastic or rubber or any other soft material to make it easier to handle and also provide more grip while using the device.
[0020] The resistance mechanism provided in the exercise device comprises of springs or any other elastic material or a combination of different materials to provide the resistance and also consists of a knob or any other system to alter the degree of resistance.
[0021] Stop ends are provided to limit the movement of the movable platform as per the exercise to be performed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Further objects, features and advantages of the invention appear from the following description of the exemplary embodiments which are diagrammatically illustrated on the attached drawings, wherein:
[0023] FIG. I: Shows the top view of the exercise device in accordance with an embodiment of the present invention.
[0024] FIG. II: Shows the side view of the device showing the sliding platform of the device in the start position.
[0025] FIG. III: Shows the side view of the device showing the sliding platform of the device pushed out from the start position.
[0026] FIG. IV: Shows the side view of the of the sliding platform of the device.
[0027] FIG. V: Shows the end view of the sliding platform of the device.
[0028] FIG. VI: Shows the top view of the base board of the device.
[0029] FIG. VII: Shows the side view of the base board of the device.
[0030] FIG. VIII: Shows the bottom view of the sliding platform attached to the resistance mechanism of the device.
[0031] FIG. IX: Shows the close-up of the side view showing the arrangement of the resistance mechanism of the device.
[0032] FIG. X: Shows the top view of the exercise device in accordance with another embodiment of the present invention.
[0033] FIG. XI: Shows the side view of the device shown in FIG. X, with it's lid in lifted up position.
[0034] FIG. XII: Shows the top view of the device shown in FIG. X, with it's lid removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Although following examples shows the operation of specific embodiments, many modifications and variations will readily occur to those skilled in the art, accordingly it is not intended to limit the scope of the invention.
[0036] Accordingly with reference to the diagrams and initially to FIG. I to IX, an exercising device with sliding platform in accordance with the preferred embodiment of this invention that can be used in weight bearing/close chain or non weight bearing/open chain exercise situation to allow active, passive, and resisted exercises comprises of a base board ( 1 ) having end stops ( 2 , 6 ) one at each end of it to limit the slide. The end stop ( 6 ) being deeper than the end stop ( 2 ) to accommodate the foot or hand of the user and is called as master stop. Each stop is preferably provided with a handle ( 3 , 7 ) on the top. A sliding platform consists of a foot/hand plate ( 5 ) provided with a slide runner ( 4 ) fixed to the base board ( 1 ) and underside of the plate ( 5 ). The foot/hand plate ( 5 ) guided by the slide runner ( 4 ) moves from one end of the base board ( 1 ) to the other end in a controlled manner. The plate ( 5 ) is supported a wheel frame ( 11 ) having at least one wheel ( 10 ). A resistance mechanism is installed under the plate ( 5 ) which consists of resistance end plates ( 12 ) with holes ( 15 ) for allowing resistance bands ( 17 ) to pass through. The base board has a non-slip surface on the underside.
[0037] With reference to FIG. I the movable foot/hand plate ( 5 ) runs on a thick plastic base board ( 1 ). At each end of the base board ( 1 ) are the end stops ( 2 , 6 ) The depth of the end stop ( 6 ) can be increased to allow a foot to be placed on it. On the top of each end stops is a handle ( 3 , 7 ). The foot/hand plate ( 5 ) is guided by the slide runner ( 4 ) which is screwed to the base board ( 1 ) and the under side of the foot/hand plate ( 5 ). The slide runner ( 4 ) made of any metal or any other hard material, ensures the foot/hand plate ( 5 ) moves from one end of the base board to the other in a controlled fashion. Attached to the end stop ( 6 ) is the resistance mechanism's slotted end stop housing ( 9 ).
[0038] With reference to FIG. II the side view of the assembled device with the end stops ( 2 , 6 ) with handles ( 3 , 7 ) and foot/hand plate ( 5 ) using the runner ( 4 ) as a guide. The foot/hand plate ( 5 ) is in the start position.
[0039] With reference to FIG. III the side view shows the foot/hand plate ( 5 ) in a position where it has been pushed out from the start position and the resistance is supplied from rubber bands ( 17 ) or springs or any other elastic material.
[0040] With reference to FIG. IV shows the side view of the foot/hand plate ( 5 ). The foot/hand plate ( 5 ) has the end bent up to allow a foot or hand to push or pull the plate. This provides a better grip. Each end of the foot plate or the complete surface of it is provided/covered with a plastic ( 14 ) or rubber or any other soft material to increase the grip of the hand or foot when using the device and to make the aluminum end of the foot/hand plate ( 5 ) safer. The foot/hand plate ( 5 ) is supported by the wheel frame ( 11 ) and runs on wheels ( 10 ).
[0041] With reference to FIG. V the foot/hand plate is supported by a wheel frame ( 11 ) on which are mounted the wheels ( 10 ). Under the foot/hand plate ( 5 ) is the resistance mechanism. There is a resistance end plate ( 12 ) screwed to each end of the foot/hand plate ( 5 ). The resistance end plate ( 12 ) has at least one hole/opening ( 15 ) in it to allow the resistance rubber band or springs or any other elastic material to pass through. There is a center support ( 13 ) which is screwed to the foot/hand plate on the upper surface and about which the resistance end plates ( 12 ) are attached. The center support is screwed to the runner ( 4 ) on the under surface. The runner ( 4 ) and the center support ( 13 ) is the link between the base board ( 1 ) and the foot/hand plate ( 5 ).
[0042] With reference to FIG. VI the top view of the base board of the device ( 1 ) shows the end stops ( 2 , 6 ) at the end and the handles on each ( 3 , 7 ) end stop. The runner ( 4 ) is the track in which the foot/hand plate sides. This is sufficiently long to give the correct range of motion. The resistance bands ( 17 ) are slotted/installed into the end stop housing ( 9 ) on the master end stop ( 6 ).
[0043] With reference to FIG. VII the side view of the base board of the device ( 1 ) shows the end stops ( 2 , 6 ) and the handles ( 3 , 7 ) on each end stop. The resistance bands ( 17 ) are slotted/installed into the end stop housing ( 9 ) on the master end stop ( 6 ).
[0044] With reference to FIG. VIII the bottom view of the foot/hand plate ( 5 ) with the resistance mechanism attached. The resistance bands ( 17 ) are made of rubber tubing but can be metallic springs or other resistance/elastic material and can be of various tensions or strengths. The number of resistance bands ( 17 ) shown are four. There can be any number of resistance bands and any combination of these of any resistance/elasticity as long as these fit within the space provided. The resistance bands ( 17 ) are prevented from being pulled through the holes ( 15 ) in the end plates ( 12 ) by a washer ( 18 ) and pull knob mechanism ( 8 ). The mid line stay ( 16 ) is attached to the foot/hand plate ( 5 ) above and the runner ( 4 ) below.
[0045] With reference to FIG. IX The close up side view of the resistance mechanism is shown where the slotted housing ( 9 ) has the resistance band ( 17 ) in place. The knob ( 8 ) is used for ease of gripping when there is a need to alter the degree of resistance of the device. The pull knob ( 8 ) is held in place by a washer ( 8 ). The handle ( 7 ) is on the master end stopper ( 6 ). The resistance band ( 17 ) is clamped on the shaft of the pull knob ( 8 ) by a clip ( 19 ) made of plastic or any other hard material.
[0046] Now referring to FIG. X to XII showing another embodiment of the present invention FIG. X shows a base board ( 22 ) is longer than the base board ( 1 ). The longer device is designed a person can stand on the lid ( 27 ). The foot plate ( 21 ) is moved by pushing out using the other foot placed on the plate ( 21 ). The end stop ( 23 , 20 ) are not provided with any handles. The handle ( 25 ) is on the side of the foot board ( 21 ) and is in the center of the balance of the device. The runner ( 4 ) is longer, giving a greater range of motion than the previous embodiment.
[0047] With reference to FIG. XI diagram shows the side view of the embodiment shown in FIG. X where the stops ( 23 , 20 ) are at the end of the board. The lid ( 27 ) is shown in the lifted up position where the resistance band knobs may be accessed. The foot plate ( 21 ) is bent up one end only.
[0048] With reference to FIG. XII the diagram shows the top view of the exercise device where the lid ( 27 ) is has been removed. This exposes the resistance knobs ( 8 ) and the lid hinges ( 26 ). The weight of the body on the lid ( 27 ) is supported by the sides ( 24 ).
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A sliding exercise device comprising of a base board on which is mounted a sliding platform movable from one end of the board to the other in a controlled fashion and a resistance mechanism to provide resistance to the movement of the platform with respect to the board. The base board is sufficiently thick to hold a sliding board and wide enough to fit a large foot. The sliding exercise device has a non-slip surface on the underside.
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BACKGROUND OF THE INVENTION
1. The Field Of The Invention
The present invention relates to an improved strip form screw and in particular to a strip of screws stamped and formed from a continuous web of metal stock.
2. The Prior Art
The conventional method of assembly utilizing a plurality of loose piece fasteners is both slow and costly since the operators must handle each individual fastener. Some improvement in speed and reduction in cost can be achieved by providing the fasteners in strip form in an applicator tool. A conventional stapler is an illustration of fasteners in cartridge form loaded in a manual applicator tool. Many times though, it is unsatisfactory to use staples, nails and the like since the assembled part must have the ability of being disassembled for repair and/or replacement.
It has been known that fasteners, such as screws and the like, can be formed in strip form for machine assembly. An example of such a strip form of screw is shown in U.S. Pat. No. 2,279,401. However, the strip of screws shown in this patent is apparently molded in a nose to tail form and thus would be very expensive to produce. It would also have the disadvantage of being rather limited in length and therefore be suitable only for operations in which frequent reloading of the applicator tool would not be a handicap. Somewhat of an improvement is shown in U.S. Pat. Nos. 3,211,352 and 3,554,246 in which a plurality of fasting devices, nails and screws, respectively, are strip fed into a machine for application. The nails and screws are held in rather expensive carrier strips which are removed from the fastener as it is applied. This causes problems in initially forming the strip of fasteners.
SUMMARY OF THE INVENTION
The present invention is directed to a method for forming a continuous strip of screws and the resulting product. The subject screw is stamped and formed from a continuous web of metal stock material and includes a slotted driving head portion and a pair of integral leg portions which together form a threaded shank for the screw. The individual screws are stamped and formed from metal stock with a carrier strip interconnecting the head portions of adjacent screws. The carrier strip is removed from the screws by an applicator tool. The screws have an external thread configuration on the shank portion so designed that the screws can be directly driven into a prebored hole and yet be threadedly removed and reapplied to the hole.
It is therefore an object of the present invention to produce an improved stamped and formed screw which is continuously formed from a web of metal stock with the individual screws being interconnected by an intermediate carrier strip.
It is a further object of the present invention to produce a metal stamped and formed screw which is in a continuous strip and is adapted for machine application without losing the ability for manual threaded withdrawal and replacement.
It is yet another object of the present invention to teach a method for stamping and forming a strip of a plurality of screws from a continuous web of metal stock material.
It is a further object of the present invention to produce a metal stamped and formed screw which can be readily and economically manufactured.
The means for accomplishing the foregoing objects and other advantages of the present invention will become apparent to those skilled in the art from the following detailed description taken with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a single metal screw stamped and formed according to the present invention;
FIG. 2 is a perspective view of a strip of metal screws stamped and formed according to the present invention;
FIG. 3 is a side elevation, taken along line 3--3 of FIG. 4, of a single metal screw stamped and formed according to the present invention;
FIG. 4 is a side elevation, taken along line 4--4 of FIG. 3, of a metal screw stamped and formed according to the present invention;
FIG. 5 is a horizontal transverse section taken along line 5--5 of FIG. 3; and
FIG. 6 is a plan view of the blank for forming the subject screw.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The subject screw 10 includes a driving head portion 12 and an integral threaded shank 14 formed by a pair of mating leg portions 16, 18. The driving head 12 has a substantially square top plate 20 with a slot 22 therein and carrier strips 24, 26 extending from an opposite first pair of sides. Sidewalls 28, 30 are integral with surface 20 and extend from an opposite second pair of sides. Under plates 32, 34 extend from sidewalls 28, 30, respectively, back under top plate 20 and include tabs 36, 38, 40 and 42 which are upturned so that their free ends lie adjacent the bottom of plate 20 and serve to support plate 20. Points 44, 46 of tabs 36, 42, respectively, are downturned, as best noted from FIG. 3, and serve to lock the screw against unintended loosening, such as by vibration. FIG. 3 also shows how under plates 32, 34 are deformed to accommodate the rounding of the leg portions 16, 18. This deformation also serves the purpose of forming elevated abutments 48, 50 which underlie slot 22 and serve to stop a blade of a screwdriver from going too far into the head thereby limiting the torque that can be applied to the screw. The leg portions 16, 18 each have an essentially elongated profile with a series of projecting tabs 52, 54 and recesses 56, 58 on a first long side and like tabs 60, 62 and recesses 64, 66 on the opposite long side. Each tab 52, 54, 60, 62 is matched on the opposite side of the leg portion with a recess 64, 66, 56, 58, respectively. When the screw is formed, tabs 52, 54, 60, 62 are received in recesses 58, 56, 66, 64, respectively in the opposite leg portion for intermating engagement, as best shown in the section view of FIG. 5. Each leg portion 16, 18 is further provided with a plurality of inclined parallel slots 68. Like sides of each slot are formed into a series of protrusions which form an interrupted external thread on the finished screw.
The subject screw is formed by first stamping out the blank shown in FIG. 6. The blank is then passed through a series of dies which form the slots 68 and protrusions 70 and then sequentially form the head 12 and bring the leg portions 16, 18 into the interlocking configuration, as shown in FIGS. 1 through 5. It will be noted from FIG. 5 that the tabs 52, 54, 60, 62 extend into the opposite aligned recesses 58, 56, 66, 64 and secure the leg portions together.
The subject screw is preferably formed in strip fashion as shown and thus is quite suitable for machine application. The strip of screws can be fed into an applicator machine, cut from the carrier strip, and driven straight into prebored holes in the member to be secured, which preferably is formed of a high impact plastics material such as commonly used as in telephones, radios, toys, automobiles, and the like. The tapered threads on the leg portions allow the screws to be driven directly into the holes at very high speed insertion rates without any rotational movement of the screw being required. Removal and reinsertion of the screws is facilitated by application of an ordinary screwdriver to the slot 22 or a wrench, nut driver, or the like to the outer profile of the square head. The screws thus can be inserted rapidly and automatically and withdrawn manually without derogatory effect upon either the screw or the member receiving the screw. The subject screws can be reinserted into the bored holes by normal threaded rotation or by a straight diving action.
The present invention may be subject to many modifications and changes without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive of the scope of the invention.
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An improved metal stamped and formed screw is disclosed. The subject screw is stamped and formed from continuous web of metal stock to form a plurality of screws joined by a carrier strip. The thus formed strip of screws can be machine applied to prebored holes and manually withdrawn therefrom and reapplied by conventional means.
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CROSS REFERENCE TO RELATED APPLICATION(S)
This application is a divisional of U.S. patent application Ser. No. 11/103,188, filed Apr. 11, 2005, and issued as U.S. Pat. No. 8,653,495 on Feb. 18, 2014. This application and patent are incorporated herein by reference, in their entirety, for any purpose.
TECHNICAL FIELD
This invention relates generally to phase change memories.
BACKGROUND OF THE INVENTION
Phase change memory devices use phase change materials, i.e., materials that may be electrically switched between a generally amorphous and a generally crystalline state, for electronic memory application. One type of memory element utilizes a phase change material that may be, in one application, electrically switched between a structural state of generally amorphous and generally crystalline local order or between different detectable states of local order across the entire spectrum between completely amorphous and completely crystalline states. The state of the phase change materials is also non-volatile in that, when set in either a crystalline, semi-crystalline, amorphous, or semi-amorphous state representing a resistance value, that value is retained until changed by another programming event, as that value represents a phase or physical state of the material (e.g., crystalline or amorphous). The state is unaffected by removing electrical power.
In phase change memories, a heater heats the phase change material to change the state of the phase change material. These heaters may consume sufficient power to be an issue in some applications, such as in those applications that rely on battery power. In addition, the heater may add to the size of the phase change memory device.
Thus, there is a need for better ways to heat phase change memories.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of a phase change memory in accordance with one embodiment of the present invention;
FIG. 2 is an enlarged, cross-sectional view of a phase change memory in accordance with one embodiment of the present invention;
FIG. 3 is an enlarged, cross-sectional view of a phase change memory in accordance with still another embodiment of the present invention;
FIG. 4 is an enlarged, cross-sectional view of still another embodiment of the present invention;
FIG. 5 is an enlarged, cross-sectional view of the embodiment shown in FIG. 4 at an early stage of manufacture in accordance with one embodiment of the present invention;
FIG. 6 is an enlarged, cross-sectional view of the embodiment shown in FIG. 5 at a subsequent stage of manufacture in accordance with one embodiment of the present invention;
FIG. 7 is an enlarged, cross-sectional view of the embodiment shown in FIG. 6 at a subsequent stage of manufacture in accordance with one embodiment of the present invention;
FIG. 8 is an enlarged, cross-sectional view of the embodiment shown in FIG. 7 at a subsequent stage of manufacture in accordance with one embodiment of the present invention; and
FIG. 9 is a schematic depiction of a system in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
Turning to FIG. 1 , an embodiment of a memory 100 is illustrated. Memory 100 may include a 3×3 array of memory cells 111 - 119 , wherein memory cells 111 - 119 each include a select device 120 and a memory element 130 . Although a 3×3 array is illustrated in FIG. 1 , the scope of the present invention is not limited in this respect. Memory 100 may have a larger array of memory cells.
In one embodiment, memory elements 130 may comprise a phase change material. In this embodiment, memory 100 may be referred to as a phase change memory. A phase change material may be a material having electrical properties (e.g. resistance, capacitance, etc.) that may be changed through the application of energy such as, for example, heat, light, voltage potential, or electrical current.
Examples of a phase change material may include a chalcogenide material.
A chalcogenide alloy may be used in a memory element or in an electronic switch. A chalcogenide material may be a material that includes at least one element from column VI of the periodic table or may be a material that includes one or more of the chalcogen elements, e.g., any of the elements of tellurium, sulfur, or selenium.
Memory 100 may include column lines 141 - 143 and row lines 151 - 153 to select a particular memory cell of the array during a write or read operation.
Column lines 141 - 143 and row lines 151 - 153 may also be referred to as address lines since these lines may be used to address memory cells 111 - 119 during programming or reading. Column lines 141 - 143 may also be referred to as bit lines and row lines 151 - 153 may also be referred to as word lines.
Memory elements 130 may be connected to row lines 151 - 153 and may be coupled to column lines 141 143 via select device 120 . While one select device 120 is depicted, more select devices may also be used Therefore, when a particular memory cell (e.g., memory cell 115 ) is selected, voltage potentials may be applied to the memory cell's associated column line (e.g., 142 ) and row line (e.g., 152 ) to apply a voltage potential across the memory cell.
Series connected select device 120 may be used to access memory element 130 during programming or reading of memory element 130 . The select device 120 may also be called an access device, a threshold device, an isolator device or a switch. It may be implemented as a MOS transistor, a bipolar junction transistor, a diode or an ovonic threshold switch.
Referring to FIG. 2 , in accordance with one embodiment of the present invention, a phase change memory cell 10 may be formed over a substrate 12 such as a silicon substrate. The cell 10 may correspond to the cells 111 - 119 . A lower contact 16 may be formed within an insulating layer 14 in one embodiment of the present invention. Over the insulating layer 14 may be a first patterned chalcogenide material 18 to form the select device 120 of FIG. 1 .
The first patterned chalcogenide material 18 and the exposed insulating layer 14 may be covered by an insulating layer 20 in accordance with one embodiment of the present invention. The insulating layer 20 may have an opening 28 . The layer 20 may be partially covered by a second patterned chalcogenide material 22 in accordance with one embodiment of the present invention. The material 22 may fill the opening 28 and contact the material 18 in one embodiment. The material 22 forms the memory element 130 of FIG. 1 . The layer 22 is, in turn, contacted by an upper contact 24 formed in still another insulating layer 26 .
As a result of the opening 28 through the layer 20 , a “bottleneck” is created for current flowing between the first patterned chalcogenide material 18 and the second patterned chalcogenide material 22 . In other words, the current primarily flows, not through the insulator 20 , but directly between the first patterned chalcogenide material and the second patterned chalcogenide material 22 at the bottleneck created by the opening 28 in the insulating layer 20 .
The higher current density through the opening 28 leads to power dissipation at the point of contact between the chalcogenide materials 18 and 22 .
This results in efficient heating. The heating may be utilized to change the state of either or both of the first or second chalcogenide materials 18 and 22 .
Materials 18 and 22 can both be chalcogenide memory alloys, in order to make an efficient memory element 130 . In this case, the select device 120 may be made in the underlying substrate.
Referring to FIG. 3 , in accordance with another embodiment of the present invention, the cell 30 is similar to the cell 10 . However, in the case of the cell 30 , a resistive layer 32 is situated between the insulating layer and the second patterned chalcogenide material 22 .
The resistive layer 32 may be a dielectric or insulating layer such as silicon nitride with a thickness of between about 10 and 50 Angstroms. When the cell 30 is first programmed, the potential developed across the layer 32 can cause it to break down in one small area of the opening 28 in the insulating layer 20 . This breakdown location or filament further reduces the area of contact between the chalcogenide materials 18 and 22 , increasing the current density or power dissipation.
The layer 32 may also be a more resistive chalcogenide alloy, such as germanium, antimony, tellurium alloy with nitrogen incorporated into the film to increase its resistivity. In one embodiment less than 10% nitrogen is used.
That higher resistivity material at the area of contact between the chalcogenide materials 18 and 22 dissipates more power and heats the region more effectively.
The more conductive chalcogenide materials 18 and 22 carry current from the small region of programming to the electrical contacts 16 and 24 , which are located away from the programming region created at the opening 28 . Because the chalcogenide materials 18 and 22 are conductive and because the current density away from the contact region is much smaller, there may be lower power dissipation in the chalcogenide materials 18 , 22 away from the contact region in some embodiments. Thus, this contact region away from the opening 28 need not change phase and remains relatively highly conductive. By reducing the area that changes phase, power dissipation may be reduced in some embodiments. This power consumption reduction may allow the memory cell 30 to cycle with lower current than current embodiments of phase change memories.
Referring to FIG. 4 , in this embodiment, the resistive layer 32 a is placed on the first patterned chalcogenide material 18 . Otherwise, the structure is similar to that of FIG. 3 .
Taking the embodiment of FIG. 4 as an example, FIGS. 5-8 show an example of a fabrication process in accordance with one embodiment of the present invention. The layers 34 of chalcogenide material and 36 of the resistive material may be deposited over the insulating layer 14 and the contact 16 as shown in FIG. 5 . Those layers 34 , 36 may then be patterned to form the first patterned chalcogenide material 18 and the resistive layer 32 a . That stack of material 18 and layer 32 a may then be covered with an insulating layer 20 as shown in FIG. 6 .
Then, as shown in FIG. 7 , an opening 28 may be formed through the insulating layer 20 in a position spaced from the contact 16 . The chalcogenide layer 34 may be deposited so that a portion thereof extends into the opening 28 .
The layer 34 may be patterned to form the second pattern chalcogenide material 22 , shown in FIG. 4 . Thereafter, the layer 26 may be deposited, an opening formed therein, and the upper contact 24 formed therein, as also shown in FIG. 4 .
The substrate 12 may be, for example, a semiconductor substrate (e.g., a silicon substrate), although the scope of the present invention is not limited in this respect.
Other suitable substrates may be but are not limited to, substrates that contain ceramic material, organic material; or a glass material.
The insulating layer 14 may be formed using, for example, a PECVD (Plasma Enhanced Chemical Vapor Deposition) process, HDP (High Density Plasma) process, or spin-on and bake sol gel process. Insulating layer 14 can be a dielectric material that may be a thermally and/or electrically insulating material such as, for example, silicon dioxide, although the scope of the present invention is not limited in this respect. Insulating layer 14 may have a thickness ranging from about 100 A to about 4000 A, although the scope of the present invention is not limited in this respect. In one embodiment, the thickness of insulating layer 14 may range from about 500 A to about 2500 A.
Although the scope of the present invention is not limited in this respect, insulating layer 14 may be planarized using a chemical or chemical mechanical polishing (CMP) technique.
The material 22 may be a phase change, program programmable material capable of being programmed into one of at least two memory states by applying a current to material 22 to alter the phase of material 22 between a substantially crystalline state and a substantially amorphous state, wherein a resistance of the material 22 in the substantially amorphous state is greater than the resistance of the material 22 in the substantially crystalline state. Programming of switching material 22 to alter the state or phase of the material may be accomplished by applying voltage potentials to contacts 16 and 24 , thereby generating a voltage potential across select device 120 and memory element 130 . When the voltage potential is greater than the threshold voltage of select device 120 and memory element 130 , then an electrical current may flow through memory material 22 in response to the applied voltage potential, and may result in heating of memory material 22 at the opening 28 .
This heating may alter the memory state or phase of memory material 22 . Altering the phase or state of memory material 22 may alter the electrical characteristic of memory material 22 , e.g., the resistance of the material may be altered by altering the phase of the memory material 22 . Memory material 22 may also be referred to as a programmable resistive material.
In the “reset” state, memory material 22 may be in an amorphous or semi-amorphous state and in the “set” state, memory material 22 may be in an a crystalline or semi-crystalline state. The resistance of memory material 20 in the amorphous or semi-amorphous state may be greater than the resistance of memory material 22 in the crystalline or semi-crystalline state. It is to be appreciated that the association of reset and set with amorphous and crystalline states, respectively, is a convention and that at least an opposite convention may be adopted.
Using electrical current, memory material 22 may be heated to a relatively higher temperature to amorphosize memory material 22 and “reset” memory material 22 (e.g., program memory material 22 to a logic “0” value). Heating the volume of memory material 22 to a relatively lower crystallization temperature may crystallize memory material 22 and “set” memory material 22 (e.g., program memory material 22 to a logic “1” value). Various resistances of memory material 22 may be achieved to store information by varying the amount of current flow and duration through the volume of memory material 22 .
Although the scope of the present invention is not limited in this respect, in one example, the composition of ovonic switching material 22 may comprise a Si concentration of about 14%, a Te concentration of about 39%, an As concentration of about 37%, a Ge concentration of about 9%, and an In concentration of about 1%. In another example, the composition of switching material 22 may comprise a Si concentration of about 14%, a Te concentration of about 39%, an As concentration of about 37%, a Ge concentration of about 9%, and a P concentration of about 1%, In these examples, the percentages are atomic percentages which total 100% of the atoms of the constituent elements.
In another embodiment, a composition for ovonic switching material 22 may include an alloy of arsenic (As), tellurium (Te), sulfur (S), germanium (Ge), selenium (Se), and antimony (Sb) with respective atomic percentages of 10%, 21%, 2%, 15%, 50%, and 2%.
Although the scope of the present invention is not limited in this respect, in other embodiments, ovonic switching material 22 may include Si, Te, As, Ge, sulfur (S), and selenium (Se). As an example, the composition of switching material 940 may comprise a Si concentration of about 5%, a Te concentration of about 34%, an As concentration of about 28%, a Ge concentration of about 11%, a S concentration of about 21%, and a Se concentration of about 1%.
Conductive material (not shown) may be applied to contact 24 in the form of a thin film material having a thickness ranging from about 20 A to about 2000 A. In one embodiment, the thickness of the material 28 may range from about 100 A to about 1000 A. In another embodiment, the thickness of the film material may be about 300 A.
Suitable materials may include a thin film of titanium (Ti), titanium nitride (TiN), titanium tungsten (TiW), carbon (C), silicon carbide (SiC), titanium aluminum nitride (TiAlN), titanium silicon nitride (TiSiN), polycrystalline silicon, tantalum nitride (TaN), some combination of these films, or other suitable conductors or resistive conductors compatible with switching material 24 .
System 500 of FIG. 9 may include a controller 510 , an input/output (I/O) device 520 (e.g. a keypad, display), a memory 530 , and a wireless interface 540 coupled to each other via a bus 550 . It should be noted that the scope of the present invention is not limited to embodiments having any or all of these components.
Controller 510 may comprise, for example, one or more microprocessors, digital signal processors, microcontrollers, or the like. Memory 530 may be used to store messages transmitted to or by system 500 . Memory 530 may also optionally be used to store instructions that are executed by controller 510 during the operation of system 500 , and may be used to store user data. Memory 530 may be provided by one or more different types of memory. For example, memory 530 may comprise any type of random access memory, a volatile memory, a non-volatile memory such as a flash memory and/or a memory such as memory 100 discussed herein.
I/O device 520 may be used by a user to generate a message. System 500 may use wireless interface 540 to transmit and receive messages to and from a wireless communication network with a radio frequency (RF) signal. Examples of wireless interface 540 may include an antenna or a wireless transceiver, although the scope of the present invention is not limited in this respect.
While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
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A phase change memory may be formed of two vertically spaced layers of phase change material. An intervening dielectric may space the layers from one another along a substantial portion of their lateral extent. An opening may be provided in the intervening dielectric to allow the phase change layers to approach one another more closely. As a result, current density may be increased at this location, producing heating.
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CROSS REFERENCE TO RELATED APPLICATION
This is a divisional of Ser. No. 08/124,245, filed Sep. 20, 1993, now U.S. Pat. No. 5,464,993
This application claims priority from EPC App'n 92830506.9, filed Sep. 18, 1992, which is hereby incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a monolithically integrated, transistor bridge circuit and a method for the manufacture thereof.
More particularly, the invention relates to a bridge circuit made up of power transistors operated at a high voltage which may exceed 250 volts, although the description which follows will make reference to an application of this kind merely for convenience of illustration.
As is known, bridge circuits are widely used for a large number of applications on account of their ability to equalize currents being supplied to an electric load.
For such specific applications, integrated circuits incorporating bipolar transistors or field-effect transistors in a half-bridge configuration have been provided in the past. A circuit of that type is described, for example, in Italian Patent No. IT 1204522 of SGS-Thomson, which is hereby incorporated by reference.
Another known technical solution is described in European Patent Application No. 91830513.7 (which is hereby incorporated by reference), which relates to an integrated bridge circuit of the type designed to optimize power losses. The approach of this application has proved advantageous by virtue of its high conversion efficiency and its ability to operate on high currents, but does not provide for integration of all the power components on a single chip.
The present invention advantageously provides a transistor bridge circuit which has such structural and functional features as to enable monolithic integration of high-voltage elements, while overcoming the current limitations of prior art embodiments. This is accomplished by combining high current-carrying IGBT devices, in combination with junction bipolar devices, into the integrated circuit. Preferably the IGBT devices are connected between output nodes and a positive power supply connection, and the junction bipolar devices are connected between the output nodes and ground.
The present invention also advantageously provides a bridge circuit which can be readily manufactured, and a process for manufacturing it.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
FIG. 1 is a diagrammatic representation of a bridge circuit according to the invention;
FIG. 2 shows, schematically and drawn to an enlarged scale, a vertical section through the structure of a monolithic semiconductor device incorporating the bridge circuit of this invention;
FIG. 3 is a diagrammatic detail view of a modified embodiment of the device shown in FIG. 2; and
FIG. 4 illustrates schematically an exemplary application of the variation shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment. However, it should be understood that this class of embodiments provides only a few examples of the many advantageous uses of the innovative teachings herein. In general, statements made in the specification of the present application do not necessarily delimit any of the various claimed inventions. Moreover, some statements may apply to some inventive features but not to others.
With reference to the drawing figures, generally and schematically shown at 1 is a bridge circuit embodying this invention in the mixed bipolar/MOS technology and being integrated monolithically on a wafer of semiconductor silicon.
The circuit 1 comprises two opposing input nodes A, B and two opposing supply nodes C, S. Connected between the first supply node C and each of the input nodes A and B, is a corresponding bipolar transistor T1, T2.
In a similar manner, between the second supply node S and each of the input nodes A, B is a corresponding power electronic device M1, M2. More particularly, each device M1, M2 is an insulated-gate bipolar transistor, commonly known by the acronym IGBT (Insulated-Gate Bipolar Transistor), which is constructed in the MOS technology.
The respective gate terminals of such IGBT transistors M1, M2 are denoted by the references G1 and G2, while the respective base terminals of the bipolar transistors T1, T2 are denoted by the references B1, B2.
The upper portion of the bridge 1, comprising the bipolar transistors T1 and T2, is connected to the lower portion, comprising the IGBT devices M1, M2, through respective connections of the emitters E1, E2 of the first transistor pair to the drain terminals D1, D2 of the second pair.
The collectors C1, C2 of the first transistor pair T1, T2 are connected together into the first output node C.
The source terminals S1, S2 of the second transistor pair M1, M2 are connected together into the second output node S.
With specific reference to the example shown in FIG. 2, shown therein are the details of the monolithic structure of this circuit 1 as yielded by the manufacturing process of this invention.
Provided over the semiconductor wafer is a monocrystalline silicon substrate 3, being doped N+ and having an epitaxial layer 4 with conductivity N- formed thereon.
Formed within this epitaxial layer 4 is a P-doped isolation well 5 adapted to receive and hold the IGBT transistors M1 and M2.
To create such transistors M1, M2, the well 5 is provided with two discrete epitaxial regions 6 and 7, doped N-.
In each of said regions 6 and 7, two discrete areas, doped P+, are diffused. These areas have been referenced 8 and 9 for transistor M1 and 18 and 19 for transistor M2.
The areas 8 and 18 constitute the so-called deep bodies of the two transistors, M1 and M2, while the areas 9 and 19 are the respective drain active areas of each transistor M1, M2. Associated with the areas 8 and 18 are also the related bodies doped P-.
Two additional discrete regions, doped N, are formed, as by diffusion, within each of the two bodies 8 and 18.
These regions represent source active areas of the IGBT devices. Indicated at 10 are two sources of transistor M1, and at 20 two sources of transistor M2.
Between each respective source area 10, 20 and drain area 9, 19, the gate terminal G1, G2 of the associated transistor is formed in a manner known per se. By providing two source active areas in each body 8, 18, the perimeter of the channel region can be doubled.
In fact, terminals G1a and G2a are provided which are connected in parallel with each gate G1, G2.
Each of the gate terminals G1, G1a, G2, G2a is formed by a layer 13 of polycrystalline silicon deposited over an insulating oxide layer 12.
Also provided is a shorting link between the source regions 10 and 20 and the corresponding body 8, 18 of the associated transistor.
As shown in FIG. 2, a metallization layer 27 interconnects the body/source shorts and the well 5, to be then run to the output node 8.
It may be noted that, with the structure just described and illustrated, two lateral conduction IGBT devices M1, M2 are provided which are characterized by having their drain terminals 9, 19 at the semiconductor surface.
The circuit 1 structure is completed by the provision of the bipolar transistors T1, T2 located at the sides of the well 5 which encloses and isolates the IGBT devices.
The transistors, T1 and T2, are formed in a manner known per se using a conventional process.
The transistors T1 and T2 are each formed of a base region 25, doped P, wherein a corresponding emitter region E1 or E2, doped N+, is diffused.
Advantageously, each emitter E1, E2 is connected, through a metallization 26, to the corresponding drain terminal 9, 19 of the IGBT transistor, as also illustrated by the diagram in FIG. 1.
In the interest of a simplification of the structure herein, a portion of a modified embodiment of the inventive circuit is depicted, to a slightly enlarged scale, in FIG. 3 which has a single body region 16 in common with an isolation well 15.
It should be noted that in the embodiment of FIG. 3, elements with the same construction and operation as in the previously described embodiment are denoted by the same references.
A single isolation well 15 accommodates both the first IGBT transistor and the second.
Formed within the well 15 are the two epitaxial regions 6 and 7. The drain 9 of the first transistor M1 is diffused through the first region 6, whilst the second region 7 accommodates the drain 19 of the second transistor M2.
A single diffused body region 16 is, on the other hand, shared by the two transistors and connected to the well 15 through a region 30 (FIG. 3) bounded by the epitaxial regions 6 and 7.
Formed within the last-mentioned body region 16 are the sources 10 and 20, each on the side of the corresponding transistor M1 or M2.
The gate terminals G1 and G2 are formed conventionally between the respective drain and source terminals, 9-10 and 19-20, of each transistor M1, M2.
This, the second, embodiment affords IGBT integrated transistors of a specially compact design, thereby minimizing the silicon area occupied by the integrated circuit.
Advantageously, since the IGBT transistors are to pass high currents, the structure described with reference to FIG. 3 may be duplicated to connect in parallel several transistors of one type.
Shown in FIG. 4 is an embodiment wherein each transistor, M1 or M2, is constructed by associating two of the semiconductor devices shown in FIG. 3, in parallel together.
To summarize, the drain regions 9 and 19, doped P+, and the source regions 10 and 20, have been adequately connected together.
This basic structure is, moreover, duplicated such that each of the transistors M1 and M2 is composed of another two IGBT transistors parallel connected together. To this aim, a double metallization level can be employed as shown in FIG. 4.
To summarize the process steps which are implemented by the bridge circuit of this invention, the essential steps involved in the manufacturing process will be suitably listed sequentially herein below.
Subsequently to growing the epitaxial layer 4 over the substrate 3, the process sequence includes the formation of the buried layer, doped P, which is to provide the well 5 and base regions 25 for the bipolar transistors T1, T2.
Thereafter, the buried layers, doped N+, for the emitters E1, E2 are formed, followed by the growth of a second epitaxial layer 31 and the definition, within this epitaxial layer 31, of isolation regions 32 which bound the portions 6 and 7 of said epitaxial layer 31.
At this stage, a series of oxide deposition, photomasking and chemical etching operations are performed to define the deep body areas 8 and 18, and the drain active areas 9, 19 bounded by field oxide.
The semiconductor is then covered with a layer 12 of polycrystalline silicon wherein pits are defined to provide the source active areas 10 and 20, doped N+.
Subsequently, the body regions doped P- are defined.
Conventional final steps of contact opening, metallization and passivation complete the manufacturing sequence.
The bridge circuit of this invention does solve, in all of its embodiments, the technical problem, and achieves a number of advantages, foremost of which is that it can ensure a high current flow to the load.
Another advantage resides in the smaller integrated circuit area occupied and consequent savings in layout.
It should be additionally noted that the solution provided by this invention can operate effectively at high voltages, even in excess of 250 volts, and still be highly stable in operation.
Note that the IGBT devices, in the presently preferred embodiment, are being used in a lateral-current-flow mode of operation. This has the advantage that (as compared with high-voltage MOSFETs) the lateral IGBTs can modulate the conductivity of the N-type layer, and therefore reduced voltage drops can be achieved in the saturation regime.
In the embodiment shown, control terminal G 1 is connected to B 2 , and G 2 is connected to B 1 . The signals at B1 and B2 are in phase opposition.
In an application, terminal S would typically be connected to ground, terminal C would be connected to Vcc, and the load (typically a motor) would be connected between D1 and D2.
The disclosed structure can be used for various application, including not only control of small motors from mains power, but also other high-voltage applications such as power inversion.
In a sample process flow, an N- epitaxial layer is grown on an N+ substrate. The P-type buried layer, bipolar base regions, and N-type buried layer are then formed, and another N- epitaxial layer is then grown. An N-well is then formed (e.g. by implanting 2.5E12 cm -2 of P at 160 KeV, followed by growth of 500 Å of oxide at the surface). A P-well is then formed (if needed for CMOS), followed by isolation and sinker diffusions. A P-type deep-body diffusion is then formed (which will provide the drain for the IGBT transistor). Field oxide is then formed, to expose "active" locations where active devices may be formed. This is followed by fabrication of polysilicon layer, P- body region, source regions, contacts, metal, and passivation (overcoat). Of course, this is only one example of a possible fabrication sequence, and it will readily be appreciated that skilled process engineers may vary this sequence in many ways.
FURTHER MODIFICATIONS AND VARIATIONS
It will be recognized by those skilled in the an that the innovative concepts disclosed in the present application can be applied in a wide variety of contexts. Moreover, the preferred implementation can be modified in a tremendous variety of ways. Accordingly, it should be understood that the modifications and variations suggested below and above are merely illustrative. These examples may help to show some of the scope of the inventive concepts, but these examples do not nearly exhaust the full scope of variations in the disclosed novel concepts.
As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given.
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A monolithically integrated, transistor bridge circuit of a type suiting power applications, comprises at least one pair of IGBT transistors (M1 , M2) together with vertically-conducting bipolar junction transistors transistors (T1, T2). These IGBT transistors are laterally conducting, having drain terminals (9, 19) formed on the surface of the integrated circuit (1), and through such terminals, they are connected to another pair of transistors (T1, T2) of the bipolar type.
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BACKGROUND
It is sometimes desirable in systems that transport fluids to adjust the flow rate of some fluids transported therethrough while allowing the flow rates of other fluids to remain unchanged. Examples of such fluid transport systems include carbon dioxide sequestration, water wells and hydrocarbon recovery, however, the invention disclosed herein is not limited to just these examples. In any fluid transport system the proportions of different fluids being transported is subject to change over time, such that the proportion of some fluids that are undesirable to transport increases. Typical systems require that the undesirable fluid be separated from the desirable fluids at a later time. Separating the undesired fluids after having transported them is usually less efficient that preventing their transport in the first place. Systems and methods that provide greater control of flow rates of different fluids earlier in the process are well received in fluid transporting industries.
BRIEF DESCRIPTION
Disclosed herein is a flow control device. The device includes, a body defining at least a portion of a flow passageway, at least one movable member in operable communication with the body, movable between at least a first position that provides a first restriction to flow through the flow passageway and a second position that provides a second restriction to flow through the flow passageway, and a circuit in operable communication with the at least one movable member that is configured to sense conductivity of fluid flowing through the flow passageway and to promote movement of the at least one movable member to move from the first position to the second position in response to a change in conductivity of fluid flowing through the flow passageway.
Further disclosed herein is a flow control device comprising a variable flow area passageway, the flow control device is configured to alter area of the variable flow area passageway in response to a change in conductivity of fluid flowing therethrough.
Further disclosed herein is a method of controlling fluid flow rates. The method includes, maintaining a flow passageway at a fully open position in response to conductivity of fluid flowing through the flow passageway having a first conductivity, and adjusting the flow passageway to be more restrictive than the fully open position in response to changes in conductivity of fluid flowing through the flow passageway.
Further disclosed herein is a production adjustment arrangement for a well. The production adjustment arrangement includes, a plurality of flow control devices distributed along the well that are configured to restrict flow therethrough in response to an increase in conductivity of fluid flowing therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
FIG. 1 depicts a partial cross sectional view of a flow control device disclosed herein;
FIG. 2 depicts a partial cross sectional view of the flow control device of FIG. 1 ;
FIG. 3 depicts a schematic side view of a well that employs a plurality of the flow control devices of FIG. 1 ; and
FIG. 4 depicts a schematic side view of an alternate well that employs a plurality of the flow control devices of FIG. 1 .
DETAILED DESCRIPTION
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring to FIGS. 1 and 2 , an embodiment of a flow control device disclosed herein is illustrated at 10 . The flow control device 10 includes a body 14 that defines a flow passageway 18 and movable members 22 , shown in this embodiment as fins that move at least between a fully open position as shown in FIG. 1 and a restricted position as shown in FIG. 2 . A flow area of the flow passageway being less when in the restricted position. A circuit 26 is in operable communication with the movable members 22 and includes elements 30 , such as an electric motor, for example that are able to move the movable members 22 from the first position to the second position. At least two conductors 34 are also part of the circuit 26 and are positioned such that at least a portion of each conductor 34 is exposed to the flow passageway 18 such that the conductors 34 are exposed and are contacted by fluid 38 flowing through the flow passageway 18 . The conductors 34 enable the circuit 26 to sense electrical conductivity of the fluid 38 . The circuit 26 is further configured to respond to changes in conductivity of the fluid 38 by moving the movable members 22 . In this embodiment the movable members 22 are moved from the less restrictive position to the more restrictive position in response to an increase in conductivity of the fluid 38 .
In this embodiment the circuit 26 is configured such that electrical current is flowable from one of the conductors 34 through the fluid 38 to the other of the conductors 34 . As such, the fluid 38 serves directly as part of the circuit 26 and consequently conductivity of the fluid 38 affects the flow of electrical current through the circuit 26 . The flow control device 10 of this embodiment is configured to extend the movable members 22 to a more restrictive position in response to an increase in current flowing through the circuit 26 . This is done by directly supplying the current that flows through the fluid 38 to the motor(s) 30 that when electrically energized move the movable members 22 toward the restrictive position. The device 10 is further configured to be reversible such that as conductivity of the fluid 38 drops, so does the current in the circuit 26 and the movable members 22 are automatically moved back to their less restrictive positions.
The control device 10 disclosed in these figures include optional batteries 42 and generators 46 that supply power to the circuit 26 . The generators 46 in this embodiment employ turbines 50 that rotate in response to the fluid 38 flowing thereby. The electrical power generated is supplied to the batteries 42 to maintain charge thereof, thereby negating the need for power to be provided from remote locations. However, alternate embodiments are contemplated, although not shown, that include conductors that provide power to the circuit 26 from a remote location such as surface 48 , for example. Such remotely supplied power can come from the grid or from solar, wind or other power generating systems. For systems with remote power supply, the batteries 42 may or may not be utilized.
Other embodiments of the device 10 could employ latching devices, not shown, that hold the movable members 22 in a position once moved, such as in the more restrictive position, without electrical power having to be continuously supplied to the elements 30 . Such an embodiment could intentionally be non-reversible and could find use in applications where it is thought that once a higher conductivity fluid 38 causes the movable members 22 to move such fluid 38 will continue to flow thereby negating the need to allow the movable members 22 to return to a less restrictive position.
The flow control device 10 described above can be employed in tubular applications, for example, to automatically adjust flow resistance through the device 10 depending upon the conductivity of the fluid 38 . One application where the disclosed device 10 may be employed is in the hydrocarbon recovery industry. In this industry, undesirable water is commonly recovered along with desirable hydrocarbon fluids. The device 10 when employed in a hydrocarbon recovery well can automatically decrease the production of water in response to increases in the proportion of hydrocarbon being produced.
Referring to FIGS. 3 and 4 , wells 54 and 58 respectively, are illustrated each of which employs a plurality of the flow control devices 10 disclosed herein. The well 54 has four groups of the devices 10 distributed along a single wellbore 62 separated by packers 66 . The illustration represents differences in flow rates at each location by the relative size of the arrows, with the arrows representing the flow of water 68 having a different shading darkness than arrows that represent the flow of hydrocarbons 69 . In this example, the flows from the earth formation 70 into the wellbore 54 between each set of adjacent packers 66 are approximately equal whether the flows are of water 68 or hydrocarbons 69 . However flow through each of the groups of the flow control devices 10 distributed along the wellbore 54 differ depending upon whether the flow therethrough is primarily water 68 or primarily hydrocarbon 69 , the hydrocarbon 69 being oil in this case. Since water 68 has greater conductivity than oil and other hydrocarbons 69 , the groups of the flow control devices 10 passing water 68 therethrough automatically adjust to a more restrictive position as detailed above thereby decreasing flow rates therethrough. The groups of the flow control devices 10 are placed outside of the wellbore 62 and connected to the formation 70 to control fluid flowing into the wellbore 62 . Each section of the wellbore 62 is isolated by a pair of the packers 66 and includes a group of the flow control devices 10 (smaller tube size) that are placed outside of the wellbore 62 . The flow direction of the devices 10 are shown in the illustration of FIG. 3 as being perpendicular to that of the wellbore 62 .
The well 58 employs four of the devices 10 . Unlike the well 54 , however, the well 58 has each of the devices 10 positioned inside of the tubulars of separate legs 74 , 76 , 78 and 80 of the multilateral well 58 . In this embodiment the device 10 in the leg 78 is more restrictive than the devices 10 in the other legs 74 , 76 and 80 due to the high concentration of water 68 sensed thereby. Thus the flow of water 68 from the leg 78 is less than the flow of oil 69 through each of the legs 74 , 76 and 80 . This automatic reduction in the production of water 68 decreases the amount of water 68 that needs to be separated from hydrocarbons 69 later in the process thereby lowering operating costs and improving overall efficiency of the well 58 .
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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A flow control device includes, a body defining at least a portion of a flow passageway, at least one movable member in operable communication with the body, movable between at least a first position that provides a first restriction to flow through the flow passageway and a second position that provides a second restriction to flow through the flow passageway, and a circuit in operable communication with the at least one movable member that is configured to sense conductivity of fluid flowing through the flow passageway and to promote movement of the at least one movable member to move from the first position to the second position in response to a change in conductivity of fluid flowing through the flow passageway.
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BACKGROUND OF THE INVENTION
[0001] 1. Filed of the Invention
[0002] The invention, in general, relates to a novel tub for washing fluid and, more particularly to a tub of the kind referred to for rotatably accommodating a washing machine drum and provided at its exterior wall with rib structures.
[0003] 2. The Prior Art
[0004] A washing fluid tubs made of non-metallic materials for washing machines is well known in the art. The tub is made of a synthetic material and is mounted as a molded part in the interior of a washing machine. The structure of the tub is such as to accommodate components or aggregates cooperating with the tub thereon. The tub is characterized by an opening in its axis of rotation for receiving the drive shaft of the rotatable drum disposed in the tub. Moreover, brackets may be arranged below the tub for receiving a drive motor, for instance connected to the drum by a fan belt or the like. The tub is also provided with at least one connecting pipe for feeding and removing the washing fluid.
[0005] In order to impart to the rear wall of the tub the rigidity or strength required rotatably to support the drum thereon, the tub, as disclosed, for instance, by German patent specification DE 199 60 501 A1, is provided with rib structures which lend stiffness or structural strength to the rear area of the tub in particular. Such a washing fluid tub, in a washing machine which is loaded through the sidewall of the drum, is mounted within the housing of the machine with the loading opening being disposed at the upper side of the cylindrical wall. Since in such an arrangement requires opening of the tub for placing laundry into the drum, it is possible that when loading wet laundry or adding water through the opening water may drip or swill between housing and the outer wall of the tub. However, for reasons of electrical safety, it is absolutely necessary that neither water nor humidity reach the electrical components mounted within the machine.
[0006] In a front-loading washing machine the loading opening is disposed in the front wall of the washing fluid tub and the opening is sealed with respect to the housing of the machine by a folding bellows seal. In a normal operation it may be assumed that the tub in the housing is protected from water leakage. However, with a leaking feed hose above the tub it is nevertheless possible in a front-loading washing machine that water leaks to the outer surface, particularly in the area of its cylindrical surface, of the washing fluid tub. Here, too, it is absolutely necessary that neither water nor humidity reach any electrical components.
[0007] While according to the state of the art the integral rib structures are capable of preventing this, they nevertheless leave room for improvement. A further known possibility is to protect electrical components from penetrating water and humidity by housings, covers or encapsulations. Such measures would, however, not only be relatively complex and, therefore, expensive, but they would also impede heat dissipation. Another known construction proposes an elastic folding bellows between the loading opening of the washing fluid tub and the opening of the housing for preventing the penetration of water in this area. However, since the loading opening is of rectangular configuration a lasting and reliable seal between the surrounding margin of the loading opening and the housing cover cannot be ensured because of possible leakage of the folding bellows.
[0008] JP 02305596 A of “Patent Abstracts of Japan” discloses a tub washing machine having a vertical rotational axis. In this case, the drive motor is arranged beneath the bottom of the tub. To prevent condensation water from running along the wall of the tub to the bottom of the tub and in this area from dripping onto the motor, an outwardly directed collar-shaped rib is arranged on the wall of the tub. However, the rib acts rather like a cover in the vicinity of the motor. Water sprays and splashes may easily get below this cover and drip onto the motor. Another disadvantage is that water dripping off the cover precipitates and splashes on the bottom of the housing immediately adjacent the motor.
OBJECTS OF THE INVENTION
[0009] It is therefore a primary object of the invention to provide a washing fluid tub capable of withstanding problems caused by leaking or splashing water.
[0010] Another object of the invention is to provide a washing fluid tub provided with means for diverting undesired water from critical areas of the washing machine.
[0011] Other object will in part be obvious and will in part appear hereinafter.
SUMMARY OF THE INVENTION
[0012] In the accomplishment of these and other objects, the invention, in a preferred embodiment thereof, provides a washing fluid tub having at its exterior wall integrally formed stiffening rib structures and, adjacent thereto, water deflection ribs for protecting aggregates cooperating with the tub from leaking water and humidity and for collecting and diverting water, and in the upper area of its external wall a plurality of ribs affecting an advance channeling of water and humidity.
[0013] Advantageously, further ribs are surrounding the lower area of the external wall for catching the water in a controlled manner and for diverting it. The surrounding rib is provided with defined drip-off sites for diverting the water from exactly defined sites so that it will be either directly or indirectly guided to areas where it cannot cause any damage. In this manner it is possible to prevent water from flowing over the deflection rib to critical areas, for instance those, where electrical components are present.
[0014] An advance channeling of water running along the outside of the tub ensures early on that water is kept away from critical areas. In accordance with the invention water is caused to drip off exactly defined sites. In case a deflection rib is flowed over by a wave of water, it is deflected by an additional rib at sites, for instance over the drive motor. The major purpose of the advance channeling is to keep water away from areas where it could drip off from a large height and thus splash directly or indirectly to critical areas. Moreover, larger quantities of water are divided to prevent subsequent spilling from water diverting ribs. The advance channeling ribs are pointed at their lower end sections. Accordingly, water running along the outer edge of the rib is returned to the washing fluid tub. The surrounding rib then serves to keep advance channeled water running long the outside of the washing fluid tub away from the lower range of the tub where the motor is mounted and to direct it to defined drip-off sites. The drip-off sites are selected such that water can neither directly or indirectly reach electrical contact areas. In case water is returned to the washing fluid tub because of overflow from a water diverting rib or undefined dripping or flowing off, a third redundant stage is provided. Remaining water which has not been detained by prior means is diverted in a defined manner by the pointedly converging ribs.
[0015] All brackets, tabs, etc. mounted at the lower range are provided with points from which water may drip off. The angles of the points are selected such that water running along the extended edge cannot flow to critical areas.
[0016] The defined drip-off sites are advantageously characterized by being of V-shaped configuration. In this connection, a first embodiment provides for a drip-off nose below a V-shaped drip-off site for ensuring a defined dripping-off of water without allowing it to flow back in the direction of the tub.
[0017] In another embodiment the V-shaped ribs converge, or are formed such, that they impart a defined direction of flow to the water. There may be provided a forward directed recess in the tip of the V-shape with a downwardly pointing lug being provided on one of the two ribs. Water thus initially moved to the lowest point of the V-shape, with the water, because of the recess, assuming a direction of flow along the downwardly pointed lug and parallel to the wall of the tub at some distance therefrom. In a practical embodiment the lower edge of the lug is of a large radius so that the water no longer drips vertically downwardly but, because of forces of adhesion, is diverted laterally.
[0018] In accordance with a particularly advantageous embodiment of a defined drip-off site a notch open in a forward direction is provided at the top of ribs converging in a V-shaped configuration which also results in a defined flow direction. Advantageously, the notch may be provided in a lug provided below the line of intersection of the ribs.
DETAILED DESCRIPTION OF THE SEVERAL DRAWINGS
[0019] The novel features which are considered to be characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, in respect of its structure, construction and lay-out as well as its manufacturing techniques, together with other advantages and objects thereof, will be best understood from the following description of preferred embodiments when read in connection with the appended drawings, in which:
[0020] FIG. 1 is a perspective view of a washing fluid tub from the rear wall thereof;
[0021] FIG. 2 is a further perspective view of the washing fluid tub from the front side thereof;
[0022] FIG. 3 is a detailed view of a defined drip-off site;
[0023] FIG. 4 is a further embodiment according to FIG. 3 ;
[0024] FIG. 5 is a further embodiment of a drip-off site according to FIG. 3 ;
[0025] FIG. 6 is a further embodiment of a defined drip-off site according to FIG. 3 ; and
[0026] FIG. 7 a washing fluid tub arranged within a washing machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] FIG. 7 schematically depicts a washing machine 21 provided with a washing fluid tub 1 with a drum 22 rotatably disposed therein. Aggregates 23 , for instance the motor for rotating the drum 22 , are disposed at the lower section of the washing fluid tub 1 .
[0028] FIG. 1 is a perspective view of a washing fluid tub 1 for a washing machine with a drum being mounted for rotation therein. The washing fluid tub 1 is preferably made of a synthetic material with rib structures 3 being integrally joined with the exterior wall 2 of the washing fluid tub 1 . As may be seen in the rear wall view of the washing fluid tub 1 the rib structures 3 extend concentrically in the direction of a bearing sleeve 4 which serves to seat and bear the drive shaft (not shown in detail) of the drum rotatably mounted in the washing fluid tub 1 . Brackets 5 are provided beneath the washing fluid tub 1 for supporting a motor (not shown in detail) for driving the drum.
[0029] In a lower portion of the cylindrical wall of the washing fluid tub 1 there is provided an opening 6 through which the washing fluid may be removed.
[0030] FIG. 2 depicts the washing fluid container 1 from its closed front side, with a closure device 7 being provided above the washing fluid tub 1 as is customary in top-loading machines. As may be seen from looking at FIGS. 1 and 2 , water run-off ribs 8 are formed at the outer wall 2 of the tub 2 which on the one hand protect aggregates (not shown in any detail) cooperating with the tub 1 from leaking water and/or humidity and which on the other hand collect and divert the leaked water and humidity. For instance, ribs 9 are formed at the upper region of the outer wall of the tub 1 which affect an advance channeling of the water. The ribs 9 are shaped such that in the direction of flow they extend to a tip or convergent so that this advance channeling provides for an effective diversion. For instance, at the rear surface, FIG. 1 , ribs 9 are connected in the manner of wings to the receiving sleeve 4 of the bearing, on both sides thereof, so that water occurring at the upper section is initially caught while the section below the receiving sleeve 4 remains free of any water. FIG. 2 , which depicts the front side of the washing fluid tub 1 , also depicts a wing-like arrangement of ribs 10 which point angularly away from the center and also maintain the lower section free of water.
[0031] As may be seen further from FIGS. 1 and 2 , axially extending ribs 11 embracing the outer wall of tub 1 are integrally formed to the lower area of the tub 1 which serve to catch water in a controlled manner. Such a rib 11 may be seen in FIG. 1 in particular with the shape of the rib extending at the rear surface and on the surface of the cylindrical wall. A separate rib 13 is integrally formed with the front surface at the lower portion thereof which serves to catch water from the upper ribs 10 to divert it to the lower area of the washing fluid tub 1 . As may be particularly seen in the perspective view of FIG. 1 , defined drip-off sites 14 are formed into the embracing ribs 11 which affect a controlled diversion of the occurring water. It will be understood by those skilled in the art that additional drip-off ribs 15 are provided on the brackets 5 for the motor, dampeners or shock-absorbers for particularly critical sections at the exterior wall 2 of the tub 1 .
[0032] The drip-off site 14 may be differently shapes as shown in FIGS. 3 , 4 and 5 . Thus, FIG. 3 depicts a defined drip-off site 14 which preferably is V-shaped. The perspective presentation of FIG. 3 reveals a drip-off nose 16 integrally formed below the V-shaped drip-off site 14 . It will be apparent that if water occurs between the two branches of the V-shape it will collect at the deepest part thereof and that it will want to flow out of the V-shape. To prevent a return flow to the wall 17 of the tub, the collected water will be diverted by way of the drip-off nose 16 parallel to the wall of the tub 17 , at some distance therefrom.
[0033] Another embodiment of a defined drip-off site 14 is also shown in perspective FIG. 4 . The ribs 18 and 19 forming the V-shape are converging or are shaped such that a recess 21 is formed at the tip of the V-shape. However, the recess 21 extends over only part of the width of the ribs at their side opposite from the wall 17 of the tub. A lug is formed at one of the two ribs 18 , 19 , at rib 19 , converging in the V-shape which extends beyond the deepest point of the drip-off site 14 . As a consequence of the flow path thus formed is direction of flow is attained which extends parallel to the wall 17 of the tub at some spacing therefrom. The flow pattern of the water is also improved by the recess 21 at the tip of the converging ribs 18 , 19 always directing the water to one of the vertically downwardly pointing ribs. A large radius at the lower edge of the lug the water, because of adhesion forces, experiences a large lateral component of movement, pointing from the lower edge parallel to the wall 12 of the tub as indicated by the flow arrows.
[0034] A further variant of a drip-off site 14 in accordance with the invention is shown in FIGS. 5 and 6 . FIG. 5 depicts a notch 20 opened in a forward direction at the tip of the ribs 18 , 19 converging in a V-shape. The opening angle of the notch 20 results in a direction of flow of the water away from the wall 17 of the tub. The notch 20 is sunk in a lug below the intersecting line of the ribs 18 , 19 .
[0035] As a result of the forward-pointing notch, FIG. 5 , the flowing-off water attains a stronger component of movement. The mass inertia of the water results in the water dripping or running off in a forward direction. Moreover, because of the pointedly converging notch 20 the water is progressively further separated from the ribs 18 , 19 since the contact surfaces become increasingly smaller.
[0036] The adhesion force causes drops of water initially to be retained in the forward notch 20 , FIG. 6 , until further water causes drops to fall off in a vertical direction. In this manner, the tendency of the water under the ribs 18 , 19 to flow to the area to be protected is effectively counteracted.
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A washing fluid tub of a washing machine for accommodating a rotatably driven laundry drum and provided with electrical components in its vicinity, the tub being provided at its outer surface with a plurality of rib structures for diverting any leaking water from the electrical components, at least some of the rib structures being provided with V-shaped drip-off sites for controlling the direction of flow of the water.
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BACKGROUND OF THE INVENTION
This invention concerns a method for fastening anchoring means in boreholes, and more particularly, this invention is directed to the use of a mortar composed of foamable, 2-component, reactive resin composition to fix anchoring means such as a tie bar in boreholes.
The use of 2-component reactive resins as fastening agents, for example, to fix tie bars in boreholes, is well known. Generally, 2-chamber cartridges are used for this purpose; the walls of the cartridge consist of material that can easily be destroyed, or double cartridges with a static mixer are used. In one case, the mixing of the two components, which is required for curing, takes place with the help of the anchoring means by mixing the cartridge contents after destruction of the cartridge walls or by mixing the two components in the static mixer and using the mixture so obtained for the particular fixing purpose. The use of reactive resin compositions for such purposes as the fixing means in hollow checker firebrick, in punched boreholes or in cleaved materials makes it necessary to employ considerable quantities of resin composition. As a consequence, the consumption of raw material is high and the manufacture, packaging, transport and storage are correspondingly expensive. At times, several 2-chamber cartridges are required for one fixing process, or only a few points of attachment can be produced with one double cartridge.
SUMMARY OF THE INVENTION
It is an object of the present invention to avoid the foregoing disadvantages.
Another object of the invention is to ensure that a higher number of points of attachment can be produced with comparatively lesser amounts of reactive resin mortar composition without any loss in the quality of the attachment.
These and other objectives are accomplished by the invention, according to which, it has been found that anchoring means such as tie bars and the like may be fixed in boreholes by use of a foamable, free radical curable, 2-component reactive resin composition.
DETAILED DESCRIPTION OF THE INVENTION
Due to foaming of the free radical curable reactive resins at the site of use, it is possible to avoid the useless spread of reactive resins into cavities, crevasses, etc. Fully satisfactory attachments are achievable, on one hand, because of the good strength of the resultant resin foams and, on the other, because of the production of a form-fitting shape under the pressure of the foaming agent.
As reactive resins, the usual, well known, free radical curable resins can be used, such as unsaturated polyester resins with reactive diluents, such as styrene, vinyl esters, notably the reaction products of bisphenols and novolak with unsaturated carboxylic acids, such as acrylic acid, especially dissolved in reactive diluents, such as styrene, other acrylate resins, etc. Vinyl ester resin and also mixtures of vinyl ester resin and unsaturated polyester resin are preferred.
The usual peroxide compounds, such as dibenzoyl peroxide, cumoyl peroxide and similar compounds can be used as the curing agent for the free radical curable reactive resins. The peroxides are customarily contained in organic desensitizing agents, especially phthalic esters, generally in amounts of about 40 to about 60% by weight. The use of a peroxide curing agent in an organic desensitizing agent is preferred.
The foaming agents contained in the foamable, free radical curable, 2-component resin compositions, used according to the invention, may be low-boiling halogenated hydrocarbons, especially fluorinated hydrocarbons, which become volatile under the exothermic curing conditions and thus develop a blowing agent effect. Within the scope of the present invention, those mortar compositions are preferred which contain as foaming agent a combination of inorganic carbonates and carboxylic acids, especially polycarboxylic acids. Before the reactive resin is mixed with the curing agent, the inorganic carbonate and the polycarboxylic acid are kept separate from one another, the carbonate being contained in the one component of the 2-component system and the organic carboxylic acid in the other. However, the foaming combination of carbonate and carboxylic acid may also be contained in one of the two components of the 2-component system, for example, as a dry mixture. Foaming is then initiated by mixing with the other component of the 2-component system, for example, with addition of water.
The carboxylic acids must have a pH sufficient under the conditions of mixing to release carbon dioxide, which acts as a foaming agent, from the carbonate. As inorganic carbonates, those carbonates are preferred which are easily decomposed while giving off carbon dioxide, especially the carbonates of multivalent compounds. Carboxylic acids which form a component of the foaming agents include polyacrylic acids and their derivatives, such as polymethacrylic acid, copolymers of acrylic acid and/or methacrylic acid with itaconic acid and/or maleic or fumaric acid and/or acrolein. Preferred are carboxylic acids which are polymerizable or copolymerizable themselves, and also carboxymethyl-cellulose (acid form), alkyl and acryl polycarboxylic acids, etc. As inorganic carbonates, especially the carbonates of multivalent metals, such as calcium carbonate (chalk, calcite), magnesium carbonate, magnesium hydroxy carbonate, calcium magnesium carbonate (dolomite), zinc carbonate, zinc hydroxy carbonate, etc. have proven their value. The use of carbonates of multivalent metals has the advantage that, after the carbonate is decomposed by the organic carboxylic acid with release of carbon dioxide, the remaining metal ions form carboxylate groups with the carboxylic acid groups of the organic carboxylic acids; the compounds thus formed lead to cross linking and thereby, to an increase in the strength of the cured mortar.
The reactive resins generally are present together with reactive compounds containing vinyl groups, especially with those compounds, which at the same time act as solvents, such as styrene or similar reaction diluents. This is the case particularly for unsaturated polyester resins and vinyl ester resins, which are generally contained in such reactive diluents in amounts of 40 to 60% by weight. In the following, the quantitative data relating to reactive resins is based on the mixtures, in the usual manner; in those cases where such vinyl components, in addition to the actual reactive resin, are unwanted or unnecessary, as in the case of the acrylate resins, the quantitative data is based on the resins as such.
The mortar compositions, used pursuant to the invention, may contain fillers such as staple fibers, short glass fibers, glass flakes, quartz sand, quartz powder, glass fly ash spheres, hollow glass fly ash spheres, etc. When such hollow spheres are used, the mortar compositions have excellent strength properties, in spite of a low specific gravity.
Moreover, thixotropic agents may be included in the composition, such as pyrogenic silica which has optionally been treated with an organic material, bentonites, methylcelluloses and castor oil derivatives, pyrogenic silica generally being preferred.
The presence of surface active substances has proven to be advantageous. On one hand, the surface active agents facilitate the homogeneous miscibility of the two components of the 2-component system and frequently stabilize the foam until the reactive resin components gel and on the other hand, they exert a wetting effect on the absorbing material, as well as on the anchoring material, such as tie bars and the like. Oil-in-water emulsifiers have proven to be especially useful. As foam stabilizers, particularly compounds based on polysiloxanes can be used.
The mortar compositions used according to the invention may contain organic or inorganic solvents, especially water and the like. Moreover, the use of accelerators, especially amine accelerators, has been found to be advantageous, as has the use of stabilizers such as quinones and hydroquinones. In addition to or instead of fillers, inorganic or organic extender, such as those of a mineral nature, finely divided grit, stone dust and the like may also be included.
After the two components are mixed, two reactions take place independently of one another, namely the free radical polymerization of the reactive resins and a foaming reaction. The free radical polymerization is initiated in the usual manner by the peroxide curing system, which optionally contains accelerators. The curing time can be controlled in the manner known in the art, by the nature and amount of the peroxides and the accelerators, such as amine accelerators, and by inhibitors such as t-butyl pyrocatechin.
At the same time as polymerization proceeds, the foaming reaction takes place, for example, by the evaporation of low boiling fluorinated hydrocarbons or by the reaction of carboxylic acids with inorganic carbonate with the release of gaseous carbon dioxide. The rate of foam formation can be controlled by the nature and amount of the particular blowing agent used, for example, by the nature, amount and particle size of the carbonate, and by the nature and amount of the carboxylic acids, particularly by the pH and by the amount of water.
It has proven to be expedient for the foaming reaction to be essentially completed before the gelling phase or while the polymerization reaction is still in the initial gelling phase. The foam expansion ratio can be controlled arbitrarily; values ranging from 1:1.5 to 1.7 especially have been found to be advantageous.
The basic formulation as well as the two examples which follow are intended to further illustrate the best mode currently contemplated for carrying out the invention, but are not to be construed as limiting the invention in any manner. All percentages are by weight based on the total formulation, unless otherwise noted.
Basic Formulation
Component A:
reactive resin: 40-80%
inorganic carbonate: 5-50%
filler: 5-50%
thixotropic agent: 1-7%
surface active substances (emulsifier, foam stabilizer): 0-3%
Component B:
dibenzoyl peroxide: 0.5-4% (*)
polymeric carboxylic acid: 1-10%
water: 2-10%
thixotropic agent: 0.1-1%
surface active substance(s) (emulsifier, foam stabilizer) 0-1%
filler: 0-10%
EXAMPLE 1
Component A:
unsaturated polyester resin, amine accelerated, 35% styrene content: 47.5%
1600 mesh quartz powder: 26.0%
short, 0.3 mm long, glass fibers: 4.0%
hollow fly ash spheres with an average particle diameter of 0.12 mm, bulk density of 410 kg/m3: 10.0%
calcium carbonate (calcite) with a particle diameter of 5 microns: 10.0%
pyrogenic silica: 2.5%
Component B:
dibenzoyl peroxide, 50% in phthalate ester: 28.0%
polyacrylic acid: 22.5%
water: 29.5%
hollow fly ash spheres: 15.0%
pyrogenic silica: 5.0%
mixing ratio: 1 part by weight of component B to 9 parts by weight of A
rise time: 4 minutes
volume increase: 2.5 fold (free foaming)
gel time: 5 minutes
curing time: 1 hour
EXAMPLE 2
Component A:
unsaturated polyester resin, amine accelerated, styrene content of 30%: 56.4%
siloxane-glycol copolymer (foam stabilizer): 0.6%
1600 mesh quartz powder: 6.0%
short glass fibers: 4.0%
calcium carbonate (chalk) particle diameter of 1 micron: 30.0%
pyrogenic silica: 3.0%
Component B
50% dibenzoyl peroxide in chloroparaffin: 20.0%
polyacrylic acid: 40.0%
water: 24.0%
1600 mesh quartz powder: 10.0%
pyrogenic silica: 6.0%
mixing ratio: 1 part by weight of component B to 7 parts by weight of A
rise time: 6 minutes
volume increase: 5 fold (free foaming)
gel time: 8 minutes
curing time: 1.5 hours
The formulations of both examples are suitable for processing from normal double cartridges with static mixers in a volume ratio of component A to component B of 7:1. They can be used for anchoring in hollow checker firebrick in conjunction with conventional, commercial threaded rods, threaded bushings and screens.
The following is an example of an anchoring in hollow checker firebrick with the formulation of Example 1.
EXAMPLE 3
A borehole with a diameter of 16 mm. and a depth of 90 mm. is prepared. A screen with a diameter of 15 mm. and a length of 80 mm. and consisting of wire mesh with a wire thickness of 0.5 mm. and a mesh width of 1 mm. is introduced into this borehole. Into the screen, 15 cc. of mortar composition are injected and subsequently an M 12 threaded rod is inserted. Due to the foaming and curing of the mortar composition, a form-fitting anchorage is produced in the substratum formed from the hollow checker firebrick.
For an anchorage similar to that of this example, but with the previously known nonfoaming mortar composition, a volume of at least 30 cc. mortar composition would be required.
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A foamable, 2-component mortar composition is used to fix tie bars and similar anchoring means in boreholes, especially in hollow checker firebrick. The mortar composition is composed of a reactive resin, a curing agent component, as well as a foaming agent. The volume of the mortar composition required for the anchoring can be reduced significantly with the inventive composition. This is particularly important for anchorings which cross hollow checker firebrick.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a novel type of multibranch osteosynthesis clip having dynamic-compression, self-retention and mechanical stability properties.
2. Discussion of the Related Art
The term "dynamic compression" signifies the ability of certain clips to generate a resultant compressive force between the points at which they are implanted and, more particularly, on either side of a bone fracture focus.
Surgical clips used for reduction of fractures and fixation of bones and soft tissue must have several essential properties. First, they must develop a compression effect which is constant over time. They must be well anchored so as to prevent them from detaching after implantation, which detachment is generally inherent with the movements of the joint or simply of the bone on which they are implanted. In addition, the stabilization of the fracture zone by good immobilization constitutes an important condition for achieving bone consolidation. Finally, the mode of implantation or removal of the clips must be simple, easy to employ and generate a minimum of bone traumatism.
Among the various types of clips hitherto known, there is one in which said clips are made of a martensitic material, for example an alloy of the nickel/titanium titanium/niobium type, and which are given a so-called shape-memory phenomenon capable of causing movement of their ends together when the clip is at a temperature greater than the austenitic transformation temperature of the material which forms it. This shape-memory phenomenon is due to reversible thermoelastic martensitic transformation. This phenomenon, which is now well known, consists in giving a defined shape to a material which is treated at a temperature greater than the austenitic transformation temperature A s of the material, then in giving it another shape, which is also defined, at a temperature less than the martensitic temperature M s of the material, and repeating this operation a certain number of times, depending on the nature of the alloy used, in order to give this material its final shape memory. The martensitic temperature is less than the austenitic temperature.
Although these clips indeed make it possible to generate dynamic compression at the end of their branches, this generally proves insufficient for the complete fracture at which they are implanted, and even sometimes detrimental, since this compression is asymmetric. In fact, it has a tendency to draw together the deep part of the zone of the fracture and move apart the surface part of this same zone.
In order to overcome these drawbacks, an osteosynthesis clip was proposed in document EP-A-0,488,906 of the Applicant, made of martensitic material in which the change in temperature from the martensitic temperature the austenitic temperature induces shortening of the length of the base of the clip, at least partially, and, in conjunction, drawing together of the ends of said constituent branches of the clip. In addition to the generation by this type of clip of a dynamic compression which is constant over time and homogeneous, it also allows compression both at the surface part of the bone and in its deep part, in view of the fact that the ends of the branches which constitute it are also educated to move toward each other.
However, all double-branch clips do not give mechanical stability to the focus of the bone fracture. In fact, it is often necessary to position several clips in order to achieve this stability, requiring several consecutive operations and also leading to imperfect stability.
In addition, this type of clip is difficult to produce, in view of its particular shape, especially of the arrangement at its base of a portion with reduced cross section which therefore leads to an education which is difficult to induce.
OBJECTS AND SUMMARY OF THE INVENTION
The object of the invention is to propose a multibranch osteosynthesis clip of the type in question, making it possible in a single operation to ensure mechanical stability of two or more elements of the bone of the fracture zone by virtue of its shape and its ability to adapt to the shape of the bone to be repaired.
This osteosynthesis clip made of a thermoelastic martensitic alloy, the martensitic and austenitic transformation temperatures M s and A s of which can vary, depending on the applications, between -20° C. to 70° C., includes side branches intended to be inserted on either side of the focus of the fracture of a bone to be repaired, the branches being connected together by at least one connection portion, the branches and the connection portion being educated in order respectively to curve substantially towards the center of the clip and to shorten under the effect of temperature when it exceeds the austenitic transformation temperature A s of the material which forms it.
It consists of a unitary and monobloc wire, with which at least one of the branches which constitute it is made by at least partial folding back of the wire on itself. The two free ends of the wire can each constitute another branch, the branches being intended to be inserted into or come into contact with the bone at one of the edges of the fracture.
According to the invention, it is possible to obtain a certain number of additional branches consisting of partial folding back of the wire on itself.
According to the invention, the connection portion of the clip, educated so as to shorten under the effect of temperature, adopting an at least partially curved shape when passing to a temperature greater than the austenitic transformation temperature of the martensitic material which constitutes it, also consists of partial folding back of the constituent wire of the clip, in the extension of the side branch or branches thus constituted.
According to another feature of the invention, the side branch or branches consisting of partial folding back of the constituent wire on itself are capable of adopting a curved shape under the effect of temperature. In this way, the self-retention capacities of the clip are improved.
According to another feature of the invention, the shortening of the connection portion of the clip under effect of temperature is obtained by partial folding down toward the middle of the clip of the elements of the portion consisting of the wire alone and not by partial folding back thereof on itself.
According to another feature of the invention, the shortening of the connection portion of the clip under the effect of temperature is obtained under the combined effect of the adoption of a curved shape by the zone of the portion consisting of partial folding back of the constituent wire, and by folding down toward the middle of the clip of the elements of the portion which consist of the wire alone.
According to a first embodiment of the invention, the Y-shaped clip includes three branches, one of which consists of partial folding back of the constituent wire of the clip on itself, the other two branches being capable of moving together or apart with respect to one another when passing to a temperature greater than the austenitic transformation temperature of the material.
In another embodiment in which the clip also includes three branches, these are distributed so as to give the clip a T-shape, namely a main branch consisting of partial folding back and the other two branches located at the end of the upper bar of the T consisting of the two free ends.
In another embodiment in which the clip also includes three branches, these are distributed so as to give the clip a V-shape, in which one of the branches consists of partial folding back on itself of the constituent wire of the clip, and in which the other two branches are capable of moving together or apart with respect to one another when passing to a temperature greater than the austenitic transformation temperature of the material.
In another embodiment in which the clip also includes three branches, these are distributed so as to give the clip a stool shape, in which each of the branches consists of partial folding back of the constituent wire of the clip on itself.
In another embodiment, the clip includes four branches, distributed so as to give the clip a double-Y shape, the central bar being common to the two Ys, the two branches of one of them consisting of partial folding back on itself of the wire, and the two branches of the other consisting of the two free ends of said wire, the two branches of each of the two sets being also capable of moving together or apart, depending on the shape-memory education given to them, when the temperature passes to a temperature greater than the austenitic transformation temperature of the material.
In another embodiment with four branches, the clip has a double-T shape, these being connected together by their main bar, two of the branches being made by partial folding back on itself of the wire, the other two consisting of the two free ends of the wire.
In another embodiment, also with four branches, the clip has a stool shape, each of the branches of the stool consisting of the partial folding back of the wire on itself, the two free ends of the wire joining at one of the branches. Depending on the education given to the clip, the various interconnection portions of the branches adopt amongst themselves a corrugated shape when the temperature passes to a temperature greater than the austenitic transformation temperature of the material, or only two opposite connection portions undergo such shortening.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which the invention can be implemented and the advantages which derive therefrom will emerge more clearly from the embodiments which follow and which are given by way of indication and as non-limiting examples, with reference to the attached figures wherein;
FIGS. 1, 2a, 2b and 2c represent a first embodiment of the invention with three branches in Y-shape, respectively at a temperature lower than the martensitic transformation temperature and greater than the austenitic transformation temperature of the material which forms it.
FIGS. 3, 4a, 4b are schematic representations of the Y-shaped clip in FIGS. 1 and 2, in place at a bone fracture zone.
FIGS. 5 and 6 are similar representations to FIGS. 1 and 2, of a three-branch clip in T-shape.
FIG. 7 is a schematic representation of the fitting of the clip in FIGS. 5 and 6 at a bone fracture focus.
FIGS. 8 and 9a, 9b and 9c are similar representations to FIGS. 1 and 2, of a clip with four branches in double-Y shape.
FIGS. 10 and 11 are similar representations to FIGS. 1 and 2, of a clip with four branches in double-T shape.
FIGS. 12 and 13 are similar figures to FIGS. 10 and 11 of a clip which is also in double-T shape, according to another embodiment of the invention.
FIG. 14 is a schematic representation of the fitting of the clip in FIGS. 12 and 13 at a bone fracture focus.
FIGS. 15 and 16 are similar representations to FIGS. 1 and 2, of a three-branch clip in V-shape.
FIGS. 17 and 18 are schematic representations similar to those in FIGS. 1 and 2 of a three-branch clip in stool shape.
FIGS. 19, 20 and 21 are schematic representations similar to FIGS. 1 and 2 of a four-branch clip in stool shape, FIG. 21 being a variant of FIG. 20.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The osteosynthesis clips according to the invention are made of a martensitic material satisfying the required biocompatibility properties. Typically, this martensitic material consists of a nickel/titanium alloy or an alloy based on copper, aluminum or zinc.
The osteosynthesis clip (1) according to the invention fundamentally comprises side branches (2, 3, 4) connected together by a base or connection portion (5, 6, 7, 8), all these various elements consisting of a single monobloc wire of circular or polygonal (square, rectangular), etc. cross section, made of the alloy.
At a temperature below M s , the side branches (2, 3, 4) described in more detail hereinbelow are straight and directed substantially perpendicularly with respect to the connection portion.
In a first embodiment described, in particular, in conjunction with FIGS. 1 to 4b, the clip includes three side branches (2, 3 and 4) and the connection portion forms a Y, the base (7, 8) of which consists of partial folding back of the constituent wire of the clip on itself, and which continues in two divergent branches (5, 6), constituted in unitary manner by the wire, and whose free ends form two of the side branches (3, 4). The clip thus consists of a single monobloc wire, folded back on itself, the end branch (2) consisting of partial folding back of the wire on itself, and continuing in the base of the Y. The wire is educated so that, when the temperature is less than the martensitic temperature M s of the material which forms it, the side branches (2, 3, 4) are straight, as are the elements (5, 6, 7, 8) constituting the connection portion of said Y and, when the temperature is greater than the austenitic transformation temperature A s of said material, the side branches adopt a curved position directed toward the inside of the clip, as represented in FIG. 2 a, and in addition, the connection portion (7, 8) also adopts a corrugated or curved profile, for example lying in the plane of said portion, so as to obtain shortening of the initial length L of the clip 1 to a new value L' (L'<L) (see FIG. 2a).
This shape memory can be acquired by the various elements, namely the side branches (2, 3, 4) and the connection portion (7, 8) by giving them a particular shape at a temperature greater than the austenitic transformation temperature A s of the material which forms them, then by giving them another shape, and especially a straight shape, at a temperature lower than the martensitic transformation temperature M s of the material. By repeating this mechanical transformation a certain number of times, a straight shape memory is acquired, respectively for the connection portion and for the side branches at a temperature lower than the martensitic transformation temperature, and a corrugated or curved shape memory for the connection portion (7, 8), with the side branches (2, 3, 4) adopting a curved shape for a temperature greater than the austenitic threshold, are obtained.
In a variant of the invention, the separation 1 between the two upper branches (5, 6) constituting the Y of the connection portion, and thereby between the side branches (2, 3), may be either reduced, or increased when the temperature exceeds the austenitic threshold A s of the material, depending on the desired effect.
In this way, when fitting the clip in the patient, therefore leading to a change in temperature to a temperature greater than the austenitic transformation temperature A s of the material, shortening of the connection portion (7, 8) of the clip (1) results, and resultingly a dynamic compression effect and in parallel, a curvature of the side branches (2, 3, 4) which constitute it, which may also be accompanied either by movement apart of the branches (3, 4) or, in contrast, by movement together thereof.
This clip is fitted at the fracture in the following manner. The clip is heated to a temperature lower than the martensitic transformation temperature M s of the material which forms it, the connection portion (7, 8) and the side branches being therefore straight, the latter even being substantially perpendicular to said portion. The clip is then implanted on either side of the focus of the fracture, this being done by compression, preliminary orifices having advantageously been made beforehand by the surgeon. When the temperature is greater than the austenitic threshold, the clip deforms and adopts a shape defined by its shape memory. In this way, a double compression effect is obtained, respectively at the cortical bone and the spongy bone, as well as a self-retention effect inherent to the curvature of the side branches (2, 3, 4).
FIGS. 3 and 4 represent the clip in place at the focus of a bone fracture, in which the jagged line represents the fracture zone. According to a first mode of fitting (FIGS. 3 and 4a), only one of the cortical walls of the bone is pierced in order to allow positioning of the clip. According to another mode of fitting (FIG. 4b), the two opposite cortical walls of the bone are pierced, so as to allow the side branches (2, 3, 4) to pass entirely through the bone and thereby ensure better compression of the two elements of the bone in contact with each other, and increased stability.
In a variant of the preceding clip, represented in FIG. 2b, the shortening of the connection portion is obtained by folding down of the upper branches (5, 6) of the portion in the direction of the side branch (2), also obtained by shape memory at a temperature greater than the austenitic threshold.
In a variant of the two preceding forms, represented in FIG. 2c, the shortening of the connection portion is obtained by a combination of the two preceding effects, namely both by adoption by the base (7, 8) of the portion of a curved profile, and by folding back or down in the direction of the side branch (2) of the upper branches (5, 6) of this portion.
In another embodiment of the invention, represented in FIGS. 5 and 6, the clip still includes three side branches (2, 3, 4), but the connection portion between these branches has a T-shape. As in the preceding case, one of the branches (2) consists of the partial folding back on itself of the wire which forms it, and the connection portion (7, 8) can shorten by adopting a corrugated or curved profile when the temperature passes below the austenitic threshold. In addition, at such a temperature, the two upper branches (5, 6) constituting the connection portion, and therefore the two side branches (3, 4) which extend them, are advantageously educated to move toward each other, as indicated by the two arrows in FIG. 6. In addition, the two side branches (3, 4) curve toward one another at such a temperature. In this way, and as represented in FIG. 7, such a clip is designed to ensure, on the one hand, compression at a bone fracture focus, and also a second compression effect, at a crack zone (14) adjoining the fracture proper, while ensuring effective clamping inherent to the movement together of the two upper branches (5, 6) of the connection portion.
In a variant of the preceding embodiment, the two upper branches (5, 6) remain substantially parallel and the side branches (3, 4) which extend them can be introduced into the bone to be consolidated, either at two orifices made beforehand by the practitioner, this being at a greater or lesser separation, or at one and the same orifice, depending on the size of the bone and the pathology encountered. Passage of the temperature below the austenitic transformation temperature of the material then causes:
shortening of the clip, by the adoption by the connection portion of a corrugated or looped profile, and thereby generating a compression effect,
movement together of the ends of the side branches (3, 4), or their movement apart, this being either in the general plane of the clip, or in a plane perpendicular to the clip, or alternatively, displacement of the ends along one and the same direction, this being in the direction of the branch (2) or, in contrast, in the opposite direction to this branch (2).
In another embodiment, represented in FIGS. 8 and 9, the clip has four side branches (2, 3, 4, 9) in a general shape of two Ys end-to-end. Two of the side branches (2, 9) consist of partial folding back of the wire on itself, and the other two consist of the two free ends of the wire. As can be seen, the connection portion consists, on the one hand, of the extension of the side branches (2, 9), and therefore of partial folding back on itself of the constituent wire of the clip and, on the other hand, of the upper branches (5, 6) which diverge from the central zone of the clip, the free ends of which constitute the two side branches (3, 4). As in the preceding case, the "double" connection portion (7, 8) can undergo a shape memory deformation in a double corrugation or curvature, advantageously in the plane of the portion, resulting in a shortening of the clip (1). In addition, this shortening may also be obtained by partial folding down or back of the upper branches (5, 6) of the connection portion in the direction of the side branches (2, 9) (see FIG. 9b), or alternatively by combination of the two preceding effects (see FIG. 9c).
In parallel, the two side branches, (3, 4) and 2, 9) respectively constituting the two sets of branches of the double-Y can move apart or, in contrast, move toward one another when the temperature passes below the austenitic transformation threshold of the material, or alternatively one of the sets can move apart and the other can move together depending on the desired effect. This effect is obtained by education, in the manner of the effects previously described.
An embodiment represented in FIGS. 10 and 11, the clip includes four side branches (2, 3, 4, 9) connected together by a connection portion in double-T shape, respectively comprising two side branches (2, 9) made by partial folding back on itself of the constituent wire of the clip, and two side branches (3, 4) consisting of the two free ends of said wire. At a temperature greater than the austenitic transformation temperature A s of the material, the adoption by the "double" connection proportion (7, 8) of a corrugated or curved profile is observed in FIG. 11, which profile can lead to a decrease in the distance separating the two sets of two side branches, and thereby ensure dynamic compression at the fracture. In addition, the side branches of each of the two sets, (2, 9) and (3, 4) respectively, are educated so that, at such a temperature, they curve in the direction of the opposite set of side branches.
In a variant of the preceding embodiment, represented in FIGS. 12 and 13, the side branches (2, 3, 4, 9) are educated in order to exhibit a slightly bent shape at a temperature lower than the martensitic transformation temperature M s of the material, and to adopt a much more bent shape (FIG. 13) at a temperature greater than the austenitic threshold. This bending takes place substantially in the plane incorporating the two respective sets (2, 9) and (3, 4) of side branches. This embodiment of the invention proves advantageous to apply for reducing a small bone fracture or crack. In fact, and as schematically represented in FIG. 14, the side branches no longer penetrate into the bone, but surround it, and ensure clamping and dynamic compression capable of allowing its "repair", the dimensions of the clip, and especially the degree of bending of the side branches, being chosen so as to ensure the desired degree of clamping.
In another embodiment of the invention, in which the clip includes three side branches, represented in FIGS. 15 and 16, the connection portion is in V-shape. As in the preceding examples, the portion (7, 8) is educated in order to shorten by adopting a curved or corrugated profile as soon as the temperature exceeds the austenitic threshold, and each of the side branches (2, 3, 4) curves in the direction of the center of the clip at such a temperature.
In another embodiment of the invention, represented in FIGS. 17 and 18, the clip also includes three side branches (2, 3, 9), but in a stool shape. The three branches then each consist of partial folding back on itself of the constituent wire of the clip, and are educated in order to curve in the direction of the center of the clip at a temperature greater than the austenitic threshold of the material. In parallel, at such a temperature, the connection portions between the branches are educated in order to adopt a bent profile, so as to reduce the distance separating the side branches. In fact, this type of clip is applicable for reducing multiple bone fractures of the metacarpal type.
In the same spirit, FIGS. 19, 20 and 21 represent a clip in stool shape, but including four regularly distributed side branches. In the embodiment described, each of the branches consists of partial folding back of the wire, the two free ends of the wire joining, for example, at one of the branches. When passing above the austenitic threshold A s of the material, the various connection portions (10-13) undergo a shape alteration according to a corrugated or bent shape, leading to shortening of each of the diagonals constituting the base of the stool.
In the embodiment illustrated in FIG. 21, provision may be made for only two opposite connection portions, for example (11, 12) to be educated so as to exhibit a corrugated shape, and thereby shortening of the distance separating the two pairs of side branches (2, 4) and (3, 9) when the temperature passes above the austenitic threshold, this being according to the choice of the surgeon.
It is therefore seen that, by adopting a monobloc unitary wire for producing these multibranch clips, their education with a view to giving them a highly specific shape memory is much easier. In addition, in view of the double compression effect desired, of their self-retention capacity and of the enhanced mechanical stability which they produce at the fracture focus, these clips prove particularly suited for reduction of numerous types of fracture.
While this invention has been described in detail with reference to certain preferred embodiments, it should be appreciated that the present invention is not limited to those precise embodiments. Rather, in view of the present disclosure which describes the best mode for practicing the invention, many modifications and variations would present themselves to those of skill in the art without departing from the scope and spirit of this invention, as defined in the following claims.
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An osteosynthesis clip is made of a thermoelastic martensitic alloy, the martensitic and austenitic transformation temperatures M s and A s of which can vary, depending on the applications, between -20° C. to 70° C. The clip includes side branches intended to be inserted on either side of the focus of a fracture of a bone to be repaired. The side branches are connected together by at least one connection portion. The side branches and the connection portion are educated respectively, to curve substantially toward the center of the clip and to shorten under the effect of temperature, when temperature exceeds the austenitic transformation temperature A s of the material. The clip is comprised of a unitary and monobloc wire consisting of the alloy. At least one of the side branches which form the clip is made by at least a partial folding back of the wire onto itself.
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[0001] This claims priority to U.S. Provisional Patent Application Ser. No. 61/060,833, filed Jun. 12, 2008, and is a continuation in part of and claims priority to U.S. patent application Ser. No. 11/382,353, filed May 9, 2006, which in turn was a continuation in part of and claimed priority to U.S. patent application Ser. No. 11/295,259, filed Dec. 6, 2005. Each of these identified prior applications is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates to screening machines of the type used to separate or classify mixtures of solid particles of different sizes. The invention also relates to screening machines of the type used for liquid/solid separations, i.e., for separating solid particles of specific sizes from a liquid in which they are carried. More particularly, the invention relates to an improved screen panel for use within the screening machine.
[0003] In screening machines of the type described, a screen (which may be woven, an aperture plate or another design) is mounted in what is often called a “screen frame” or “screen deck” which includes a supporting peripheral frame around the perimeter of the screen. Some screens are tensioned when they are installed in the screening machine and other screens are pre-tensioned in a frame prior to being installed in the machine. Typically associated with the screen deck are other material handling elements that are moved with the screen and form walls or partitions above or below the screen for containing the liquid and/or particulate materials adjacent to the screen and directing them to appropriate outlets. These elements may include a top cover and a pan beneath the screen deck. In the case of screening machines with multiple screens or deck units, spacer pans or frames are provided between the multiple screens.
[0004] The screens are often removed from the screening machines for cleaning, replacement, readjustment, or installation of a screen of a different mesh size or the like. The screen is releasably mounted to a carrier, table or box to which vibratory motion is imparted, typically by one or more eccentric motors or other means of excitation. The carrier, table or box is referred to herein as a “vibratory carrier”. The vibratory carrier may be moved in oscillatory, vibratory, gyratory, gyratory reciprocating, fully gyratory, rotary or another type of motion or combinations thereof, all of which are herein collectively referred to as “vibratory” motion or variations of that term.
[0005] In large commercial screening machines, the weight of the various components including the screen assembly carried by the vibratory carrier, and the weight of the material being processed on the screen assembly may total several hundred pounds or more. Screening machines which tension the screen, as opposed to those utilizing pre-tensioned screens, include the added weight associated with the screen tensioning mechanism and related components. This presents a very substantial inertial mass that resists the changes of motion applied thereto by the vibratory drive acting through the vibratory carrier. As a result of these inertial forces, a relative motion may exist between the vibratory carrier and the screen assembly. Typically, the screen assembly and vibratory carrier are each constructed of metal that could result in significant noise, wear and damage due to the relative motion or rubbing action there between. The resulting impact forces between the screen assembly and vibratory carrier significantly increase the stresses on the components and reduce their useful life.
[0006] Reducing the metal-to-metal contact minimizes the wear on the various metal components and the noise associated with the operation of the screening machine. Currently, certain screen assembly designs may not be sealed or secured relative to the remainder of the screening machine, particularly in larger screening machines. This results in the above-described metal-to-metal contact between the screen assembly and the remainder of the screening machine and prevents the screening of very fine material, such as sand or the like. The screens in larger screening machines are typically inserted and/or removed from the machine in a generally horizontal, longitudinal direction typically through an opening or slot at the head or foot end of the machine. This method of installation and removal of the screen is detrimental to known sealing arrangements because a seal that would engage the screen assembly could be torn or damaged during the installation/removal of the screen. In other screening machines, the screen is inserted vertically, typically from the top of the machine. Access to the screens from the top of the machine or the longitudinal ends is often very inconvenient and difficult.
[0007] Thus, it would be desirable to provide a screen panel and screening machine to overcome these and other aspects of screening machines and screen panels.
SUMMARY OF THE INVENTION
[0008] The above-described and other problems with prior art screening machines and associated screen panels have been resolved by this invention. Screening machines according to one embodiment of this invention utilize a machine frame, a perforate screen assembly engaging the machine frame, and a driver imparting vibratory motion to the screen assembly, the machine frame and screen assembly designed to hold particulate matter to be screened. The screening machine also includes a first outlet which discharges a first portion of the particulate matter that remains on top of the screen assembly and a second outlet which discharges a second portion of the particulate matter that passes through the screen assembly.
[0009] One aspect of this embodiment is the screen assembly including a screen panel having a generally planar screening surface and a peripheral rim or outer edge extending around at least a portion of the screening surface and being recessed, offset or beveled relative to the screening surface. A seal member positioned relative to the screening surface. The peripheral profile of the screen panel also enhances the strength of the panel so that the tensioning forces of the screen material will not alter the shape of the screen panel. In one embodiment, the rim on the screen panel has a shaped cross section designed to hold the seal member. The rim in one embodiment can also include rounded corners so that the seal member is one continuous seal attached around the perimeter of the screen panel.
[0010] The machine frame in one embodiment includes lining rails that engage the seal member of the screen panel when the screen panel is inserted into the screening machine. The seal member closes any gap between the lining rails of the machine frame and the screen panel so that particulate matter cannot escape to the interior components of the screening machine. The machine frame may also include transition caps permanently sealed to each lining rail, and the transition caps help ensure a proper seal between the screen panel and the machine frame.
[0011] Therefore, according to various embodiments of this invention, the screening operation is much more efficient and more easily accomplished while offering significant advantages in screen service life, strength, installation and removal while avoiding the opportunities for operator error when installing the screen panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The objectives and features of the various embodiments and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0013] FIG. 1 is a perspective view of an exemplary screening machine and associated screen panel being installed therein according to one embodiment of this invention;
[0014] FIG. 2 is a top plan view of the screen panel of FIG. 1 ;
[0015] FIG. 2A is a bottom plan view of an alternative embodiment of a screen panel frame;
[0016] FIG. 3 is a front, partially cross-sectional view of the screen panel of FIG. 2 ;
[0017] FIG. 4A is a side elevational view of a portion of the screening machine of FIG. 1 and a screen panel inserted therein prior to a screening operation;
[0018] FIG. 4B is a view similar to FIG. 4A with the screen panel engaged with the machine frame of the screening machine in preparation for a screening operation; and
[0019] FIGS. 5A-5E are side cross-sectional views of alternative embodiments of a seal member attached to the screen panel.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIG. 1 , an exemplary embodiment of a screening machine 10 in which this invention may be used is shown. Screening machines of many types are sold commercially by Rotex, Inc. of Cincinnati, Ohio, the assignee of this invention. However, this invention is not limited to any particular type of screening machine design or application and the machine shown and disclosed herein is only for illustrative purposes.
[0021] The screening machine 10 includes an inlet port 12 near an inlet section 14 proximate a head end 16 of the machine 10 . The screening machine 10 may also include a top cover 18 in any one of a variety of forms. Particulate or other material to be screened is fed into the inlet port 12 from a hopper (not shown) for screening and processing by the machine 10 .
[0022] The screening machine 10 is supported structurally by a machine frame 20 including beams 22 connected together by laterally oriented struts 24 on each end of the screening machine 10 . The screening machine 10 includes an electric motor 26 coupled to a drive weight (not shown) to impart an oscillatory, vibratory, gyratory, gyratory reciprocating, fully gyratory, or other motion or combinations thereof (herein collectively referred to as “vibratory” motion or variations of that term) to at least the head end 16 .
[0023] Within a screening chamber of the screening machine 10 , one or more screen panels 28 are each mounted in combination to form one or more screen assemblies 30 to receive the material being screened from the feed chute 12 at the head end 16 of the machine 10 . The screen panels 28 are mounted on slightly sloping planes (approximately 4°) with the head end thereof being slightly elevated relative to a foot end so that during the screening process the material advances, in part by gravity, over the screen panels 28 toward a discharge end 32 of the machine 10 . Even though the screen panels 28 of the screening machine 10 may be on a slightly sloping plane, to provide a reference for the purposes of clarity herein, these components will be considered to be generally horizontal and the direction perpendicular or orthogonal to the screen panels 28 will generally be referred to as a vertical orientation or direction. The direction of travel of the material being screened from the head end 16 to the discharge end 32 across the screen panels 28 is referred to as the longitudinal direction and the perpendicular orientation extending from side to side on the screen panels 28 is a lateral direction.
[0024] In the embodiment of the screening machine 10 shown in FIG. 1 , upper and lower screen assemblies 30 each include four screen panels 28 mounted generally coplanar with each other in the associated screen assembly 30 . Accordingly, as the material to be screened is deposited from the inlet port 12 onto the upper screen assembly 30 , the vibratory motion of the screening machine 10 advances the material longitudinally across the top of the screen panels 28 of the upper screen assembly 30 toward the discharge end 32 . Appropriately sized and configured material passes through the upper screen assembly 30 and falls onto the lower screen assembly 30 . The screen panels 28 of the upper screen assembly 30 may include a fine mesh screen material 34 adjacent the inlet port 12 through which dust and other fine particulate matter passes for collection and discharge. Certain material also passes through the upper screen assembly 30 and is deposited on the lower screen assembly 30 . Therefore, the lower screen assembly 30 is included to provide an additional separating mechanism for the appropriately sized particles to pass through the lower screen assembly 30 for collection in a lower pan (not shown).
[0025] The unacceptably sized particles remain atop the first upper screen assembly 30 and fall off the terminal edge thereof into a collection basin for discharge through a first outlet (not shown) in the exit section 36 . Material that passes through the upper screen assembly 30 and remains atop the lower screen assembly 30 falls off the terminal edge thereof and into the collection basin for discharge through a second outlet (not shown) in the exit section 36 . The first and second outlets are separated by a baffle (not shown) to keep the classified particles separate from one another. The acceptably sized particles that pass through both the upper and lower screen assemblies 30 are collected in a lower pan and discharged through a third outlet (not shown) located at the discharge end 32 of the machine 10 .
[0026] Referring to FIG. 1 , one or more doors 38 are each pivotally connected by a hinge 40 to a lateral side 42 of the screening machine 10 . When opened, the doors 38 provide access for insertion and removal in the lateral direction of the screen panels 28 . It will be appreciated that although one side 42 of the screening machine 10 is shown in FIG. 1 , additional doors 38 on the opposite side of the screening machine 10 may also be provided. Advantageously, the screen panels 28 are inserted horizontally and laterally or perpendicularly to the longitudinal direction of travel of the material being screened in the screening machine 10 .
[0027] Referring to FIGS. 2-3 , one embodiment of the screen panel 28 includes a generally perforated mesh screen material 34 making a screening surface 44 . The mesh screen material 34 includes a number of intersecting longitudinal threads or wires 46 and lateral threads or wires 48 which are oriented orthogonally to each other to provide appropriately sized and configured openings 50 in the screening surface 44 to prevent or allow the passage of particulate matter. The screen panel 28 includes a generally rigid frame 51 with a peripheral rim 52 extending around at least a portion of the screening surface 44 . At least a portion of the peripheral rim 52 is recessed, offset or beveled relative to the screening surface 44 , and the peripheral rim 52 can have a shaped cross section designed to accept a seal member 54 . Alternatively, the peripheral rim 52 includes a cross section with a generally horizontal first portion 58 adapted to hold the mesh screen material 34 , a generally vertical second portion 60 integral with first portion 58 , and a generally horizontal third portion 62 integral with the second portion 60 . The portion 62 may be offset or recessed relative to the screening surface 44 and/or may be positioned at a lower surface of the screen panel 28 . Alternatively, the rim 52 may be of a different configuration or location relative to the screening surface 44 including spaced from the lower surface of the screen panel 28 . The portion 62 is shown in FIG. 3 as being oriented perpendicularly to the portion 60 and generally parallel to the screening surface 44 . Alternatively, the rim 52 may be of a different configuration or orientation relative to the screening surface 44 including obliquely oriented relative to the screening surface 44 .
[0028] An alternative embodiment of a frame 51 a of the screen panel 28 according to this invention is shown in FIG. 2A . Frame 51 a includes a lattice arrangement 53 inside the peripheral rim 52 to provide added stiffness to the screen panel 28 . The added stiffness assists in maintaining tension on the screen material 54 (not shown in FIG. 2A ). The lattice arrangement 53 of FIG. 2A includes longitudinal members 55 a intersecting lateral members 55 b oriented orthogonally to each other. The members 55 a, 55 b may be generally flat members with rectangular cross sections, rounded bars with circular cross sections, or of another shape within the scope of this invention. Further alternative embodiments of this invention include screen panels 28 with only longitudinal members 55 a, only lateral members 55 b and members 55 a, 55 b intersecting in non-orthogonal orientations.
[0029] The members 55 a, 55 b may be tack welded to each other at their common points of intersection and at their intersection with the peripheral rim 52 . Adhesive is an alternative to the welding according to alternative embodiments. Moreover, the lattice arrangement 53 may be integral with the peripheral rim 52 as a result of a burnout design or other production technique.
[0030] The seal member 54 in one embodiment is coupled to the peripheral rim 52 along the second portion 60 and third portion 62 of the cross section of the peripheral rim 52 . Alternatively, the seal member 54 may be positioned at other locations on the screen panel 28 relative to the rim 52 . The peripheral rim 52 in one embodiment also has rounded corners 56 which allow the seal member 54 to be a continuous seal member 54 that follows the rounded corners 56 without buckling. The rounded corners 56 also allow for clearance room for internal hardware (not shown) inside the machine frame 20 . The corners 56 may be produced by a stamping operation to enhance quality and lower production costs. The rim 52 in FIG. 2 is shown as extending entirely around the perimeter of the screen panel 28 , but other configurations are possible within the scope of this invention, including portions of the rim only along the trailing and/or leading edges of the screen panel 28 .
[0031] The screen panel 28 may be manufactured by a variety of processes, including stretching a mesh screen material 34 to put longitudinal wires 46 and lateral wires 48 in tension, robotically applying adhesives to a peripheral rim 52 , raising the peripheral rim 52 up into the mesh screen material 34 , curing with ultraviolet light for about 30 seconds, and trimming or grinding off any excess wire 46 , 48 . The screen material 34 may be bonded to the peripheral rim 52 via adhesive or welding in alternative embodiments. A seal member 54 is then permanently mounted on the peripheral rim 52 . In some embodiments, a silicone bead can be installed on the perimeter where the ends of wires 46 , 48 are exposed. This silicone bead is not necessary in all embodiments, as the seal member 54 can be large enough to cover the exposed ends of wires 46 , 48 . In another embodiment, the screen panel 28 can be manufactured by dipping the peripheral rim 52 in epoxy and pressing the mesh screen material 34 onto the peripheral rim 52 with a heat press. Additionally, the screen panel 28 of FIG. 2 is shown with the screen material 34 tensioned uninterrupted within the confines of the rim 52 . Other embodiments are included within the scope of this invention, including smaller cells defined within the interior of the rim 52 by transverse and longitudinally extending ribs within the peripheral rim 52 . Additionally, one or more labels 57 can be included on a lower surface of the frame 51 ( FIG. 2A ) to permit identification of the panel 28 while it is installed in the machine 10 .
[0032] Another aspect of this invention is the ability to recondition existing screen panels 28 when the screen material 34 is torn, worn, used or otherwise in need of replacement. The frame and rim 52 of the screen panel typically are not damaged or worn and are capable of repeated use. As such, the used screen material 34 is removed from the frame and rim 52 and likely the seal member 54 as well. New screen material of the same type, material mesh and the like or of different characteristics relative to the used screen material is positioned on the frame, tensioned, bonded to the frame and trimmed to size as appropriate and previously described herein above. A new seal member 54 is then applied to the screen panel 28 and it is ready to be returned to service.
[0033] The screen panel 28 of the current embodiment has several advantages over conventional screen panels. The shaped cross section of the peripheral rim 52 allows for a large seal member 54 to be permanently attached to the screen panel 28 , removing the need to carefully position the screen panel 28 within the machine frame 20 to ensure a good seal. The shaped cross section also allows for a continuous seal 54 around each panel 28 in one uniform plane while maintaining a flush product flow surface between the panels 28 and internal components of the machine 10 . Screen panels 28 of other embodiments include interior lattice arrangement 53 ( FIG. 2A ) connected to the peripheral rim to support the tension levels of the mesh screen material. With a shaped cross section, the peripheral rim 52 has an increased stiffness allowing for the optional removal of the lattice network and promoting better conveying and blinding control. Conventional screen panels required calibration of seal size to varying wire thicknesses in the mesh screen material, but the current embodiment's large compliant seal member 54 makes the seal effectiveness far less sensitive to varying wire 46 , 48 sizes in the mesh screen material 34 . These improvements create more economical manufacturing processes and more reliable seals in a screening machine 10 .
[0034] The leading side edge 64 of the screen panel 28 is typically inserted laterally into the machine frame 20 through door 38 as shown by arrow 68 in FIG. 1 . A user or operator can easily grab the trailing side edge 66 thanks to the shaped cross section of the peripheral rim 52 and the large seal member 54 protecting the hands of the user or operator from exposed wire. In some embodiments, the user slides the screen panel 28 over a vibratory ball tray (not shown) or other device that has balls or agitation producing members that bounce against the underside of screen panel 28 to reduce blinding or other occlusion of the mesh screen material 34 when the electric motor 26 provides vibratory motion to the machine 10 . Advantageously, the screen panel 28 in this embodiment can be removed and replaced for manual cleaning or other maintenance without removing the heavier ball tray.
[0035] Referring now to FIGS. 4A-4B , the placement and configuration of a screen panel 28 inside the screening machine 10 according to one embodiment will now be described. The machine frame 20 of the screening machine 10 includes lining rails 70 permanently attached to the interior of machine frame 20 , the lining rails 70 including a downwardly-angled portion 72 and a horizontal portion 74 below the angled portion and designed to engage the screen panel 28 . The lining rails 70 can be slightly resilient to allow vibration with the machine frame 20 to force particulate matter onto the screening surface 44 . Also permanently attached to the interior of the machine frame 20 are transition caps 76 , generally horizontal edge pieces that engage the screen panel 28 and the lining rail 70 to eliminate leakage concerns and eliminate any time needed for fixturing during assembly. Below the lining rails 70 and adjacent to the transition caps 76 is an upper portion 77 of screen assembly 30 . A flat seal member 78 on the underside of the transition caps 76 rests between the lining rails 70 and the transition caps 76 and upper portion 77 .
[0036] The machine frame 20 further includes a bracket 80 in which a rotational cam 82 is located. The peripheral rim 52 in one embodiment of the screen panel 28 is supported on the rotational cam 82 when initially inserted in the screening machine 10 as illustrated in FIG. 4A . The rotation of the cam 82 is accomplished by an actuator 84 accessible to the operator or user when the door 38 of the machine 10 is open. For example, one known mechanism suitable for use with this invention to raise/lower the screen panel 28 is disclosed in Rotex' U.S. Pat. No. 6,070,736, which is incorporated by reference herein.
[0037] Upon rotation of the actuator 84 in the direction of arrow A, the cam 82 is rotated, thereby raising the screen panel 28 supported thereon upwardly to sealing engagement with upper portion 77 of screen assembly 30 as shown in FIG. 4B . As the screen panel 28 is raised, the mesh screen material 34 is juxtaposed on the upper portion 77 and the seal member 54 is compressed against transition cap 76 , upper portion 77 , and lining rail 70 . As a result, the upper portion 77 of screen assembly 30 , the screen panel 28 , and the lining rails 70 are sealed to prevent and inhibit the discharge of particulate matter being screened into other interior components of the machine frame 20 . Due to the design and configuration of the screen panel 28 , machine frame 20 and seal member 54 , the seal member 54 is neither damaged nor compromised during lateral installation of the screen panel 28 , thus extending the service life of the associated components. The invention thus offers a screen panel 28 that is pre-tensioned, ready to use, lightweight, standardized in size to lower cost, simple design, mass producible, easy to handle, and stronger or stiffer than conventional screen panels of similar weight.
[0038] Referring now to FIGS. 5A-5E , alternative embodiments of large seal members 54 for use on screen panel 28 are illustrated. In FIG. 5A , a typical round seal member 54 is attached to screen panel 28 . The embodiment in FIG. 5A includes a seal lip 86 which helps cover exposed wire ends of mesh screen material 34 and also extends to further fill the gap between the machine frame 20 and the screen panel 28 when the screen panel 28 is raised by cam 82 into engagement with the machine frame 20 as shown in FIG. 4B . This seal lip 86 allows for minor manufacturing tolerances and insertion forgiveness. The embodiment illustrated in FIG. 5B is another possible large seal member 54 with an irregular cross section for more resiliency or seal effectiveness. Seal members 54 of FIGS. 5 A and 5 C- 5 E each include ridges 88 which assist in improving the overall sealing effectiveness of the member 54 . One skilled in the art will recognize that many other possible configurations are possible of seal members used with the screen panel 28 of this invention.
[0039] In another unillustrated embodiment, screening machine 10 could also include a removable seal holder as well as the machine frame 20 and the screen panel 28 . The removable seal holder would include the large seal member 54 and be a resilient holder to be sandwiched between the machine frame 20 and the screen panel 28 when screen panel 28 is raised into engagement with the machine frame 20 . This would allow the seal to be reuseable and extend the life of individual components of the screening machine 10 beyond the previously described embodiments.
[0040] From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.
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A screening machine of the type used to separate or classify mixtures of solid particles of different sizes includes a machine frame and a perforate screen panel mounted for movement relative to the machine frame during a screening operation. The screen panels are pre-tensioned mesh screen material mounted in a peripheral rim for separating various granular and particulate materials. The screen panel is slid into the side of the machine frame in a direction orthogonal to the direction particulate matter moves when the screening machine is operating. The screen panel peripheral rim has a shaped or other cross section adapted to hold a large seal member that provides a positive sealing surface for contact with the machine frame to prevent particulate matter from escaping off of the screen panel during use.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of PCT International Application No. PCT/EP2010/004969 entitled “Rotor Blade Control Based On Detecting Turbulence” and filed on Aug. 6, 2010 and further claims the benefit of U.S. Provisional Application Ser. No. 61/231,858 entitled “Rotor Blade Control Based On Detecting Turbulence” and filed Aug. 6, 2009, and claims priority to Great Britain Patent Application No. 0913739.9 entitled “Rotor Blade Control Based On Detecting Turbulence” and filed Aug. 6, 2009.
The present invention relates to a rotor blade control system for a wind turbine, and in particular a blade control system that controls an aerodynamic parameter of the blade, such as pitch angle, based on a measurement of turbulence.
FIG. 1 illustrates a wind turbine 1 , comprising a wind turbine tower 2 on which a wind turbine nacelle 3 is mounted. A wind turbine rotor 4 comprising at least one wind turbine blade 5 is mounted on a hub 6 . The hub 6 is connected to the nacelle 3 through a low speed shaft (not shown) extending from the nacelle front. The wind turbine illustrated in FIG. 1 may be a small model intended for domestic or light utility usage, or may be a large model, such as those that are suitable for use in large scale electricity generation on a wind farm for example. In the latter case, the diameter of the rotor could be as large as 100 meters or more.
In wind turbine power generation, the power efficiency of the turbine is largely dependent on two factors, the pitch angle and the tip speed ratio. The pitch angle θ is the angle at which the rotor blade is orientated relative to the rotor plane, that is the direction in which the rotor blade is rotating. The orientation of the blade is assessed with respect to the blade chord which connects the leading and trailing edge. This is illustrated in more detail in FIG. 2 .
The pitch angle is not the same as the Angle of Attack (AOA), which is the angle made between the direction of the incident wind on the blade, and the pitch angle. The incident wind is indicated by vector V, and a rotational component as the blade moves through the air indicated by vector w R R. This results in a relative wind direction of V r . The lift L provided by the blade is at right angles to the relative wind direction V r .
The operation of a wind turbine can broadly be classified as either partial load or full load. In partial load operation, the blades of the wind turbine are rotating and power is being produced, but due to low wind speeds the power generated is below the maximum possible or rated power value for the turbine. In such cases, it is desirable to maximise the power that can be extracted by angling the wind turbine fully into the wind, and for pitch controlled wind turbines by changing the pitch angle of the blades to maximise the lift on the blade. For full load operation, or at wind speeds that are too high, the wind turbine has to be carefully controlled so that damage to the wind turbine is avoided.
In non-pitch stall controlled wind turbines, the blades are connected to the rotor hub at a fixed angle, but are aerodynamically shaped so that when the incident wind speed is in excess of a predetermined value turbulence is created on the leeward side of the blade. The turbulence results in the lift experienced by the blade, and consequently the generated power, being limited to a range dependent on the aerodynamic shape chosen.
For pitch controlled wind turbines, at wind speeds that are within the range of safe operating speeds for power generation, the way in which the blades are pitched is largely the same for all designs, namely they are pitched into the wind as much as possible in order to extract the maximum energy from the incident wind. If the blades are pitched too much, however, then they will cause a stall in the flow of wind around the blades. This principle is used in active stall control wind turbines to protect the generator from overloads caused by excessive wind speeds. However, during normal operation a stall condition is undesirable as it means that the wind turbine is not operating efficiently.
In full load operation, the wind turbine blades are rotating and power is being produced, but the power generated is now at a maximum and there is a danger of overloading the generator or on the grid. In such cases, the blades or the turbine itself can be angled with respect to the wind to reduce the tip speed and reduce the generated power. In pitch controlled wind turbines for example, the blades may be deliberately under-pitched, by angling them out of the wind in order to reduce the power extracted and avoid overloading the generator. In active stall wind turbines, the blades are actively pitched further into the wind, and are overpitched to such an extent that stall-like conditions are deliberately introduced to reduce the power extracted from the wind. In effect, the efficiency is tailored to meet the maximum rated power.
There is therefore a need for a control to ensure that blades respond to quickly to changes in wind speed and direction to maintain the optimal pitch and avoid undesirable stall conditions. This is particularly important at low wind speeds, say between 3 m/s and 15 m/s where the turbine is operating in partial load conditions below its maximum rated power, and extracting the maximum power available from the wind is therefore crucial. Further, the general efficiency and operation of a wind turbine blade is highly dependent on the quality of the airflow over the leeward or suction side of the blade. It would be desirable to be able to monitor this more closely for operation, maintenance and control considerations.
SUMMARY OF THE INVENTION
According to a preferred embodiment of the invention, a wind turbine rotor blade control system is provided that comprises: a plurality of sensors for detecting turbulent air flow across a rotor blade surface; a controller for receiving data from the plurality of sensors, and based on the detection of turbulent air flow controlling an aerodynamic parameter of the rotor blade. Each of the plurality of sensors comprises: a sensor membrane for detecting the turbulence of air flow past a surface of the wind turbine blade, and wherein the sensor membrane is integral to the surface, and covers at least part of a cavity in the wind turbine blade; a light source located in the cavity for illuminating the surface of the sensor membrane inside the cavity; a light detector located in the cavity for detecting light reflected from the surface of the membrane, and for providing an output to a processor, the processor determining from the output a turbulence value for the air flow across the sensor membrane.
The invention therefore allows the aerodynamic interaction of the blade with the air flow to be monitored in real time, and adjusted as desired based on a measure of turbulence.
The invention provides a sensitive sensor system due to the fact that small displacements of the sensor membrane can be detected using the light source and detector. Further, the sensor is relatively easy to install and can be situated in the wind turbine blade for protection, and to ensure that the presence of the sensor does not interfere with the measurement. As there are few moving parts, the sensor is resistant to extreme changes of temperature.
In one embodiment, the aerodynamic parameter is the pitch angle of the rotor blade. This offers a responsive and finely tuned rotor blade pitch control mechanism based both on the immediate aerodynamic conditions of the rotor blade. If the blade angle is too great, the turbulence sensors detect the resulting stall condition and the pitch controller reduces the pitch. This leads to improved electricity generation regime.
Advantageously, the control system comprises a power sensor for detecting the output power of the wind turbine and outputting a signal to the pitch controller, wherein the pitch controller additionally controls the pitch of the rotor blades based on the detection of wind turbine output power. The combination of two control signals means that output power control can be used to give a coarse grained control over the blade pitch, and the turbulence sensors used to provide a fine grained control. The pitch controller preferably controls the pitch of the rotor blades to minimise the turbulence, and maximise the wind turbine output power.
To detect stall-like conditions, the plurality of sensors are advantageously located on the suction surface of the blade, and even more advantageously are located in greater numbers towards the trailing edge of the suction side of the blade, than in other areas.
Preferably, the controller reduces the pitch of the rotor blade into the wind, when a predetermined number of sensors indicate turbulent air flow.
In alternative embodiments, the aerodynamic parameter is the shape of the rotor blade, or is the air flow past the blade. Provision of suitable mechanisms to change the blade shape or adjust the flow of air past the blade can then be operated based on the sensor output to ensure that, to the extent possible, operating conditions are maintained according to pre-set desired values or ranges.
In one embodiment, the light source and light detector in the cavity are optical fibres connected to an opto-electrical light source. This allows the use of electrical components in the sensor to be avoided, and means that the sensor will be resistant to lighting strikes. These are especially common for wind turbine blades. Any electrical components for the sensor can be housed in part of the wind turbine that is electrically shielded.
Preferably, the sensor comprises an adder for adding light reflected from the surface of the membrane to a reference light signal to give an interference pattern that indicates displacement of the membrane. Use of an interference pattern provides the most accurate way of interpreting the displacement of the membrane, as small displacements of the membrane can be used to give large variations in intensity. For larger displacements, a sinusoidal intensity pattern is produced, meaning that information about the speed at which the displacement is occurring as well as the direction of displacement can be obtained from analysis of the sinusoidal frequency and rate of occurrence.
In one embodiment, the adder comprises a partial mirror located in the sensor cavity to reflect a portion of the light from the light source to the light detector and provide the reference light signal. Thus, all of the components of the sensor are provided locally inside the cavity for ease of replacement and maintenance.
In a further embodiment, the sensor cavity is sealed. This allows the cavity environment to be maintained at levels of humidity and temperature that ensure good operation of the sensor membrane. Furthermore, the cavity may be filled with a gas other than air, such as an inert gas.
In one embodiment, the sensor membrane may be formed of a different material to that from which the surface of the wind turbine component is formed. This allows it to be tailored more precisely to its function as a sensor, in terms of tension and responsiveness. Depending on installation, the sensor membrane may alternatively be formed by the blade surface itself.
In one embodiment, the turbulence sensor comprises a processor for analysing the sinusoidal variations in the interference pattern over a predetermined period of time to determine whether the air flow is turbulent. The processor may analyse the pattern using pattern recognition or statistical techniques and give a determination with an associated level of confidence. Analysis for a longer period of time may give a higher degree of confidence in the sensor outcome.
In a further embodiment, the control system comprises a memory for storing data from the plurality of sensors and generating a log of air flow conditions over the surface of the wind turbine blade. This allows the real time performance of the rotor blade to be monitored and recorded for the purposes of blade design improvement.
A corresponding method and computer program product are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described in more detail, by way of example, and with reference to the drawings in which:
FIG. 1 illustrates a wind turbine;
FIG. 2 is a schematic cross-section through a wind turbine rotor blade indicating useful terminology and principles;
FIG. 3 illustrates a first example of a turbulence sensor according to the invention;
FIG. 4 illustrates a second example of a turbulence sensor according to the invention;
FIG. 5 illustrates an example sensor system incorporating sensors such as those shown in FIG. 3 or 4 ;
FIG. 6 is an illustration of an example intensity pattern developed from the sensor signals;
FIG. 7 is a longitudinal elevation of a wind turbine blade showing an example arrangement of the turbulence sensors in a pitch control system;
FIG. 8 is cross-sectional view through the line A-A in FIG. 7 in non-stall-like conditions;
FIG. 9 is a cross-sectional view through the line A-A in FIG. 7 in stall-like conditions;
FIG. 10 is a schematic illustration of a sensor results table used in a control and alarm system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 illustrates a first example of a turbulence sensor according to a preferred embodiment of the invention. The turbulence sensor is shown in situ integrated into the blade of a wind turbine rotor, or other component.
The sensor 10 comprises a sensor housing 11 , having side walls 12 that define a cavity 13 . In the cavity 13 , sensor apparatus, denoted generally by reference number 14 , is situated. One surface of the sensor housing 11 is provided with a sensor membrane 15 . In practice, the sensor 10 is mounted in the blade such that the sensor membrane 15 separates the cavity 13 from the outside air, and such that the membrane 15 is in contact with the air flow across the surface of the blade. The cavity is entirely sealed off from the external environment by the side walls 12 and the membrane 15 , so that movement of the membrane surface can be considered wholly attributable to variations in the air flow across the blade surface. Sealing the cavity also acts to keep the internal surface of the membrane clean, and allows the internal environment of the cavity to be regulated to avoid build up of moisture that could affect the sensor membrane 15 and apparatus 14 . The cavity 13 may for example be filled with an inert gas.
Preferably, the blade surface and the membrane 15 are arranged so that they form a smoothly continuous blade surface. It is undesirable both for the aerodynamic properties of the blade and for the sensitivity of the sensor if the connection between the membrane 15 and the blade surface is not continuous as this may introduce obstructions or impediments into the air flow.
The membrane 15 is arranged such that it is susceptible to changes in air flow at the surface of the wind turbine component. It is therefore relatively thin, in some embodiments between 0.5 and 2 mm, and is tensioned so that turbulent airflow will result in only a small movement of the membrane surface. An interference pattern is produced by shining light on to the membrane in order to measure the displacement of the membrane. In practice, therefore, a range of movement of the membrane of the order of several μm has been found advantageous, owing to the wavelength of the light used. The choice of the membrane material is critical to ensure it is suitable for measurement. A material that is too light and flexible will be too sensitive to changes in air flow even in laminar conditions will not be suitable for distinguishing turbulent and laminar flow. Preferably, the material is therefore strong and stiff enough to ensure that only strong vibrations (in the range of 10 to 100 Hz) from turbulent air flow give a sufficient interference signal.
It is possible to use the outside surface of the rotor blade itself as the membrane 15 . In this case, the sensor apparatus 14 can be installed in the rotor blade under the outer surface, with or without the sensor housing 11 creating a sealed cavity for the apparatus. If the sensor 10 is installed into the rotor blade or other wind turbine component, as a separate unit, then a hole of diameter 30 to 100 mm has been found adequate to accommodate the sensor housing 11 and apparatus 14 .
The internal construction of the sensor apparatus 14 will now be explained in more detail. Sensor apparatus 14 comprises a light source 16 aimed at the membrane 15 . Where possible, it is advantageous to avoid the use of electrical components in rotor blades as they are more susceptible to damage from lighting strikes. Thus, the light source 16 preferably comprises an optical fibre 17 connected to an opto-electronic light source, such as a photo-diode or laser, located remotely in the rotor blade hub. In this embodiment the light source 16 constitutes the exposed end of the optical fibre 17 and a suitable mount to support the fibre in the sensor cavity and ensure that it is securely aimed at the membrane 15 .
In FIG. 3 , the light source 16 comprising the optical fibre 17 also acts as a receiver for light that is reflected back from the membrane 15 . The light source 16 is therefore arranged perpendicularly to the membrane 15 so that at least some of the reflected light from the membrane will be incident on the open end of the optical fibre. The apparatus 14 optionally comprises one or more lenses 18 provided between the optical fibre 17 and the membrane 15 . In this way, a beam of light 19 emitted from the fibre 17 may be focussed into a tighter beam incident on the membrane and the beam reflected back can be at least partially focussed on the end of the fibre 17 .
The apparatus 14 may also comprise a partially reflecting mirror 20 , located between the membrane and the optical fibre 17 . In this way, the optical fibre will receive light reflected back from both the plane of the mirror 20 and also from the plane of the membrane 15 . If one or more lenses 18 are installed, the partially reflecting mirror 20 may be advantageously located between the membrane 15 and the one or more lenses 18 . The apparatus 14 may be secured inside cavity 13 by suitable connections to housing walls 12 .
It will be appreciated that some internal reflection of the light in the optical fibre 17 will occur at the fibre to air interface in the fibre 17 . As a result, even without the partial mirror 20 , an interference pattern can be produced using solely the optical fibre 17 and the membrane surface 15 . However, the amount of light subject to internal reflection is only around 4% of the total. While this is sufficient to produce a useful reference signal to interfere with the sensor signal from the membrane 15 , in some embodiments it is useful to provide a stronger unreflected reference signal. As reflection from the partial mirror is around 40 to 50%, and the reflection from the membrane 15 a similar order of magnitude, the partial mirror provides a reference and sensor signal of similar magnitude. It also allows light sources that are not especially powerful to be used, thereby making the sensor cheaper to produce. In this case, the most significant interference occurs at the partial mirror, although as before, interference will still occur at the fibre to air interface.
Locating the partially reflecting mirror 20 in the sensor cavity 13 is advantageous, as it means that all of the components likely to require installation and maintenance are located together in same location of the component. Alternatively, the partially reflecting mirror may be omitted from cavity and located instead in the path of the optical fibre 17 , as will be described below. This can be useful if it is desired to save space in the sensor cavity 13 .
In the sensor described above with reference to FIG. 3 , a single optical fibre 17 is used as to form a single light source and receiver sensor pair. The interference may occur in the cavity 13 as described above, either at the mirror or fibre interface, or even at a location away from the cavity, if the returned signal is interfered with a reference light signal.
An alternative embodiment will now be described with reference to FIG. 4 . In FIG. 4 the sensor apparatus 14 comprises a light source optical fibre 21 and 23 and a light receiving optical fibre 22 and 24 . The optical fibres are typically angled so that the beam from one fibre 21 , is reflected by the membrane 15 , and is subsequently incident on the other fibre 22 . As before, the light that is incident on the membrane 15 undergoes a change in path length as a result of movement of the membrane with respect to the sensor cavity. This light is then received by the other fibre 22 and is interfered with an unreflected, or reference portion of the light, in order to produce an interference pattern. In FIG. 4 , the light is transmitted to and from the sensor cavity by means of the different optical fibres 23 and 24 .
Other suitable arrangements of sensor could be implemented and will occur to the skilled person.
The turbulence sensors shown in FIG. 3 or 4 are part of a larger wind turbine sensing and control system 40 as shown in FIG. 5 . The turbine sensing and control system 40 comprises one or more light sources 41 , such as a laser or photo diodes, coupled to one or more optical mixers 42 . The optical mixer for example can be used to provide mixing of the reflected signal light, and unreflected reference light in cases where the partial mirror 20 is not used in the sensor cavity.
Optical fibres 43 are connected between the one or more optical mixers 42 and respective turbulence sensors 44 . The turbulence sensors 44 may for example be those illustrated in FIGS. 3 and 4 above, in which case fibres 43 correspond to fibres 17 , 23 and 24 as shown in the figures. Additionally, the fibres 43 carry reflected light signals from the turbulence sensors back to the optical mixer 42 .
As shown in FIG. 5 , a plurality of sensors 44 are preferably distributed at a number of different locations across the leeward or windward surfaces of the wind turbine blades. The number of sensors per blade may be three or greater, per blade surface, for example. In this way, the air flow over of the blade surface can be accurately sensed and used to control of the blade pitch in real time. This will be explained in more detail below.
The optical mixer 42 is coupled to light sensing device 45 . For each turbulence sensor, the light sensing device receives at least two light signals, the first being a light signal that has been reflected from the membrane 15 , and the second being a signal that has been reflected, not by the membrane 15 , but by the partially reflecting mirror 20 , either in the sensor cavity 13 or into the optical path between the light source 41 and the light sensor 45 . A suitable location is of course optical mixer 42 , in which instead of a mirror, a portion of the light from the light source can simply be diverted directly to the light sensor 45 .
The light sensor 45 is in turn connected to an Analogue to Digital Converter (ADC) 46 which is connected to a processor 47 for processing the results. Processor 47 preferably has access to a timer unit 48 and a memory 49 . The processor 47 may also be connected to a turbine blade pitch controller 50 .
Many wind turbines, especially those installed in wind parks, are monitored and controlled by sophisticated control systems, such as the SCADA Supervisory Control and Data Acquisition system. It will therefore be appreciated that in practice, processor 47 will typically be connected to a larger control system, and may have access to data or information gathered at the wind turbine other than that received from the turbulence sensor. This need not always be the case however, such as where turbines are installed as stand-alone individual units.
Preferably the light source 41 , the light sensor 45 , the ADC 46 and processor 47 are housed separately from the rotor blade, either in the rotor blade hub, or in the nacelle, where they may be protected from lighting strikes by a suitable arrangement of lighting conductors or electrical shielding.
It will be appreciated that the phase of the signal received from the partially reflecting mirror will be solely determined by the phase of the light source 41 , and that it can therefore be used as a reference signal. The phase of the signal that has been reflected by the membrane will however vary according to the optical path length between the emitting and receiving optical fibres 17 , 23 or 24 in the sensor cavity 13 . In turn, this path length is affected by movement or vibration of the membrane 15 caused by the air flow past outer surface of the blade. Thus by allowing the two signals to interfere with one another and sensing changes in phase of the two signals, information can be generated about the quality of the air flow.
In ideal operating conditions, the air flow across the surface of the rotor blade will be laminar, resulting in little or no disturbance of the membrane 15 . Turbulent air flow caused by the pitch of the blade inducing stall like conditions will result in sudden and unpredictable movement of the membrane 15 and associated changed in phase of the light reflected back from the membrane relative to the reference phase.
FIG. 6 is a line graph schematically illustrating a sensor signal developed by the processor 47 over time, based upon the interference between the reference and sensor light signals. Beginning at the left of the diagram, the flat region of the graph corresponds to periods in which the membrane is not moving. The phase difference between the sensor signal and the reference signal is therefore constant, and the line graph is flat. Gentle movement of the membrane under the influence of external atmospheric pressure will be reflected by small changes in phase and associated changes in the intensity of the resulting light signal due to the interference.
If the membrane moves further, then the phase between the reference signal and the sensor signal will change and result in further changes in intensity. If the magnitude of the movement of the membrane is sufficiently large, a sinusoidal variation in the intensity of the light will be seen as the phase difference increases through complete phase oscillations. The sinusoidal variation will continue for the period in which the membrane is moving, and will reverse direction as the direction of movement of the membrane reverses. The time taken for the intensity to vary from peak to peak additionally indicates the time taken for the membrane to move half of the distance indicated by the wavelength of the light signal.
The intensity graph of FIG. 6 which is developed by the processor can therefore be used to give an indication of the air flow conditions across the surface of the blade. Turbulent air flow will result in buffeting of the blade and the sensor membrane, and the corresponding graph of intensity will indicate frequent and chaotic movements of the membrane. This will be characterised by many occurrences of sinusoidal variation of the signal, and relatively few periods where the intensity is essentially unchanging or is changing slowly. Further the sinusoidal variations themselves are likely to have higher frequencies of oscillation, indicating faster movement of the membrane than at other times.
Laminar air flow or non-turbulent background conditions, on the other hand, will result in little or less movement of the membrane. The intensity graph would therefore be characterised by more and longer periods of flat lines, gentle variations, or periods in which although a sinusoidal variation is seen, it has a long wavelength indicating that it is occurring relatively slowly.
The flat line regions of the graph representing no movement of the membrane may or may not always indicate the same intensity of light. In practice, although the rest position of the membrane may be largely determined at least in part by the membrane tension and the material of which the membrane is made, the instantaneous force exerted by the air flow will ultimately determine the instantaneous position.
The processor 47 analyses the intensity of the light signals received at ADC 46 , to determine the present quality of air flow across the blade. It may do this using suitable mathematical processing techniques to determine the amount of variation in the light signal, such as that shown in FIG. 5 . In other embodiments, it may use neural network techniques to develop a memory of the visual appearance of the intensity patterns for turbulent and laminar air flow, and determine the current air flow conditions by comparison with pre-developed model patterns. Such patterns may be stored in memory 49 .
As well identifying whether the results from an individual sensor 44 indicate turbulence, the processor 47 has the further function of assessing the current operating performance of the wind turbine blades based on the results collected from the plurality of sensors 44 over time. It will be appreciated that a separate processor could be provided for this purpose, but that for the sake of simplicity in the present description, processor 47 will be assumed to perform both roles.
Referring to FIG. 7 , the pitch control system provided an example of the present invention will now be described. FIG. 7 shows a view of the leeward side of a wind turbine blade. Turbulence sensors 44 as described above are disposed across the surface of the blade at a plurality of locations. Although it is possible in some embodiments that the sensors will be provided at equally spaced locations across the blade surface, in practice it is sufficient if they are at disposed to give at least some coverage in the longitudinal and lateral directions. As shown in FIG. 7 therefore the sensors are provided in at least one linear array along the trailing edge of the blade, and in a number of lateral linear arrays disposed along the length of the blade. FIG. 8 illustrates a cross sectional view through one of the lateral linear arrays showing sensors located on both the windward and leeward sides.
The sensors are shown as being generally equally spaced, as this will allow data about the flow of air around the entire blade surface to be collected. It will however be appreciated that for detecting stall-like conditions, the area of most interest is the leeward trailing side of the blade. More sensors may be mounted in that region for this reason.
FIG. 8 shows a wind turbine blade in conditions representing essentially laminar air flow, while FIG. 9 shows the blade profile of FIG. 8 in stall-like conditions. The shaded area shown above and behind the blade is an area of non-laminar, turbulent air resulting from the greater than optimal pitch of the wind turbine blade into the air flow. The processed sensor output of the sensors on the leeward (top) side of the blade is shown in FIG. 10 . Sensors indicating turbulence are denoted by crosses in the table.
The processor 47 communicates with the pitch control unit 50 of the wind turbine control system and indicates a pitch control instructions based upon the number of sensors 44 indicating turbulent air flow. The pitch control system 50 also receives an input from a power monitor (not shown) that measures the output power being generated by the turbine. In normal use, the pitch controller increases the pitch at which the blades are angled into the wind in order to maximise the output power, and avoid making the pitch too large and inducing a stall condition.
Blade pitch control based solely on the output power can be slow in responding to changes in wind speed and direction. The input from processor 47 however provides a finer, more responsive level of control based on the immediate wind condition at the blade. Thus, where the number of sensors indicating turbulence exceeds a predetermined value, and continues to do so for a predetermined period of time, the processor 47 instructs the pitch controller 50 to reduce the pitch until the number of turbulence sensors which indicate turbulence falls below the predetermined number. In this way, the pitch of the blade can be controlled in real time and be responsive to the measured turbulence of the air flow across the blade.
In further examples, the data from the plurality of sensors mounted on the blade surface can be used to monitor the performance of a wind turbine blade in real time from the perspective of the blades aerodynamic design. By transmitting data from different turbines to a central store for analysis, sufficient data could be collected about the air flow performance of the wind turbine blades, allowing them to be improved in future re-designs.
In alternative applications, the turbulence sensor described above can be applied to the control of further wind turbine rotor blade aerodynamic parameters such as rotor blade shape and rotor blade air flow. This will now be briefly described.
The shape of a rotor blade can be dynamically adjusted using a variety of techniques. To some extent these will change the air flow properties across the blade and by directly affecting the lift experienced by the blade will also affect the power generated. Such techniques can be used with both pitch control and stall control wind turbines as desired. A number of techniques are discussed below:
1) Flaps and ailerons are hinged regions of the blade that can be adjusted as required to change the flow of air over the blade surface. Although, these are typically located at the trailing edge of the turbine blade, they could also be located on other parts of the blade as required. Their effect in this case would be more like that of a spoiler acting to reduce lift.
2) Micro tabs are actuable elements located in the blade or on the surface that can be rapidly extended into the air flow to change its dynamic properties. They can be used to reduce stress on the blade, dampen vibrations as well as increasing lift.
3) Slots and slats in the blade can be used in the same way as 1) and 2) above. In other designs, concave or convex bumps on the blade surface can also be activated to change air flow.
4) Fluid filled cavities or voids inside the blade can be used to change the shape of the blade as they are filled with fluid or evacuated. In some designs, air can be sucked into the blade or expelled from it to change the air flow. Variable vortex generators in the blade fall into this category.
5) Deformation of the blade shape or variation in the blade span can also be achieved by control of the underlying structural supports.
The optical turbulence sensor described above can be used with any of the control mechanisms described above,
The sensor described above is relatively inexpensive to produce and is easy to mount. Thus, sensor systems comprising a large number of sensors can be installed relatively easily into both new and existing turbines. Furthermore, the membrane may be painted the same colour as the surrounding component surface to ensure that the visual appearance of the wind turbine is not impaired.
The above examples of the invention relate to control of the wind turbine blade aerodynamic properties. It will be appreciated that the sensor system could also be used to detect the accummulation of ice or other accumulated material on the surface of the blade. In this case, sensors would be located across the blade surface at a plurality of locations. As ice, for example, tends to accummulate at the leading edge of the wind turbine blade, more sensors can be located along the leading edge than elsewhere. This is contrary to the illustrative sensor arrangement shown in FIG. 7 . It would not be problematic to have a sensor membrane that followed the curve of the leading edge. As ice built up over the turbulence sensors located at the leading edge, the sensor membrane would no longer be able to vibrate under the influence of the passing air, and the sensor signal produced from that sensor would therefore appear to be cut-off or unvarying. The processor could therefore monitor changes in the sensor output for such changes and use this to identify a likely ice accummulation condition. Furthermore, as ice build-up at the leading edge would affect the aerodynamic shape of the blade, and likely to lead to increased turbulence towards the trailing edge, it can be possible to identify ice accumulation from the different responses of sensors at different locations.
The above description is intended only to be illustrative of the invention defined by the claims. Alternative techniques for implementing the invention will occur to the skilled person in the art. In one alternative embodiment, the ADC 46 and the turbulence detection part of the processor may be replaced by an analogue filter that passes the high frequencies associated with rapid deflection of the membrane 15 , and a circuit that activates an output if the amount of signal within these frequencies exceeds a certain limit or rate of occurrence.
As rotor blades are susceptible to lightning strikes, the preferred device employs optical fibres as both light source and light detector in the sensor housing. In alternative embodiments however, opto-electronic devices such as light emitting diodes and photo detectors may be used directly inside the sensor housing, with appropriate electrical and signalling connections to a controller and power source. In certain embodiments it may of course be appropriate to install the control electronics and power systems locally or in the sensor itself.
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A control system may be used for rotor blade control. The control system comprises a number of turbulence sensors provided across the surface of a wind turbine blade. The control system monitors the turbulence sensors and when turbulent airflow is detected controls an aerodynamic parameter of the blades. In one embodiment, the parameter is the pitch of the rotor blades. This means that stall-like blade conditions can be avoided, and power generation from the wind turbine can be optimized. The control system may also use measurements of output power to be considered in combination with the turbulence based measurements to add a higher level of responsiveness and precise control.
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STATEMENT OF COOPERATIVE RESEARCH AGREEMENT
[0001] This application claims benefit of the filing date of U.S. Provisional Application No. 60/949,947, filed on Jul. 16, 2007, the contents of which are herein incorporated by reference.
STATEMENT OF COOPERATIVE RESEARCH AGREEMENT
[0002] The present invention, as defined by the claims herein, was made by parties to a Joint Research Agreement (“Agreement”) between Arius Research Inc. and Takeda Pharmaceutical Company Limited, as a result of activities undertaken within the scope of that Agreement. The Agreement was in effect prior to the date of the invention.
FIELD OF THE INVENTION
[0003] This invention relates to the isolation and production of cancerous disease modifying antibodies (CDMAB) and to the use of these CDMAB in therapeutic and diagnostic processes, optionally in combination with one or more chemotherapeutic agents. The invention further relates to binding assays which utilize the CDMAB of the instant invention.
BACKGROUND OF THE INVENTION
[0004] Monoclonal Antibodies as Cancer Therapy: Each individual who presents with cancer is unique and has a cancer that is as different from other cancers as that person's identity. Despite this, current therapy treats all patients with the same type of cancer, at the same stage, in the same way. At least 30 percent of these patients will fail the first line therapy, thus leading to further rounds of treatment and the increased probability of treatment failure, metastases, and ultimately, death. A superior approach to treatment would be the customization of therapy for the particular individual. The only current therapy which lends itself to customization is surgery. Chemotherapy and radiation treatment cannot be tailored to the patient, and surgery by itself, in most cases is inadequate for producing cures.
[0005] With the advent of monoclonal antibodies, the possibility of developing methods for customized therapy became more realistic since each antibody can be directed to a single epitope. Furthermore, it is possible to produce a combination of antibodies that are directed to the constellation of epitopes that uniquely define a particular individual's tumor.
[0006] Having recognized that a significant difference between cancerous and normal cells is that cancerous cells contain antigens that are specific to transformed cells, the scientific community has long held that monoclonal antibodies can be designed to specifically target transformed cells by binding specifically to these cancer antigens; thus giving rise to the belief that monoclonal antibodies can serve as “Magic Bullets” to eliminate cancer cells. However, it is now widely recognized that no single monoclonal antibody can serve in all instances of cancer, and that monoclonal antibodies can be deployed, as a class, as targeted cancer treatments. Monoclonal antibodies isolated in accordance with the teachings of the instantly disclosed invention have been shown to modify the cancerous disease process in a manner which is beneficial to the patient, for example by reducing the tumor burden, and will variously be referred to herein as cancerous disease modifying antibodies (CDMAB) or “anti-cancer” antibodies.
[0007] At the present time, the cancer patient usually has few options of treatment. The regimented approach to cancer therapy has produced improvements in global survival and morbidity rates. However, to the particular individual, these improved statistics do not necessarily correlate with an improvement in their personal situation.
[0008] Thus, if a methodology was put forth which enabled the practitioner to treat each tumor independently of other patients in the same cohort, this would permit the unique approach of tailoring therapy to just that one person. Such a course of therapy would, ideally, increase the rate of cures, and produce better outcomes, thereby satisfying a long-felt need.
[0009] Historically, the use of polyclonal antibodies has been used with limited success in the treatment of human cancers. Lymphomas and leukemias have been treated with human plasma, but there were few prolonged remission or responses. Furthermore, there was a lack of reproducibility and there was no additional benefit compared to chemotherapy. Solid tumors such as breast cancers, melanomas and renal cell carcinomas have also been treated with human blood, chimpanzee serum, human plasma and horse serum with correspondingly unpredictable and ineffective results.
[0010] There have been many clinical trials of monoclonal antibodies for solid tumors. In the 1980s there were at least four clinical trials for human breast cancer which produced only one responder from at least 47 patients using antibodies against specific antigens or based on tissue selectivity. It was not until 1998 that there was a successful clinical trial using a humanized anti-Her2/neu antibody (Herceptin®) in combination with CISPLATIN. In this trial 37 patients were assessed for responses of which about a quarter had a partial response rate and an additional quarter had minor or stable disease progression. The median time to progression among the responders was 8.4 months with median response duration of 5.3 months.
[0011] Herceptin® was approved in 1998 for first line use in combination with Taxol®. Clinical study results showed an increase in the median time to disease progression for those who received antibody therapy plus Taxol® (6.9 months) in comparison to the group that received Taxol® alone (3.0 months). There was also a slight increase in median survival; 22 versus 18 months for the Herceptin® plus Taxol® treatment arm versus the Taxol® treatment alone arm. In addition, there was an increase in the number of both complete (8 versus 2 percent) and partial responders (34 versus 15 percent) in the antibody plus Taxol® combination group in comparison to Taxol® alone. However, treatment with Herceptin® and Taxol® led to a higher incidence of cardiotoxicity in comparison to Taxol® treatment alone (13 versus 1 percent respectively). Also, Herceptin® therapy was only effective for patients who over express (as determined through immunohistochemistry (IHC) analysis) the human epidermal growth factor receptor 2 (Her2/neu), a receptor, which currently has no known function or biologically important ligand; approximately 25 percent of patients who have metastatic breast cancer. Therefore, there is still a large unmet need for patients with breast cancer. Even those who can benefit from Herceptin® treatment would still require chemotherapy and consequently would still have to deal with, at least to some degree, the side effects of this kind of treatment.
[0012] The clinical trials investigating colorectal cancer involve antibodies against both glycoprotein and glycolipid targets. Antibodies such as 17-1A, which has some specificity for adenocarcinomas, has undergone Phase 2 clinical trials in over 60 patients with only 1 patient having a partial response. In other trials, use of 17-1A produced only 1 complete response and 2 minor responses among 52 patients in protocols using additional cyclophosphamide. To date, Phase III clinical trials of 17-1A have not demonstrated improved efficacy as adjuvant therapy for stage III colon cancer. The use of a humanized murine monoclonal antibody initially approved for imaging also did not produce tumor regression.
[0013] Only recently have there been any positive results from colorectal cancer clinical studies with the use of monoclonal antibodies. In 2004, ERBITUX® was approved for the second line treatment of patients with EGFR-expressing metastatic colorectal cancer who are refractory to irinotecan-based chemotherapy. Results from both a two-arm Phase II clinical study and a single arm study showed that ERBITUX® in combination with irinotecan had a response rate of 23 and 15 percent respectively with a median time to disease progression of 4.1 and 6.5 months respectively. Results from the same two-arm Phase II clinical study and another single arm study showed that treatment with ERBITUX® alone resulted in an 11 and 9 percent response rate respectively with a median time to disease progression of 1.5 and 4.2 months respectively.
[0014] Consequently in both Switzerland and the United States, ERBITUX® treatment in combination with irinotecan, and in the United States, ERBITUX® treatment alone, has been approved as a second line treatment of colon cancer patients who have failed first line irinotecan therapy. Therefore, like Herceptin®, treatment in Switzerland is only approved as a combination of monoclonal antibody and chemotherapy. In addition, treatment in both Switzerland and the US is only approved for patients as a second line therapy. Also, in 2004, AVASTIN® was approved for use in combination with intravenous 5-fluorouracil-based chemotherapy as a first line treatment of metastatic colorectal cancer. Phase III clinical study results demonstrated a prolongation in the median survival of patients treated with AVASTIN® plus 5-fluorouracil compared to patients treated with 5-fluourouracil alone (20 months versus 16 months respectively). However, again like Herceptin® and ERBITUX®, treatment is only approved as a combination of monoclonal antibody and chemotherapy.
[0015] There also continues to be poor results for lung, brain, ovarian, pancreatic, prostate, and stomach cancer. The most promising recent results for non-small cell lung cancer came from a Phase II clinical trial where treatment involved a monoclonal antibody (SGN-15; dox-BR96, anti-Sialyl-LeX) conjugated to the cell-killing drug doxorubicin in combination with the chemotherapeutic agent TAXOTERE®. TAXOTERE® is the only FDA approved chemotherapy for the second line treatment of lung cancer. Initial data indicate an improved overall survival compared to TAXOTERE® alone. Out of the 62 patients who were recruited for the study, two-thirds received SGN-15 in combination with TAXOTERE® while the remaining one-third received TAXOTERE® alone. For the patients receiving SGN-15 in combination with TAXOTERE®, median overall survival was 7.3 months in comparison to 5.9 months for patients receiving TAXOTERE® alone. Overall survival at 1 year and 18 months was 29 and 18 percent respectively for patients receiving SNG-15 plus TAXOTERE® compared to 24 and 8 percent respectively for patients receiving TAXOTERE® alone. Further clinical trials are planned.
[0016] Preclinically, there has been some limited success in the use of monoclonal antibodies for melanoma. Very few of these antibodies have reached clinical trials and to date none have been approved or demonstrated favorable results in Phase III clinical trials.
[0017] The discovery of new drugs to treat disease is hindered by the lack of identification of relevant targets among the products of 30,000 known genes that could contribute to disease pathogenesis. In oncology research, potential drug targets are often selected simply due to the fact that they are over-expressed in tumor cells. Targets thus identified are then screened for interaction with a multitude of compounds. In the case of potential antibody therapies, these candidate compounds are usually derived from traditional methods of monoclonal antibody generation according to the fundamental principles laid down by Kohler and Milstein (1975, Nature, 256, 495-497, Kohler and Milstein). Spleen cells are collected from mice immunized with antigen (e.g. whole cells, cell fractions, purified antigen) and fused with immortalized hybridoma partners. The resulting hybridomas are screened and selected for secretion of antibodies which bind most avidly to the target. Many therapeutic and diagnostic antibodies directed against cancer cells, including Herceptin® and RITUXIMAB, have been produced using these methods and selected on the basis of their affinity. The flaws in this strategy are two-fold. Firstly, the choice of appropriate targets for therapeutic or diagnostic antibody binding is limited by the paucity of knowledge surrounding tissue specific carcinogenic processes and the resulting simplistic methods, such as selection by overexpression, by which these targets are identified. Secondly, the assumption that the drug molecule that binds to the receptor with the greatest affinity usually has the highest probability for initiating or inhibiting a signal may not always be the case.
[0018] Despite some progress with the treatment of breast and colon cancer, the identification and development of efficacious antibody therapies, either as single agents or co-treatments, has been inadequate for all types of cancer.
Prior Patents:
[0019] U.S. Pat. No. 5,750,102 discloses a process wherein cells from a patient's tumor are transfected with MHC genes which may be cloned from cells or tissue from the patient. These transfected cells are then used to vaccinate the patient.
[0020] U.S. Pat. No. 4,861,581 discloses a process comprising the steps of obtaining monoclonal antibodies that are specific to an internal cellular component of neoplastic and normal cells of the mammal but not to external components, labeling the monoclonal antibody, contacting the labeled antibody with tissue of a mammal that has received therapy to kill neoplastic cells, and determining the effectiveness of therapy by measuring the binding of the labeled antibody to the internal cellular component of the degenerating neoplastic cells. In preparing antibodies directed to human intracellular antigens, the patentee recognizes that malignant cells represent a convenient source of such antigens.
[0021] U.S. Pat. No. 5,171,665 provides a novel antibody and method for its production. Specifically, the patent teaches formation of a monoclonal antibody which has the property of binding strongly to a protein antigen associated with human tumors, e.g. those of the colon and lung, while binding to normal cells to a much lesser degree.
[0022] U.S. Pat. No. 5,484,596 provides a method of cancer therapy comprising surgically removing tumor tissue from a human cancer patient, treating the tumor tissue to obtain tumor cells, irradiating the tumor cells to be viable but non-tumorigenic, and using these cells to prepare a vaccine for the patient capable of inhibiting recurrence of the primary tumor while simultaneously inhibiting metastases. The patent teaches the development of monoclonal antibodies which are reactive with surface antigens of tumor cells. As set forth at col. 4, lines 45 et seq., the patentees utilize autochthonous tumor cells in the development of monoclonal antibodies expressing active specific immunotherapy in human neoplasia.
[0023] U.S. Pat. No. 5,693,763 teaches a glycoprotein antigen characteristic of human carcinomas and not dependent upon the epithelial tissue of origin.
[0024] U.S. Pat. No. 5,783,186 is drawn to Anti-Her2 antibodies which induce apoptosis in Her2 expressing cells, hybridoma cell lines producing the antibodies, methods of treating cancer using the antibodies and pharmaceutical compositions including said antibodies.
[0025] U.S. Pat. No. 5,849,876 describes new hybridoma cell lines for the production of monoclonal antibodies to mucin antigens purified from tumor and non-tumor tissue sources.
[0026] U.S. Pat. No. 5,869,268 is drawn to a method for generating a human lymphocyte producing an antibody specific to a desired antigen, a method for producing a monoclonal antibody, as well as monoclonal antibodies produced by the method. The patent is particularly drawn to the production of an anti-HD human monoclonal antibody useful for the diagnosis and treatment of cancers.
[0027] U.S. Pat. No. 5,869,045 relates to antibodies, antibody fragments, antibody conjugates and single-chain immunotoxins reactive with human carcinoma cells. The mechanism by which these antibodies function is two-fold, in that the molecules are reactive with cell membrane antigens present on the surface of human carcinomas, and further in that the antibodies have the ability to internalize within the carcinoma cells, subsequent to binding, making them especially useful for forming antibody-drug and antibody-toxin conjugates. In their unmodified form the antibodies also manifest cytotoxic properties at specific concentrations.
[0028] U.S. Pat. No. 5,780,033 discloses the use of autoantibodies for tumor therapy and prophylaxis. However, this antibody is an antinuclear autoantibody from an aged mammal. In this case, the autoantibody is said to be one type of natural antibody found in the immune system. Because the autoantibody comes from “an aged mammal”, there is no requirement that the autoantibody actually comes from the patient being treated. In addition the patent discloses natural and monoclonal antinuclear autoantibody from an aged mammal, and a hybridoma cell line producing a monoclonal antinuclear autoantibody.
SUMMARY OF THE INVENTION
[0029] This application utilizes methodology for producing patient specific anti-cancer antibodies taught in the U.S. Pat. No. 6,180,357 patent for isolating hybridoma cell lines which encode for cancerous disease modifying monoclonal antibodies. These antibodies can be made specifically for one tumor and thus make possible the customization of cancer therapy. Within the context of this application, anti-cancer antibodies having either cell-killing (cytotoxic) or cell-growth inhibiting (cytostatic) properties will hereafter be referred to as cytotoxic. These antibodies can be used in aid of staging and diagnosis of a cancer, and can be used to treat tumor metastases. These antibodies can also be used for the prevention of cancer by way of prophylactic treatment. Unlike antibodies generated according to traditional drug discovery paradigms, antibodies generated in this way may target molecules and pathways not previously shown to be integral to the growth and/or survival of malignant tissue. Furthermore, the binding affinities of these antibodies are suited to requirements for initiation of the cytotoxic events that may not be amenable to stronger affinity interactions. Also, it is within the purview of this invention to conjugate standard chemotherapeutic modalities, e.g. radionuclides, with the CDMAB of the instant invention, thereby focusing the use of said chemotherapeutics. The CDMAB can also be conjugated to toxins, cytotoxic moieties, enzymes e.g. biotin conjugated enzymes, or hematogenous cells, thereby forming an antibody conjugate.
[0030] The prospect of individualized anti-cancer treatment will bring about a change in the way a patient is managed. A likely clinical scenario is that a tumor sample is obtained at the time of presentation, and banked. From this sample, the tumor can be typed from a panel of pre-existing cancerous disease modifying antibodies. The patient will be conventionally staged but the available antibodies can be of use in further staging the patient. The patient can be treated immediately with the existing antibodies, and a panel of antibodies specific to the tumor can be produced either using the methods outlined herein or through the use of phage display libraries in conjunction with the screening methods herein disclosed. All the antibodies generated will be added to the library of anti-cancer antibodies since there is a possibility that other tumors can bear some of the same epitopes as the one that is being treated. The antibodies produced according to this method may be useful to treat cancerous disease in any number of patients who have cancers that bind to these antibodies.
[0031] In addition to anti-cancer antibodies, the patient can elect to receive the currently recommended therapies as part of a multi-modal regimen of treatment. The fact that the antibodies isolated via the present methodology are relatively non-toxic to non-cancerous cells allows for combinations of antibodies at high doses to be used, either alone, or in conjunction with conventional therapy. The high therapeutic index will also permit re-treatment on a short time scale that should decrease the likelihood of emergence of treatment resistant cells.
[0032] If the patient is refractory to the initial course of therapy or metastases develop, the process of generating specific antibodies to the tumor can be repeated for re-treatment. Furthermore, the anti-cancer antibodies can be conjugated to red blood cells obtained from that patient and re-infused for treatment of metastases. There have been few effective treatments for metastatic cancer and metastases usually portend a poor outcome resulting in death. However, metastatic cancers are usually well vascularized and the delivery of anti-cancer antibodies by red blood cells can have the effect of concentrating the antibodies at the site of the tumor. Even prior to metastases, most cancer cells are dependent on the host's blood supply for their survival and an anti-cancer antibody conjugated to red blood cells can be effective against in situ tumors as well. Alternatively, the antibodies may be conjugated to other hematogenous cells, e.g. lymphocytes, macrophages, monocytes, natural killer cells, etc.
[0033] There are five classes of antibodies and each is associated with a function that is conferred by its heavy chain. It is generally thought that cancer cell killing by naked antibodies are mediated either through antibody dependent cellular cytotoxicity or complement dependent cytotoxicity. For example murine IgM and IgG2a antibodies can activate human complement by binding the C-1 component of the complement system thereby activating the classical pathway of complement activation which can lead to tumor lysis. For human antibodies the most effective complement activating antibodies are generally IgM and IgG1. Murine antibodies of the IgG2a and IgG3 isotype are effective at recruiting cytotoxic cells that have Fc receptors which will lead to cell killing by monocytes, macrophages, granulocytes and certain lymphocytes. Human antibodies of both the IgG1 and IgG3 isotype mediate ADCC.
[0034] Another possible mechanism of antibody mediated cancer killing may be through the use of antibodies that function to catalyze the hydrolysis of various chemical bonds in the cell membrane and its associated glycoproteins or glycolipids, so-called catalytic antibodies.
[0035] There are three additional mechanisms of antibody-mediated cancer cell killing. The first is the use of antibodies as a vaccine to induce the body to produce an immune response against the putative antigen that resides on the cancer cell. The second is the use of antibodies to target growth receptors and interfere with their function or to down regulate that receptor so that its function is effectively lost. The third is the effect of such antibodies on direct ligation of cell surface moieties that may lead to direct cell death, such as ligation of death receptors such as TRAIL R1 or TRAIL R2, or integrin molecules such as alpha V beta 3 and the like.
[0036] The clinical utility of a cancer drug is based on the benefit of the drug under an acceptable risk profile to the patient. In cancer therapy survival has generally been the most sought after benefit, however there are a number of other well-recognized benefits in addition to prolonging life. These other benefits, where treatment does not adversely affect survival, include symptom palliation, protection against adverse events, prolongation in time to recurrence or disease-free survival, and prolongation in time to progression. These criteria are generally accepted and regulatory bodies such as the U.S. Food and Drug Administration (F.D.A.) approve drugs that produce these benefits (Hirschfeld et al. Critical Reviews in Oncology/Hematolgy 42:137-143 2002). In addition to these criteria it is well recognized that there are other endpoints that may presage these types of benefits. In part, the accelerated approval process granted by the U.S. F.D.A. acknowledges that there are surrogates that will likely predict patient benefit. As of year-end 2003, there have been sixteen drugs approved under this process, and of these, four have gone on to full approval, i.e., follow-up studies have demonstrated direct patient benefit as predicted by surrogate endpoints. One important endpoint for determining drug effects in solid tumors is the assessment of tumor burden by measuring response to treatment (Therasse et al. Journal of the National Cancer Institute 92(3):205-216 2000). The clinical criteria (RECIST criteria) for such evaluation have been promulgated by Response Evaluation Criteria in Solid Tumors Working Group, a group of international experts in cancer. Drugs with a demonstrated effect on tumor burden, as shown by objective responses according to RECIST criteria, in comparison to the appropriate control group tend to, ultimately, produce direct patient benefit. In the pre-clinical setting tumor burden is generally more straightforward to assess and document. In that pre-clinical studies can be translated to the clinical setting, drugs that produce prolonged survival in pre-clinical models have the greatest anticipated clinical utility. Analogous to producing positive responses to clinical treatment, drugs that reduce tumor burden in the pre-clinical setting may also have significant direct impact on the disease. Although prolongation of survival is the most sought after clinical outcome from cancer drug treatment, there are other benefits that have clinical utility and it is clear that tumor burden reduction, which may correlate to a delay in disease progression, extended survival or both, can also lead to direct benefits and have clinical impact (Eckhardt et al Developmental Therapeutics: Successes and Failures of Clinical Trial Designs of Targeted Compounds; ASCO Educational Book, 39 th Annual Meeting, 2003, pages 209-219).
[0037] The present invention describes the development and use of AR104A1289.2.2 identified by its effect in a cytotoxic assay and in animal models of human cancer. This invention describes reagents that bind specifically to an epitope or epitopes present on the target molecule, and that also have in vitro cytotoxic properties, as a naked antibody, against malignant tumor cells but not normal cells, and which also directly mediate, as a naked antibody, inhibition of tumor growth. A further advance is of the use of anti-cancer antibodies such as this to target tumors expressing cognate antigen markers to achieve tumor growth inhibition, and other positive endpoints of cancer treatment.
[0038] In all, this invention teaches the use of the AR104A1289.2.2 antigen as a target for a therapeutic agent, that when administered can reduce the tumor burden of a cancer expressing the antigen in a mammal. This invention also teaches the use of CDMAB (AR104A1289.2.2), and their derivatives, and antigen binding fragments thereof, and cytotoxicity inducing ligands thereof, to target their antigen to reduce the tumor burden of a cancer expressing the antigen in a mammal. Furthermore, this invention also teaches the use of detecting the AR104A1289.2.2 antigen in cancerous cells that can be useful for the diagnosis, prediction of therapy, and prognosis of mammals bearing tumors that express this antigen.
[0039] Accordingly, it is an objective of the invention to utilize a method for producing cancerous disease modifying antibodies (CDMAB) raised against cancerous cells derived from a particular individual, or one or more particular cancer cell lines, which CDMAB are cytotoxic with respect to cancer cells while simultaneously being relatively non-toxic to non-cancerous cells, in order to isolate hybridoma cell lines and the corresponding isolated monoclonal antibodies and antigen binding fragments thereof for which said hybridoma cell lines are encoded.
[0040] It is an additional objective of the invention to teach cancerous disease modifying antibodies, ligands and antigen binding fragments thereof.
[0041] It is a further objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is mediated through antibody dependent cellular toxicity.
[0042] It is yet an additional objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is mediated through complement dependent cellular toxicity.
[0043] It is still a further objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is a function of their ability to catalyze hydrolysis of cellular chemical bonds.
[0044] A still further objective of the instant invention is to produce cancerous disease modifying antibodies which are useful for in a binding assay for diagnosis, prognosis, and monitoring of cancer.
[0045] Other objects and advantages of this invention will become apparent from the following description wherein are set forth, by way of illustration and example, certain embodiments of this invention.
BRIEF DESCRIPTION OF THE FIGURES
[0046] FIG. 1 compares the percentage cytotoxicity and binding levels of the hybridoma supernatants against cell lines Lovo, MDA-MB-231, OVCAR-3, and CCD-27sk.
[0047] FIG. 2 represents binding of AR104A1289.2.2 to cancer and normal cell lines. The data is tabulated to present the mean fluorescence intensity as a fold increase above isotype control.
[0048] FIG. 3 includes representative FACS histograms of AR104A1289.2.2 and anti-EGFR antibodies directed against several cancer and non-cancer cell lines.
[0049] FIG. 4 demonstrates the effect of AR104A1289.2.2 on tumor growth in a prophylactic BxPC-3 pancreatic cancer model. The vertical dashed lines indicate the period during which the antibody was administered. Data points represent the mean+/−SEM.
[0050] FIG. 5 demonstrates the effect of AR104A1289.2.2 on body weight in a prophylactic BxPC-3 pancreatic cancer model. Data points represent the mean+/−SEM.
[0051] FIG. 6 demonstrates the effect of AR104A1289.2.2 on tumor growth in a prophylactic MDA-MB-231 breast cancer model. The vertical dashed lines indicate the period during which the antibody was administered. Data points represent the mean+/−SEM.
[0052] FIG. 7 demonstrates the effect of AR104A1289.2.2 on body weight in a prophylactic MDA-MB-231 breast cancer model. Data points represent the mean+/−SEM.
[0053] FIG. 8 demonstrates the effect of AR104A1289.2.2 on tumor growth in a prophylactic PC-3 prostate cancer model. The vertical dashed lines indicate the period during which the antibody was administered. Data points represent the mean+/−SEM.
[0054] FIG. 9 demonstrates the effect of AR104A1289.2.2 on body weight in a prophylactic PC-3 prostate cancer model. Data points represent the mean+/−SEM.
DETAILED DESCRIPTION OF THE INVENTION
[0055] In general, the following words or phrases have the indicated definition when used in the summary, description, examples, and claims.
[0056] The term “antibody” is used in the broadest sense and specifically covers, for example, single monoclonal antibodies (including agonist, antagonist, and neutralizing antibodies, de-immunized, murine, chimeric or humanized antibodies), antibody compositions with polyepitopic specificity, single-chain antibodies, immunoconjugates and antibody fragments (see below).
[0057] The term “monoclonal antibody” as used herein refers to an antibody obtained from a population of substantially homogeneous antibodies, i.e., the individual antibodies comprising the population are identical except for possible naturally occurring mutations that may be present in minor amounts. Monoclonal antibodies are highly specific, being directed against a single antigenic site. Furthermore, in contrast to polyclonal antibody preparations which include different antibodies directed against different determinants (epitopes), each monoclonal antibody is directed against a single determinant on the antigen. In addition to their specificity, the monoclonal antibodies are advantageous in that they may be synthesized uncontaminated by other antibodies. The modifier “monoclonal” indicates the character of the antibody as being obtained from a substantially homogeneous population of antibodies, and is not to be construed as requiring production of the antibody by any particular method. For example, the monoclonal antibodies to be used in accordance with the present invention may be made by the hybridoma (murine or human) method first described by Kohler et al., Nature, 256:495 (1975), or may be made by recombinant DNA methods (see, e.g., U.S. Pat. No. 4,816,567). The “monoclonal antibodies” may also be isolated from phage antibody libraries using the techniques described in Clackson et al., Nature, 352:624-628 (1991) and Marks et al., J. Mol. Biol., 222:581-597 (1991), for example.
[0058] “Antibody fragments” comprise a portion of an intact antibody, preferably comprising the antigen-binding or variable region thereof. Examples of antibody fragments include less than full length antibodies, Fab, Fab′, F(ab′) 2 , and Fv fragments; diabodies; linear antibodies; single-chain antibody molecules; single-chain antibodies, single domain antibody molecules, fusion proteins, recombinant proteins and multispecific antibodies formed from antibody fragment(s).
[0059] An “intact” antibody is one which comprises an antigen-binding variable region as well as a light chain constant domain (C L ) and heavy chain constant domains, C H 1, C H 2 and C H 3. The constant domains may be native sequence constant domains (e.g. human native sequence constant domains) or amino acid sequence variant thereof. Preferably, the intact antibody has one or more effector functions.
[0060] Depending on the amino acid sequence of the constant domain of their heavy chains, intact antibodies can be assigned to different “classes”. There are five-major classes of intact antibodies: IgA, IgD, IgE, IgG, and IgM, and several of these may be further divided into “subclasses” (isotypes), e.g., IgG1, IgG2, IgG3, IgG4, IgA, and IgA2. The heavy-chain constant domains that correspond to the different classes of antibodies are called α, δ, ε, γ, and μ, respectively. The subunit structures and three-dimensional configurations of different classes of immunoglobulins are well known.
[0061] Antibody “effector functions” refer to those biological activities attributable to the Fc region (a native sequence Fc region or amino acid sequence variant Fc region) of an antibody. Examples of antibody effector functions include Clq binding; complement dependent cytotoxicity; Fc receptor binding; antibody-dependent cell-mediated cytotoxicity (ADCC); phagocytosis; down regulation of cell surface receptors (e.g. B cell receptor; BCR), etc.
[0062] “Antibody-dependent cell-mediated cytotoxicity” and “ADCC” refer to a cell-mediated reaction in which nonspecific cytotoxic cells that express Fc receptors (FcRs) (e.g. Natural Killer (NK) cells, neutrophils, and macrophages) recognize bound antibody on a target cell and subsequently cause lysis of the target cell. The primary cells for mediating ADCC, NK cells, express FcγRIII only, whereas monocytes express FcγRI, FcγRII and FcγRIII. FcR expression on hematopoietic cells is summarized in Table 3 on page 464 of Ravetch and Kinet, Annu. Rev. Immunol 9:457-92 (1991). To assess ADCC activity of a molecule of interest, an in vitro ADCC assay, such as that described in U.S. Pat. No. 5,500,362 or 5,821,337 may be performed. Useful effector cells for such assays include peripheral blood mononuclear cells (PBMC) and Natural Killer (NK) cells. Alternatively, or additionally, ADCC activity of the molecule of interest may be assessed in vivo, e.g., in a animal model such as that disclosed in Clynes et al. PNAS (USA) 95:652-656 (1998).
[0063] “Effector cells” are leukocytes which express one or more FcRs and perform effector functions. Preferably, the cells express at least FcγRIII and perform ADCC effector function. Examples of human leukocytes which mediate ADCC include peripheral blood mononuclear cells (PBMC), natural killer (NK) cells, monocytes, cytotoxic T cells and neutrophils; with PBMCs and NK cells being preferred. The effector cells may be isolated from a native source thereof, e.g. from blood or PBMCs as described herein.
[0064] The terms “Fc receptor” or “FcR” are used to describe a receptor that binds to the Fc region of an antibody. The preferred FcR is a native sequence human FcR. Moreover, a preferred FcR is one which binds an IgG antibody (a gamma receptor) and includes receptors of the FcγRI, FcγRII, and Fcγ RIII subclasses, including allelic variants and alternatively spliced forms of these receptors. FcγRII receptors include FcγRIIA (an “activating receptor”) and FcγRIIB (an “inhibiting receptor”), which have similar amino acid sequences that differ primarily in the cytoplasmic domains thereof. Activating receptor FcγRIIA contains an immunoreceptor tyrosine-based activation motif (ITAM) in its cytoplasmic domain. Inhibiting receptor FcγRIIB contains an immunoreceptor tyrosine-based inhibition motif (ITIM) in its cytoplasmic domain. (see review M. in Daeron, Annu. Rev. Immunol. 15:203-234 (1997)). FcRs are reviewed in Ravetch and Kinet, Annu. Rev. Immunol 9:457-92 (1991); Capel et al., Immunomethods 4:25-34 (1994); and de Haas et al., J. Lab. Clin. Med. 126:330-41 (1995). Other FcRs, including those to be identified in the future, are encompassed by the term “FcR” herein. The term also includes the neonatal receptor, FcRn, which is responsible for the transfer of maternal IgGs to the fetus (Guyer et al., J. Immunol 117:587 (1976) and Kim et al., Eur. J. Immunol 24:2429 (1994)).
[0065] “Complement dependent cytotoxicity” or “CDC” refers to the ability of a molecule to lyse a target in the presence of complement. The complement activation pathway is initiated by the binding of the first component of the complement system (Clq) to a molecule (e.g. an antibody) complexed with a cognate antigen. To assess complement activation, a CDC assay, e.g. as described in Gazzano-Santoro et al., J. Immunol. Methods 202:163 (1996) may be performed.
[0066] The term “variable” refers to the fact that certain portions of the variable domains differ extensively in sequence among antibodies and are used in the binding and specificity of each particular antibody for its particular antigen. However, the variability is not evenly distributed throughout the variable domains of antibodies. It is concentrated in three segments called hypervariable regions both in the light chain and the heavy chain variable domains. The more highly conserved portions of variable domains are called the framework regions (FRs). The variable domains of native heavy and light chains each comprise four FRs, largely adopting a β-sheet configuration, connected by three hypervariable regions, which form loops connecting, and in some cases forming part of, the β-sheet structure. The hypervariable regions in each chain are held together in close proximity by the FRs and, with the hypervariable regions from the other chain, contribute to the formation of the antigen-binding site of antibodies (see Kabat et al., Sequences of Proteins of Immunological Interest, 5th Ed. Public Health Service, National Institutes of Health, Bethesda, Md. pp 15-17; 48-53 (1991)). The constant domains are not involved directly in binding an antibody to an antigen, but exhibit various effector functions, such as participation of the antibody in antibody dependent cellular cytotoxicity (ADCC).
[0067] The term “hypervariable region” when used herein refers to the amino acid residues of an antibody which are responsible for antigen-binding. The hypervariable region generally comprises amino acid residues from a “complementarity determining region” or “CDR” (e.g. residues 24-34 (L1), 50-56 (L2) and 89-97 (L3) in the light chain variable domain and 31-35 (H1), 50-65 (H2) and 95-102 (H3) in the heavy chain variable domain; Kabat et al., Sequences of Proteins of Immunological Interest, 5th Ed. Public Health Service, National Institutes of Health, Bethesda, Md. pp 15-17; 48-53 (1991)) and/or those residues from a “hypervariable loop” (e.g. residues 2632 (L1), 50-52 (L2) and 91-96 (L3) in the light chain variable domain and 26-32 (H1), 53-55 (H2) and 96-101 (H3) in the heavy chain variable domain; Chothia and Lesk J. Mol. Biol. 196:901-917 (1987)). “Framework Region” or “FR” residues are those variable domain residues other than the hypervariable region residues as herein defined. Papain digestion of antibodies produces two identical antigen-binding fragments, called “Fab” fragments, each with a single antigen-binding site, and a residual “Fc” fragment, whose name reflects its ability to crystallize readily. Pepsin treatment yields an F(ab′) 2 fragment that has two antigen-binding sites and is still capable of cross-linking antigen.
[0068] “Fv” is the minimum antibody fragment which contains a complete antigen-recognition and antigen-binding site. This region consists of a dimer of one heavy chain and one light chain variable domain in tight, non-covalent association. It is in this configuration that the three hypervariable regions of each variable domain interact to define an antigen-binding site on the surface of the V H -V L dimer. Collectively, the six hypervariable regions confer antigen-binding specificity to the antibody. However, even a single variable domain (or half of an Fv comprising only three hypervariable regions specific for an antigen) has the ability to recognize and bind antigen, although at a lower affinity than the entire binding site. The Fab fragment also contains the constant domain of the light chain and the first constant domain (CH I) of the heavy chain. Fab′ fragments differ from Fab fragments by the addition of a few residues at the carboxy terminus of the heavy chain CH1 domain including one or more cysteines from the antibody hinge region. Fab′-SH is the designation herein for Fab′ in which the cysteine residue(s) of the constant domains bear at least one free thiol group. F(ab′) 2 antibody fragments originally were produced as pairs of Fab′ fragments which have hinge cysteines between them. Other chemical couplings of antibody fragments are also known.
[0069] The “light chains” of antibodies from any vertebrate species can be assigned to one of two clearly distinct types, called kappa (κ) and lambda (λ), based on the amino acid sequences of their constant domains.
[0070] “Single-chain Fv” or “scFv” antibody fragments comprise the V H and V L domains of antibody, wherein these domains are present in a single polypeptide chain. Preferably, the Fv polypeptide further comprises a polypeptide linker between the V H and V L domains which enables the scFv to form the desired structure for antigen binding. For a review of scFv see Plückthun in The Pharmacology of Monoclonal Antibodies , vol. 113, Rosenburg and Moore eds., Springer-Verlag, New York, pp. 269-315 (1994).
[0071] The term “diabodies” refers to small antibody fragments with two antigen-binding sites, which fragments comprise a variable heavy domain (V H ) connected to a variable light domain (V L ) in the same polypeptide chain (V H -V L ). By using a linker that is too short to allow pairing between the two domains on the same chain, the domains are forced to pair with the complementary domains of another chain and create two antigen-binding sites. Diabodies are described more fully in, for example, EP 404,097; WO 93/11161; and Hollinger et al, Proc. Natl. Acad. Sci. USA, 90:6444-6448 (1993).
[0072] An “isolated” antibody is one which has been identified and separated and/or recovered from a component of its natural environment. Contaminant components of its natural environment are materials which would interfere with diagnostic or therapeutic uses for the antibody, and may include enzymes, hormones, and other proteinaceous or nonproteinaceous solutes. Isolated antibody includes the antibody in situ within recombinant cells since at least one component of the antibody's natural environment will not be present. Ordinarily, however, isolated antibody will be prepared by at least one purification step.
[0073] An antibody “which binds” an antigen of interest is one capable of binding that antigen with sufficient affinity such that the antibody is useful as a therapeutic or diagnostic agent in targeting a cell expressing the antigen. Where the antibody is one which binds the antigenic moiety it will usually preferentially bind that antigenic moiety as opposed to other receptors, and does not include incidental binding such as non-specific Fc contact, or binding to post-translational modifications common to other antigens and may be one which does not significantly cross-react with other proteins. Methods, for the detection of an antibody that binds an antigen of interest, are well known in the art and can include but are not limited to assays such as FACS, cell ELISA and Western blot.
[0074] As used herein, the expressions “cell”, “cell line”, and “cell culture” are used interchangeably, and all such designations include progeny. It is also understood that all progeny may not be precisely identical in DNA content, due to deliberate or inadvertent mutations. Mutant progeny that have the same function or biological activity as screened for in the originally transformed cell are included. It will be clear from the context where distinct designations are intended.
[0075] “Treatment or treating” refers to both therapeutic treatment and prophylactic or preventative measures, wherein the object is to prevent or slow down (lessen) the targeted pathologic condition or disorder. Those in need of treatment include those already with the disorder as well as those prone to have the disorder or those in whom the disorder is to be prevented. Hence, the mammal to be treated herein may have been diagnosed as having the disorder or may be predisposed or susceptible to the disorder.
[0076] The terms “cancer” and “cancerous” refer to or describe the physiological condition in mammals that is typically characterized by unregulated cell growth or death. Examples of cancer include, but are not limited to, carcinoma, lymphoma, blastoma, sarcoma, and leukemia or lymphoid malignancies. More particular examples of such cancers include squamous cell cancer (e.g. epithelial squamous cell cancer), lung cancer including small-cell lung cancer, non-small cell lung cancer, adenocarcinoma of the lung and squamous carcinoma of the lung, cancer of the peritoneum, hepatocellular cancer, gastric or stomach cancer including gastrointestinal cancer, pancreatic cancer, glioblastoma, cervical cancer, ovarian cancer, liver cancer, bladder cancer, hepatoma, breast cancer, colon cancer, rectal cancer, colorectal cancer, endometrial or uterine carcinoma, salivary gland carcinoma, kidney or renal cancer, prostate cancer, vulval cancer, thyroid cancer, hepatic carcinoma, anal carcinoma, penile carcinoma, as well as head and neck cancer.
[0077] A “chemotherapeutic agent” is a chemical compound useful in the treatment of cancer. Examples of chemotherapeutic agents include alkylating agents such as thiotepa and cyclosphosphamide (CYTOXAN™); alkyl sulfonates such as busulfan, improsulfan and piposulfan; aziridines such as benzodopa, carboquone, meturedopa, and uredopa; ethylenimines and methylamelamines including altretamine, triethylenemelamine, triethylenephosphoramide, triethylenethiophosphoramide and trimethylolomelamine; nitrogen mustards such as chlorambucil, chlomaphazine, cholophosphamide, estramustine, ifosfamide, mechlorethamine, mechlorethamine oxide hydrochloride, melphalan, novembichin, phenesterine, prednimustine, trofosfamide, uracil mustard; nitrosureas such as carmustine, chlorozotocin, fotemustine, lomustine, nimustine, ranimustine; antibiotics such as aclacinomysins, actinomycin, authramycin, azaserine, bleomycins, cactinomycin, calicheamicin, carabicin, carnomycin, carzinophilin, chromomycins, dactinomycin, daunorubicin, detorubicin, 6-diazo-5-oxo-L-norleucine, doxorubicin, epirubicin, esorubicin, idarubicin, marcellomycin, mitomycins, mycophenolic acid, nogalamycin, olivomycins, peplomycin, potfiromycin, puromycin, quelamycin, rodorubicin, streptonigrin, streptozocin, tubercidin, ubenimex, zinostatin, zorubicin; anti-metabolites such as methotrexate and 5-fluorouracil (5-FU); folic acid analogues such as denopterin, methotrexate, pteropterin, trimetrexate; purine analogs such as fludarabine, 6-mercaptopurine, thiamiprine, thioguanine; pyrimidine analogs such as ancitabine, azacitidine, 6-azauridine, carmofur, cytarabine, dideoxyuridine, doxifluridine, enocitabine, floxuridine, 5-FU; androgens such as calusterone, dromostanolone propionate, epitiostanol, mepitiostane, testolactone; anti-adrenals such as aminoglutethimide, mitotane, trilostane; folic acid replenisher such as frolinic acid; aceglatone; aldophosphamide glycoside; aminolevulinic acid; amsacrine; bestrabucil; bisantrene; edatraxate; defofamine; demecolcine; diaziquone; elformithine; elliptinium acetate; etoglucid; gallium nitrate; hydroxyurea; lentinan; lonidamine; mitoguazone; mitoxantrone; mopidamol; nitracrine; pentostatin; phenamet; pirarubicin; podophyllinic acid; 2-ethylhydrazide; procarbazine; PSK®; razoxane; sizofiran; spirogermanium; tenuazonic acid; triaziquone; 2,2′,2″-trichlorotriethylamine; urethan; vindesine; dacarbazine; mannomustine; mitobronitol; mitolactol; pipobroman; gacytosine; arabinoside (“Ara-C”); cyclophosphamide; thiotepa; taxanes, e.g. paclitaxel (TAXOL®, Bristol-Myers Squibb Oncology, Princeton, N.J.) and docetaxel (TAXOTERE®, Aventis, Rhone-Poulenc Rorer, Antony, France); chlorambucil; gemcitabine; 6-thioguanine; mercaptopurine; methotrexate; platinum analogs such as cisplatin and carboplatin; vinblastine; platinum; etoposide (VP-16); ifosfamide; mitomycin C; mitoxantrone; vincristine; vinorelbine; navelbine; novantrone; teniposide; daunomycin; aminopterin; xeloda; ibandronate; CPT-11; topoisomerase inhibitor RFS 2000; difluoromethylornithine (DMFO); retinoic acid; esperamicins; capecitabine; and pharmaceutically acceptable salts, acids or derivatives of any of the above. Also included in this definition are anti-hormonal agents that act to regulate or inhibit hormone action on tumors such as anti-estrogens including for example tamoxifen, raloxifene, aromatase inhibiting 4(5)-imidazoles, 4-hydroxytamoxifen, trioxifene, keoxifene, LY117018, onapristone, and toremifene (Fareston); and anti-androgens such as flutamide, nilutamide, bicalutamide, leuprolide, and goserelin; and pharmaceutically acceptable salts, acids or derivatives of any of the above.
[0078] “Mammal” for purposes of treatment refers to any animal classified as a mammal, including humans, mice, SCID or nude mice or strains of mice, domestic and farm animals, and zoo, sports, or pet animals, such as sheep, dogs, horses, cats, cows, etc. Preferably, the mammal herein is human.
[0079] “Oligonucleotides” are short-length, single- or double-stranded polydeoxynucleotides that are chemically synthesized by known methods (such as phosphotriester, phosphite, or phosphoramidite chemistry, using solid phase techniques such as described in EP 266,032, published 4 May 1988, or via deoxynucleoside H-phosphonate intermediates as described by Froehler et al., Nucl. Acids Res., 14:5399-5407, 1986. They are then purified on polyacrylamide gels.
[0080] In accordance with the present invention, “humanized” and/or “chimeric” forms of non-human (e.g. murine) immunoglobulins refer to antibodies which contain specific chimeric immunoglobulins, immunoglobulin chains or fragments thereof (such as Fv, Fab, Fab′, F(ab′) 2 or other antigen-binding subsequences of antibodies) which results in the decrease of a human anti-mouse antibody (HAMA), human anti-chimeric antibody (HACA) or a human anti-human antibody (HAHA) response, compared to the original antibody, and contain the requisite portions (e.g. CDR(s), antigen binding region(s), variable domain(s) and so on) derived from said non-human immunoglobulin, necessary to reproduce the desired effect, while simultaneously retaining binding characteristics which are comparable to said non-human immunoglobulin. For the most part, humanized antibodies are human immunoglobulins (recipient antibody) in which residues from the complementarity determining regions (CDRs) of the recipient antibody are replaced by residues from the CDRs of a non-human species (donor antibody) such as mouse, rat or rabbit having the desired specificity, affinity and capacity. In some instances, Fv framework region (FR) residues of the human immunoglobulin are replaced by corresponding non-human FR residues. Furthermore, the humanized antibody may comprise residues which are found neither in the recipient antibody nor in the imported CDR or FR sequences. These modifications are made to further refine and optimize antibody performance. In general, the humanized antibody will comprise substantially all of at least one, and typically two, variable domains, in which all or substantially all of the CDR regions correspond to those of a non-human immunoglobulin and all or substantially all of the FR residues are those of a human immunoglobulin consensus sequence. The humanized antibody optimally also will comprise at least a portion of an immunoglobulin constant region (Fc), typically that of a human immunoglobulin.
[0081] “De-immunized” antibodies are immunoglobulins that are non-immunogenic, or less immunogenic, to a given species. De-immunization can be achieved through structural alterations to the antibody. Any de-immunization technique known to those skilled in the art can be employed. One suitable technique for de-immunizing antibodies is described, for example, in WO 00/34317 published Jun. 15, 2000.
[0082] An antibody which induces “apoptosis” is one which induces programmed cell death by any means, illustrated by but not limited to binding of annexin V, caspase activity, fragmentation of DNA, cell shrinkage, dilation of endoplasmic reticulum, cell fragmentation, and/or formation of membrane vesicles (called apoptotic bodies).
[0083] As used herein “antibody induced cytotoxicity” is understood to mean the cytotoxic effect derived from the hybridoma supernatant or antibody produced by the hybridoma deposited with the IDAC as accession number 190607-04 which effect is not necessarily related to the degree of binding.
[0084] Throughout the instant specification, hybridoma cell lines, as well as the isolated monoclonal antibodies which are produced therefrom, are alternatively referred to by their internal designation, AR104A1289.2.2 or Depository Designation, IDAC 190607-04.
[0085] As used herein “antibody-ligand” includes a moiety which exhibits binding specificity for at least one epitope of the target antigen, and which may be an intact antibody molecule, antibody fragments, and any molecule having at least an antigen-binding region or portion thereof (i.e., the variable portion of an antibody molecule), e.g., an Fv molecule, Fab molecule, Fab′ molecule, F(ab′) 2 molecule, a bispecific antibody, a fusion protein, or any genetically engineered molecule which specifically recognizes and binds at least one epitope of the antigen bound by the isolated monoclonal antibody produced by the hybridoma cell line designated as IDAC 190607-04 (the IDAC 190607-04 antigen).
[0086] As used herein “cancerous disease modifying antibodies” (CDMAB) refers to monoclonal antibodies which modify the cancerous disease process in a manner which is beneficial to the patient, for example by reducing tumor burden or prolonging survival of tumor bearing individuals, and antibody-ligands thereof.
[0087] As used herein “antigen-binding region” means a portion of the molecule which recognizes the target antigen.
[0088] As used herein “competitively inhibits” means being able to recognize and bind a determinant site to which the monoclonal antibody produced by the hybridoma cell line designated as IDAC 190607-04, (the IDAC 190607-04 antibody) is directed using conventional reciprocal antibody competition assays. (Belanger L., Sylvestre C. and Dufour D. (1973), Enzyme linked immunoassay for alpha fetoprotein by competitive and sandwich procedures. Clinica Chimica Acta 48, 15).
[0089] As used herein “target antigen” is the IDAC 190607-04 antigen or portions thereof.
[0090] As used herein, an “immunoconjugate” means any molecule or CDMAB such as an antibody chemically or biologically linked to a cytotoxin, a radioactive agent, enzyme, toxin, an anti-tumor drug or a therapeutic agent. The antibody or CDMAB may be linked to the cytotoxin, radioactive agent, anti-tumor drug or therapeutic agent at any location along the molecule so long as it is able to bind its target. Examples of immunoconjugates include antibody toxin chemical conjugates and antibody-toxin fusion proteins.
[0091] As used herein, a “fusion protein” means any chimeric protein wherein an antigen binding region is connected to a biologically active molecule, e.g., toxin, enzyme, or protein drug.
[0092] In order that the invention herein described may be more fully understood, the following description is set forth.
[0093] The present invention provides CDMABs (i.e., IDAC 190607-04 CDMAB) which specifically recognize and bind the IDAC 190607-04 antigen.
[0094] The CDMAB of the isolated monoclonal antibody produced by the hybridoma deposited with the IDAC as accession number 190607-04 may be in any form as long as it has an antigen-binding region which competitively inhibits the immunospecific binding of the isolated monoclonal antibody produced by hybridoma IDAC 190607-04 to its target antigen. Thus, any recombinant proteins (e.g., fusion proteins wherein the antibody is combined with a second protein such as a lymphokine or a tumor inhibitory growth factor) having the same binding specificity as the IDAC 190607-04 antibody fall within the scope of this invention.
[0095] In one embodiment of the invention, the CDMAB is the IDAC 190607-04 antibody.
[0096] In other embodiments, the CDMAB is an antigen binding fragment which may be a Fv molecule (such as a single-chain Fv molecule), a Fab molecule, a Fab′ molecule, a F(ab′) 2 molecule, a fusion protein, a bispecific antibody, a heteroantibody or any recombinant molecule having the antigen-binding region of the IDAC 190607-04 antibody. The CDMAB of the invention is directed to the epitope to which the IDAC 190607-04 monoclonal antibody is directed.
[0097] The CDMAB of the invention may be modified, i.e., by amino acid modifications within the molecule, so as to produce derivative molecules. Chemical modification may also be possible.
[0098] Derivative molecules would retain the functional property of the polypeptide, namely, the molecule having such substitutions will still permit the binding of the polypeptide to the IDAC 190607-04 antigen or portions thereof.
[0099] These amino acid substitutions include, but are not necessarily limited to, amino acid substitutions known in the art as “conservative”.
[0100] For example, it is a well-established principle of protein chemistry that certain amino acid substitutions, entitled “conservative amino acid substitutions,” can frequently be made in a protein without altering either the conformation or the function of the protein.
[0101] Such changes include substituting any of isoleucine (I), valine (V), and leucine (L) for any other of these hydrophobic amino acids; aspartic acid (D) for glutamic acid (E) and vice versa; glutamine (Q) for asparagine (N) and vice versa; and serine (S) for threonine (T) and vice versa. Other substitutions can also be considered conservative, depending on the environment of the particular amino acid and its role in the three-dimensional structure of the protein. For example, glycine (G) and alanine (A) can frequently be interchangeable, as can alanine and valine (V). Methionine (M), which is relatively hydrophobic, can frequently be interchanged with leucine and isoleucine, and sometimes with valine. Lysine (K) and arginine (R) are frequently interchangeable in locations in which the significant feature of the amino acid residue is its charge and the differing pK's of these two amino acid residues are not significant. Still other changes can be considered “conservative” in particular environments.
EXAMPLE 1
Hybridoma Production—Hybridoma Cell Line AR104A1289.2.2
[0102] The hybridoma cell line AR104A1289.2.2 was deposited, in accordance with the Budapest Treaty, with the International Depository Authority of Canada (IDAC), Bureau of Microbiology, Health Canada, 1015 Arlington Street, Winnipeg, Manitoba, Canada, R3E 3R2, on Jun. 19, 2007, under Accession Number 190607-04. In accordance with 37 CFR 1.808, the depositors assure that all restrictions imposed on the availability to the public of the deposited materials will be irrevocably removed upon the granting of a patent. The deposit will be replaced if the depository cannot dispense viable samples.
[0103] To produce the hybridoma that produces the anti-cancer antibody AR104A1289.2.2, malignant cells consistent with metastatic ovarian carcinoma isolated from frozen human peritoneal fluid (patient donation obtained with informed consent) were prepared in PBS. IMMUNEASY™ (Qiagen, Venlo, Netherlands) adjuvant was prepared for use by gentle mixing. Five to seven week old BALB/c mice were immunized by injecting subcutaneously 10 million cells in 50 microliters of the antigen-adjuvant. Recently prepared antigen-adjuvant was used to boost the immunized mice intraperitoneally, 2 and 5 weeks after the initial immunization, with 10 million cells in 50 microliters. A spleen was used for fusion three days after the last immunization. The hybridomas were prepared by fusing the isolated splenocytes with NSO-1 myeloma partners. The supernatants from the fusions were tested from subclones of the hybridomas.
[0104] To determine whether the antibodies secreted by the hybridoma cells are of the IgG or IgM isotype, an ELISA assay was employed. 100 microliters/well of goat anti-mouse IgG+IgM (H+L) at a concentration of 2.4 micrograms/mL in coating buffer (0.1 M carbonate/bicarbonate buffer, pH 9.2-9.6) at 4° C. was added to the ELISA plates overnight. The plates were washed thrice in washing buffer (PBS+0.05 percent Tween). 100 microliters/well blocking buffer (5 percent milk in wash buffer) was added to the plates for 1 hour at room temperature and then washed thrice in washing buffer. 100 microliters/well of hybridoma supernatant was added and the plates were incubated for 1 hour at room temperature. The plates were washed thrice with washing buffer and 1/100,000 dilution of either goat anti-mouse IgG or IgM horseradish peroxidase conjugate (diluted in PBS containing 5 percent milk), 100 microliters/well, was added. After incubating the plates for 1 hour at room temperature the plates were washed thrice with washing buffer. 100 microliters/well of TMB solution was incubated for 1-3 minutes at room temperature. The color reaction was terminated by adding 50 microliters/well 2M H 2 S0 4 and the plates were read at 450 nm with a Perkin-Elmer HTS7000 plate reader. As indicated in FIG. 1 , the AR104A1289.2.2 hybridoma secreted primarily antibodies of the IgG isotype.
[0105] To determine the subclass of antibody secreted by the hybridoma cells, an isotyping experiment was performed using a Mouse Monoclonal Antibody Isotyping Kit (HyCult Biotechnology, Frontstraat, Netherlands). 500 microliters of buffer solution was added to the test strip containing rat anti-mouse subclass specific antibodies. 500 microliters of hybridoma supernatant was added to the test tube, and submerged by gentle agitation. Captured mouse immunoglobulins were detected directly by a second rat monoclonal antibody which is coupled to colloid particles. The combination of these two proteins creates a visual signal used to analyse the isotype. The anti-cancer antibody AR104A1289.2.2 is of the IgG2a, kappa isotype.
[0106] After a round of limiting dilution, hybridoma supernatants were tested for antibodies that bound to target cells in a cell ELISA assay. One human colon cancer cell line, one human breast cancer cell line, one human ovarian cell line and one human non-cancer skin cell line were tested: Lovo, MDA-MB-231, OVCAR-3 and CCD-27sk, respectively. All cell lines were obtained from the American Type Tissue Collection (ATCC, Manassas, Va.). The plated cells were fixed prior to use. The plates were washed thrice with PBS containing MgCl 2 and CaCl 2 at room temperature. 100 microliters of 2 percent paraformaldehyde diluted in PBS was added to each well for 10 minutes at room temperature and then discarded. The plates were again washed with PBS containing MgCl 2 and CaCl 2 three times at room temperature. Blocking was done with 100 microliters/well of 5 percent milk in wash buffer (PBS+0.05 percent Tween) for 1 hour at room temperature. The plates were washed thrice with wash buffer and the hybridoma supernatant was added at 75 microliters/well for 1 hour at room temperature. The plates were washed 3 times with wash buffer and 100 microliters/well of 1/25,000 dilution of goat anti-mouse IgG or IgM antibody conjugated to horseradish peroxidase (diluted in PBS containing 5 percent milk) was added. After 1 hour incubation at room temperature the plates were washed 3 times with wash buffer and 100 microliter/well of TMB substrate was incubated for 1-3 minutes at room temperature. The reaction was terminated with 50 microliters/well 2M H 2 S0 4 and the plates were read at 450 nm with a Perkin-Elmer HTS7000 plate reader. The results as tabulated in FIG. 1 were expressed as the number of folds above background compared to an in-house IgG isotype control that has previously been shown not to bind to the cell lines tested. The antibodies from the hybridoma AR104A1289.2.2 showed detectable binding to the Lovo colon cancer, MDA-MB-231 breast cancer and CCD-27sk non-cancer skin cell lines.
[0107] In conjunction with testing for antibody binding, the cytotoxic effect of the hybridoma supernatants (antibody induced cytotoxicity) was tested in the cell lines: Lovo, MDA-MB-231, OVCAR-3 and CCD-27sk. Calcein AM was obtained from Molecular Probes (Eugene, Oreg.) and the assay was performed as outlined below. Cells were plated before the assay at the predetermined appropriate density. After 2 days, 75 microliters of supernatant from the hybridoma microtitre plates were transferred to the cell plates and incubated in a 5 percent CO 2 incubator for 5 days. The wells that served as the positive controls were aspirated until empty and 100 microliters of sodium azide (NaN 3 , 0.01 percent, Sigma, Oakville, ON) or cycloheximide (CHX, 0.5 micromolar, Sigma, Oakville, ON) dissolved in culture medium was added. After 5 days of treatment, the plates were then emptied by inverting and blotting dry. Room temperature DPBS (Dulbecco's phosphate buffered saline) containing MgCl 2 and CaCl 2 was dispensed into each well from a multichannel squeeze bottle, tapped 3 times, emptied by inversion and then blotted dry. 50 microliters of the fluorescent calcein dye diluted in DPBS containing MgCl 2 and CaCl 2 was added to each well and incubated at 37° C. in a 5 percent CO 2 incubator for 30 minutes. The plates were read in a Perkin-Elmer HTS7000 fluorescence plate reader and the data was analyzed in Microsoft Excel. The results are tabulated in FIG. 1 . Supernatant from the AR104A1289.2.2 hybridoma produced specific cytotoxicity of 15 percent on the Lovo cells. This was 500 and 31 percent of the cytotoxicity obtained with the positive controls sodium azide and cycloheximide, respectively for Lovo. There was no observable cytotoxicity to the non-cancer skin cell line CCD-27sk. The known non-specific cytotoxic agents cycloheximide and NaN 3 generally produced cytotoxicity as expected.
[0108] Results from FIG. 1 demonstrate that the cytotoxic effects of AR104A1289.2.2 on the different cell lines did not correlate to the level of binding. Although the highest level of binding was to the MDA-MB-231 cell line, the highest level of cytotoxicity was directed against the Lovo cell line. AR104A1289.2.2 did not produce cytotoxicity in, albeit it did bind to, the CCD-27sk non-cancer skin cell line. The antibody therefore exhibited functional specificity, which was not necessarily related to the degree of binding.
EXAMPLE 2
In Vitro Binding
[0109] AR104A1289.2.2 monoclonal antibody was produced by culturing the hybridoma in CL-1000 flasks (BD Biosciences, Oakville, ON) with collections and reseeding occurring twice/week. Standard antibody purification procedures with Protein G Sepharose 4 Fast Flow (Amersham Biosciences, Baie d'Urfé, QC) were followed. It is within the scope of this invention to utilize monoclonal antibodies that are humanized, de-immunized, chimeric or murine.
[0110] Binding of AR104A1289.2.2 to ovarian (ES-2, OV2008, OVCAR-3 and SK-OV-3), breast (MDA-MB-231 and SK-BR-3), lung (A549), pancreatic (BxPC-3), colon (Lovo) and prostate (PC-3) cancer cell lines and a non-cancer cell line from skin (CCD-27sk) was assessed by flow cytometry (FACS). All cell lines except for two of the ovarian cancer cell lines were obtained from the American Type Tissue Collection (ATCC, Manassas, Va.). OV2008 and ES-2 ovarian cancer cell lines were obtained from the Ottawa Regional Cancer Center (Ottawa, ON).
[0111] Cells were prepared for FACS by initially washing the cell monolayer with DPBS (without Ca ++ and Mg ++ ). Cell dissociation buffer (Invitrogen, Burlington, ON) was then used to dislodge the cells from their cell culture plates at 37° C. After centrifugation and collection, the cells were resuspended in DPBS containing MgCl 2 , CaCl 2 and 2 percent fetal bovine serum at 4° C. (staining media) and counted, aliquoted to appropriate cell density, spun down to pellet the cells and resuspended in staining media at 4° C. in the presence of the test antibody (AR104A1289.2.2) or control antibodies (isotype control, anti-EGFR (c225, IgG1, kappa, Cedarlane, Homby ON). Isotype control and the test antibody were assessed at 20 micrograms/mL whereas anti-EGFR was assessed at 5 micrograms/mL on ice for 30 minutes. Prior to the addition of Alexa Fluor 546-conjugated secondary antibody the cells were washed once with staining media. The Alexa Fluor 546-conjugated antibody in staining media was then added for 30 minutes at 4° C. The cells were then washed for the final time and resuspended in fixing media (staining media containing 1.5 percent paraformaldehyde). Flow cytometric acquisition of the cells was assessed by running samples on a FACSarray™ using the FACSarray™ System Software (BD Biosciences, Oakville, ON). The forward (FSC) and side scatter (SSC) of the cells were set by adjusting the voltage and amplitude gains on the FSC and SSC detectors. The detectors for the fluorescence (Alexa-546) channel was adjusted by running unstained cells such that cells had a uniform peak with a median fluorescent intensity of approximately 1-5 units. For each sample, approximately 10,000 gated events (stained fixed cells) were acquired for analysis and the results are presented in FIG. 2 .
[0112] FIG. 2 presents the mean fluorescence intensity fold increase above isotype control. Representative histograms of AR104A1289.2.2 antibodies were compiled for FIG. 3 . AR104A1289.2.2 demonstrated binding to the cell lines tested with the exception of the ovarian cancer cell line OVCAR-3 and the colon cancer cell line Lovo. There was binding to the ovarian ES-2 (2.9-fold), OV2008 (2.6-fold) and SK-OV-3 (1.9-fold); breast MDA-MB-231 (4.4-fold) and SK-BR-3 (1.8-fold); lung A549 (5.2-fold); pancreatic BxPC-3 (7.3-fold) and prostate PC-3 (9.5-fold) cancer cell lines and the non-cancer skin cell line CCD-27sk (2.0-fold). These data demonstrate that AR104A1289.2.2 bound to several different cell lines with varying levels of antigen expression.
EXAMPLE 3
In Vivo Tumor Experiments with BxPC-3 Cells
[0113] Example 1 demonstrated that AR104A1289.2.2 had anti-cancer properties against a human cancer cell line. To demonstrate efficacy against a human cancer cell line in vivo, AR104A1289.2.2 was tested in a BxPC-3 pancreatic xenograft model. With reference to FIGS. 4 and 5 , 6 to 8 week old female SCID mice were implanted with 5 million human pancreatic cancer cells (BxPC-3) in 100 microliters PBS solution injected subcutaneously in the right flank. The mice were randomly divided into 2 treatment groups of 8. On the day after implantation, 20 mg/kg of AR104A1289.2.2 test antibody or buffer control was administered intraperitoneally to each cohort in a volume of 300 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibody and control samples were then administered once per week for the duration of the study. Tumor growth was measured about every 7 day with calipers. The study was completed after 8 doses of antibody. Body weights of the animals were recorded once per week for the duration of the study. At the end of the study all animals were euthanized according to CCAC guidelines.
[0114] AR104A1289.2.2 reduced tumor growth in the BxPC-3 in vivo prophylactic model of human pancreatic cancer. Treatment with Arius antibody AR104A1289.2.2 reduced the growth of BxPC-3 tumors by 53.3 percent (p=0.0010, t-test), compared to the buffer treated group, as determined on day 56, 6 days after the last dose of antibody ( FIG. 4 ).
[0115] There were no clinical signs of toxicity throughout the study. Body weight measured at weekly intervals was a surrogate for well-being and failure to thrive ( FIG. 5 ). There was no significant difference in mean body weight between the groups at the end of the treatment period. There was also no significant difference in mean body weight within each group from the start to the end of the study.
[0116] In summary, AR104A1289.2.2 was well-tolerated and decreased the tumor burden in this human pancreatic cancer xenograft model.
EXAMPLE 4
In Vivo Tumor Experiments with MDA-MB-231 Cells
[0117] Examples 1 and 3 demonstrated that AR104A1289.2.2 had anti-cancer properties against colon and pancreatic human cancer indications. To demonstrate efficacy in a breast cancer model, AR104A1289.2.2 was tested in a MDA-MB-231 breast cancer xenograft model. With reference to FIGS. 6 and 7 , 6 to 8 week old female SCID mice were implanted with 5 million human breast cancer cells (MDA-MB-231) in 100 microliters PBS solution injected subcutaneously in the right flank. The mice were randomly divided into 2 treatment groups of 8. On the day after implantation, 20 mg/kg of AR104A1289.2.2 test antibody or buffer control was administered intraperitoneally to each cohort in a volume of 300 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibody and control samples were then administered once per week for the duration of the study. Tumor growth was measured about every 7 day with calipers. The study was completed after 8 doses of antibody. Body weights of the animals were recorded once per week for the duration of the study. At the end of the study all animals were euthanized according to CCAC guidelines.
[0118] AR104A1289.2.2 reduced tumor growth in the MDA-MB-231 in vivo prophylactic model of human breast cancer. Treatment with Arius antibody AR104A1289.2.2 reduced the growth of MDA-MB-231 tumors by 94.2 percent (p=0.0003, t-test), compared to the buffer treated group, as determined on day 76, 26 days after the last dose of antibody ( FIG. 6 ).
[0119] There were no clinical signs of toxicity throughout the study. Body weight measured at weekly intervals was a surrogate for well-being and failure to thrive ( FIG. 7 ). There was no significant difference in mean body weight between the groups at the end of the treatment period. There was also no decrease in mean body weight within each group from the start to the end of the study.
[0120] In summary, AR104A1289.2.2 was well-tolerated and significantly decreased the tumor burden in this human breast cancer xenograft model.
EXAMPLE 5
In Vivo Tumor Experiments with PC-3 Cells
[0121] Examples 1, 3 and 4 demonstrated that AR104A1289.2.2 had anti-cancer properties against colon, pancreatic and breast human cancer indications. To demonstrate efficacy in a prostate cancer model, AR104A1289.2.2 was tested in a PC-3 prostate cancer xenograft model. With reference to FIGS. 8 and 9 , 6 to 8 week old female SCID mice were implanted with 1 million human prostate cancer cells (PC-3) in 100 microliters PBS solution injected subcutaneously in the right flank. The mice were randomly divided into 2 treatment groups of 8. On the day after implantation, 20 mg/kg of AR104A1289.2.2 test antibody or buffer control was administered intraperitoneally to each cohort in a volume of 300 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibody and control samples were then administered once per week for the duration of the study. Tumor growth was measured about every 7 day with calipers. The study was completed after 8 doses of antibody. Body weights of the animals were recorded once per week for the duration of the study. At the end of the study all animals were euthanized according to CCAC guidelines.
[0122] AR104A1289.2.2 reduced tumor growth in the PC-3 in vivo prophylactic model of human prostate cancer. Treatment with Arius antibody AR104A1289.2.2 reduced the growth of PC-3 tumors by 76.5 percent (p=0.0003, t-test), compared to the buffer treated group, as determined on day 33, 4 days after the 5 th dose of antibody ( FIG. 8 ). All mice were still alive on day 33. The study continued until day 53, 3 days after the last dose. Three mice in the control group and one mouse in the antibody-treated group were removed by day 53 due to large tumor volume and tumor lesions which were study endpoints. However, on day 53, AR104A1289.2.2 still significantly reduced the growth of PC-3 tumors by 61.3 percent (p=0.0483, t-test).
[0123] There were no clinical signs of toxicity throughout the study. Body weight measured at weekly intervals was a surrogate for well-being and failure to thrive ( FIG. 9 ). The mean body weight decreased significantly in the buffer treated group from the start to the end of the study (p=0.0001, t-test). However, there was no significant difference in the mean body weight of the AR104A1289.2.2 treated mice from the start to the end of the study.
[0124] In summary, AR104A1289.2.2 was well-tolerated and significantly decreased the tumor burden in this human prostate cancer xenograft model. AR104A1289.2.2 has demonstrated efficacy against four different human cancer indications: colon, pancreatic, breast and prostate. Treatment benefits were observed in several well-recognized models of human cancer disease suggesting pharmacologic and pharmaceutical benefits of this antibody for therapy in other mammals, including man. In toto, this data demonstrates that the AR104A1289.2.2 antigen is a cancer associated antigen and is expressed on human cancer cells, and is a pathologically relevant cancer target.
EXAMPLE 6
Isolation of Competitive Binders
[0125] Given an antibody, an individual ordinarily skilled in the art can generate a competitively inhibiting CDMAB, for example a competing antibody, which is one that recognizes the same epitope (Belanger L et al. Clinica Chimica Acta 48:15-18 (1973)). One method entails immunizing with an immunogen that expresses the antigen recognized by the antibody. The sample may include but is not limited to tissues, isolated protein(s) or cell line(s). Resulting hybridomas could be screened using a competition assay, which is one that identifies antibodies that inhibit the binding of the test antibody, such as ELISA, FACS or Western blotting. Another method could make use of phage display antibody libraries and panning for antibodies that recognize at least one epitope of said antigen (Rubinstein J L et al. Anal Biochem 314:294-300 (2003)). In either case, antibodies are selected based on their ability to displace the binding of the original labeled antibody to at least one epitope of its target antigen. Such antibodies would therefore possess the characteristic of recognizing at least one epitope of the antigen as the original antibody.
EXAMPLE 7
Cloning of the Variable Regions of the AR104A1289.2.2 Monoclonal Antibody
[0126] The sequences of the variable regions from the heavy (V H ) and light (V L ) chains of monoclonal antibody produced by the AR104A1289.2.2 hybridoma cell line can be determined. RNA encoding the heavy and light chains of immunoglobulin can be extracted from the subject hybridoma using standard methods involving cellular solubilization with guanidinium isothiocyanate (Chirgwin et al. Biochem. 18:5294-5299 (1979)). The mRNA can be used to prepare cDNA for subsequent isolation of V H and V L genes by PCR methodology known in the art (Sambrook et al., eds., Molecular Cloning, Chapter 14, Cold Spring Harbor laboratories Press, N.Y. (1989)). The N-terminal amino acid sequence of the heavy and light chains can be independently determined by automated Edman sequencing. Further stretches of the CDRs and flanking FRs can also be determined by amino acid sequencing of the V H and V L fragments. Synthetic primers can be then designed for isolation of the V H and V L genes from AR104A1289.2.2 monoclonal antibody and the isolated gene can be ligated into an appropriate vector for sequencing. To generate chimeric and humanized IgG, the variable light and variable heavy domains can be subcloned into an appropriate vector for expression.
(i) Monoclonal Antibody
[0127] DNA encoding the monoclonal antibody (as outlined in Example 1) is readily isolated and sequenced using conventional procedures (e.g., by using oligonucleotide probes that are capable of binding specifically to genes encoding the heavy and light chains of the monoclonal antibodies). The hybridoma cell serves as a preferred source of such DNA. Once isolated, the DNA may be placed into expression vectors, which are then transfected into host cells such as E. coli cells, simian COS cells, Chinese hamster ovary (CHO) cells, or myeloma cells that do not otherwise produce immunoglobulin protein, to obtain the synthesis of monoclonal antibodies in the recombinant host cells. The DNA also may be modified, for example, by substituting the coding sequence for human heavy and light chain constant domains in place of the homologous murine sequences. Chimeric or hybrid antibodies also may be prepared in vitro using known methods in synthetic protein chemistry, including those involving crosslinking agents. For example, immunotoxins may be constructed using a disulfide exchange reaction or by forming a thioether bond. Examples of suitable reagents for this purpose include iminothiolate and methyl-4-mercaptobutyrimidate.
(ii) Humanized Antibody
[0128] A humanized antibody has one or more amino acid residues introduced into it from a non-human source. These non-human amino acid residues are often referred to as “import” residues, which are typically taken from an “import” variable domain. Humanization can be performed the method of Winter and co-workers by substituting rodent CDRs or CDR sequences for the corresponding sequences of a human antibody (Jones et al., Nature 321:522-525 (1986); Riechmann et al., Nature 332:323-327 (1988); Verhoeyen et al., Science 239:1534-1536 (1988); reviewed in Clark, Immunol. Today 21:397-402 (2000)).
[0129] A humanized antibody can be prepared by a process of analysis of the parental sequences and various conceptual humanized products using three-dimensional models of the parental and humanized sequences. Three dimensional immunoglobulin models are commonly available and are familiar to those skilled in the art. Computer programs are available which illustrate and display probable three-dimensional conformational structures of selected candidate immunoglobulin sequences. Inspection of these displays permits analysis of the likely role of the residues in the functioning of the candidate immunoglobulin sequence, i.e. the analysis of residues that influence the ability of the candidate immunoglobulin to bind its antigen. In this way, FR residues can be selected and combined from the consensus and import sequence so that the desired antibody characteristic, such as increased affinity for the target antigen(s), is achieved. In general, the CDR residues are directly and most substantially involved in influencing antigen binding.
[0000] (iii) Antibody Fragments
[0130] Various techniques have been developed for the production of antibody fragments. These fragments can be produced by recombinant host cells (reviewed in Hudson, Curr. Opin. Immunol. 11:548-557 (1999); Little et al., Immunol. Today 21:364-370 (2000)). For example, Fab′-SH fragments can be directly recovered from E. coli and chemically coupled to form F(ab′) 2 fragments (Carter et al., Biotechnology 10:163-167 (1992)). In another embodiment, the F(ab′) 2 is formed using the leucine zipper GCN4 to promote assembly of the F(ab′) 2 molecule. According to another approach, Fv, Fab or F(ab′) 2 fragments can be isolated directly from recombinant host cell culture.
EXAMPLE 8
A Composition Comprising the Antibody of the Present Invention
[0131] The antibody of the present invention can be used as a composition for preventing/treating cancer. The composition for preventing/treating cancer, which comprises the antibody of the present invention, are low-toxic and can be administered as they are in the form of liquid preparations, or as pharmaceutical compositions of suitable preparations to human or mammals (e.g., rats, rabbits, sheep, swine, bovine, feline, canine, simian, etc.) orally or parenterally (e.g., intravascularly, intraperitoneally, subcutaneously, etc.). The antibody of the present invention may be administered in itself, or may be administered as an appropriate composition. The composition used for the administration may contain a pharmacologically acceptable carrier with the antibody of the present invention or its salt, a diluent or excipient. Such a composition is provided in the form of pharmaceutical preparations suitable for oral or parenteral administration.
[0132] Examples of the composition for parenteral administration are injectable preparations, suppositories, etc. The injectable preparations may include dosage forms such as intravenous, subcutaneous, intracutaneous and intramuscular injections, drip infusions, intraarticular injections, etc. These injectable preparations may be prepared by methods publicly known. For example, the injectable preparations may be prepared by dissolving, suspending or emulsifying the antibody of the present invention or its salt in a sterile aqueous medium or an oily medium conventionally used for injections. As the aqueous medium for injections, there are, for example, physiological saline, an isotonic solution containing glucose and other auxiliary agents, etc., which may be used in combination with an appropriate solubilizing agent such as an alcohol (e.g., ethanol), a polyalcohol (e.g., propylene glycol, polyethylene glycol), a nonionic surfactant (e.g., polysorbate 80, HCO-50 (polyoxyethylene (50 mols) adduct of hydrogenated castor oil)), etc. As the oily medium, there are employed, e.g., sesame oil, soybean oil, etc., which may be used in combination with a solubilizing agent such as benzyl benzoate, benzyl alcohol, etc. The injection thus prepared is usually filled in an appropriate ampoule. The suppository used for rectal administration may be prepared by blending the antibody of the present invention or its salt with conventional bases for suppositories. The composition for oral administration includes solid or liquid preparations, specifically, tablets (including dragees and film-coated tablets), pills, granules, powdery preparations, capsules (including soft capsules), syrup, emulsions, suspensions, etc. Such a composition is manufactured by publicly known methods and may contain a vehicle, a diluent or excipient conventionally used in the field of pharmaceutical preparations. Examples of the vehicle or excipient for tablets are lactose, starch, sucrose, magnesium stearate, etc.
[0133] Advantageously, the compositions for oral or parenteral use described above are prepared into pharmaceutical preparations with a unit dose suited to fit a dose of the active ingredients. Such unit dose preparations include, for example, tablets, pills, capsules, injections (ampoules), suppositories, etc. The amount of the aforesaid compound contained is generally 5 to 500 mg per dosage unit form; it is preferred that the antibody described above is contained in about 5 to about 100 mg especially in the form of injection, and in 10 to 250 mg for the other forms.
[0134] The dose of the aforesaid prophylactic/therapeutic agent or regulator comprising the antibody of the present invention may vary depending upon subject to be administered, target disease, conditions, route of administration, etc. For example, when used for the purpose of treating/preventing, e.g., breast cancer in an adult, it is advantageous to administer the antibody of the present invention intravenously in a dose of about 0.01 to about 20 mg/kg body weight, preferably about 0.1 to about 10 mg/kg body weight and more preferably about 0.1 to about 5 mg/kg body weight, about 1 to 5 times/day, preferably about 1 to 3 times/day. In other parenteral and oral administration, the agent can be administered in a dose corresponding to the dose given above. When the condition is especially severe, the dose may be increased according to the condition.
[0135] The antibody of the present invention may be administered as it stands or in the form of an appropriate composition. The composition used for the administration may contain a pharmacologically acceptable carrier with the aforesaid antibody or its salts, a diluent or excipient. Such a composition is provided in the form of pharmaceutical preparations suitable for oral or parenteral administration (e.g., intravascular injection, subcutaneous injection, etc.). Each composition described above may further contain other active ingredients. Furthermore, the antibody of the present invention may be used in combination with other drugs, for example, alkylating agents (e.g., cyclophosphamide, ifosfamide, etc.), metabolic antagonists (e.g., methotrexate, 5-fluorouracil, etc.), anti-tumor antibiotics (e.g., mitomycin, adriamycin, etc.), plant-derived anti-tumor agents (e.g., vincristine, vindesine, Taxol, etc.), cisplatin, carboplatin, etoposide, irinotecan, etc. The antibody of the present invention and the drugs described above may be administered simultaneously or at staggered times to the patient.
[0136] The preponderance of evidence shows that AR104A1289.2.2 mediates anti-cancer effects through ligation of an epitope present on cancer cell lines. Further it could be shown that the AR104A1289.2.2 antibody could be used in detection of cells which express the epitope which specifically binds thereto; utilizing techniques illustrated by, but not limited to FACS, cell ELISA or IHC.
[0137] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0138] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification.
[0139] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. Any oligonucleotides, peptides, polypeptides, biologically related compounds, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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The present invention relates to a method for producing cancerous disease modifying antibodies using a novel paradigm of screening. By segregating the anti-cancer antibodies using cancer cell cytotoxicity as an end point, the process makes possible the production of anti-cancer antibodies for therapeutic and diagnostic purposes. The antibodies can be used in aid of staging and diagnosis of a cancer, and can be used to treat primary tumors and tumor metastases. The anti-cancer antibodies can be conjugated to toxins, enzymes, radioactive compounds, and hematogenous cells.
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[0001] This application claims the benefit of Canadian patent application no. 2,698,434 filed Apr. 1, 2010, which is incorporated by reference herein in its entirety.
FIELD
[0002] The present invention relates to a connection system that functions via a cross-sectional dimension disparity between a duct section located in a solid body object and a restraint device in place on a flexible interconnection device that traverses that duct such that a compressive action occurs that unidirectionally fixes the components together in proportion to the magnitude of the forces involved. The primary expected application is as a marine anchoring system connection technique.
BACKGROUND
[0003] There has long been a need to connect an anchoring object to an anchored object using a flexible interconnection device. The flexible qualities of the flexible interconnection device allow dynamic conditions that typically aggravate the condition of various components, especially the terminal linkage components between the flexible interconnection device and the anchor or anchored object. Mitigating this aggravation requires particular designs and materials that at present are more of a compromise rather than a solution or are limited in application. One method to effect a terminal connection that minimizes aggravation in a particular application is that used in the manufacture of pre-stressed concrete products as detailed in U.S. Pat. No. 3,820,832 (Brandestini et al.). A method to minimize the detrimental effects of flexing of an interconnecting device used in off-shore floating structures is detailed in U.S. Pat. No. 6,422,316 B1 (Shutz et al.).
SUMMARY
[0004] There is provided a connection system comprised of an object, such as a concrete anchor, with an interior surface that defines an open ended duct with a reducing cross-sectional dimension aspect, a flexible interconnection device, such as a fibrous strap, and a restraint device, such as a wedge. The flexible interconnection device is smaller in cross-sectional dimension than all the cross-sectional dimensions of the duct. The reducing cross-sectional dimension aspect of the duct is smaller than at least one of the cross-sectional dimensions of the ends of the duct. A restraint device in place on a portion of the flexible interconnection device forms a combination that is smaller in cross-sectional dimension than the duct end that it enters but of a larger cross-sectional dimension than a reducing cross-sectional dimension of the duct that is smaller than the duct end through which the combination entered. When a force acting on the flexible interconnection device initiates and maintains surface contact between a larger cross-sectional dimension of the combination and a smaller reducing cross-sectional dimension of the duct, they become fixed together. The effectiveness of the fixed condition is proportional to the magnitude of the force that causes the surface contact. The siting of the surface contact can be such that it; allows the whole combination to be within the confines of the duct, is able to utilize a robust structure to protect the connection from incidental damage, provides structural strength for the connection and allows the use of optimal materials and complementary shapes that maximize the effectiveness of the fixed condition. The fixed condition is able to be readily discontinued when the forces that cause the surface contact are no longer present or are negated. With the duct being integral within an object the quality of the connection which fixes the components together is based on the most dependable, robust and durable aspects of the object's structure and components non-integral to the object are able to be readily replaced and composed of optimal materials.
[0005] There will hereinafter be described and illustrated embodiments in which the object that defines a duct is; a concrete block anchor, a concrete block anchor with multiple ducts, a concrete anchor designed to contain extraneous weight, a bell buoy designed to float on water, not integral to a bell buoy that floats on water but is an adjunct to it and demountable from it, or an object that attaches to and alters the relative weight of a portion of a flexible interconnection device. It will be apparent to one skilled in the art that there are numerous types of materials, forms and dimensions for these objects and the structures they are combined with.
[0006] There will hereinafter be described and illustrated embodiments in which; a restraint device is similar to a truncated cone that is bisected into symmetric halves that have large grooves on a face, the restraint device is similar to a rod, the restraint device is similar to a wedge, and the restraint device is a specific alteration to the basic form of the flexible interconnection device itself. It will be apparent to one skilled in the art that there are numerous variations in sizes, materials and shapes to be utilized to perform as a restraint device.
[0007] There will hereinafter be described and illustrated embodiments in which a flexible interconnection device is; a fibrous rope which has been fixed to a duct, a fibrous strap which has been fixed to a duct, a chain which has been fixed to a duct, and a single undefined flexible interconnection device that is fixed to ducts in two separate objects, one of which is intermediately located between an anchored and an anchoring object. It will be apparent to one skilled in the art that these illustrations represent a duct grip anchor system wherever a duct with a reducing cross-sectional dimension section, a flexible interconnection device and a restraint device interact so as to become fixed together according to the teachings of the duct grip anchor system.
[0008] It will be appreciated that there are numerous engineering design criteria that must be considered before designing an anchoring system. As such, all the following descriptions and illustrations are to be considered for explanatory purposes only.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These features and other features will become apparent from the following descriptions in which reference is made to the appended drawings, the drawings are intended for the purpose of illustration only and are not intended to be in any way limiting, wherein:
[0010] FIG. 1 is a top view of a terminal object shaped and of a weight so as to be suitable as an anchor that utilizes the teachings of the duct grip anchor system. Also illustrated are ancillary components that enhance the application of the teachings of the duct grip anchor system.
[0011] FIG. 2 is a side view of section Detail ‘A-A’ of FIG. 1 .
[0012] FIG. 3 is a top view of a terminal object designed to be an anchor similar to that illustrated in FIG. 1 and in accordance with the teachings of the duct grip anchor system there is an exterior surface and interior surfaces that defines two ducts, the smaller one of which is intended for a temporary lifting duty.
[0013] FIG. 4 is a side view of section Detail ‘B-B’ of FIG. 3
[0014] FIG. 5 is a side view of a terminal object shaped so as to be suitable as an anchor, to contain extraneous weight so as to be effective as an anchor and utilize the teachings of the duct grip anchor system.
[0015] FIG. 6 is a top view of FIG. 5 .
[0016] FIG. 7 is a side view of a terminal object designed to be anchored and float on a liquid and utilize the teachings of the duct grip anchor system such that they are integral to the terminal object.
[0017] FIG. 8 is a side view of an object designed to be anchored and float on a liquid and attached to it are separable objects that are in accordance with the teachings of the duct grip anchor system. The attached objects are adjunct to and demountable from an object that is designed to float.
[0018] FIG. 9 is a side view of a restraint device which is similar in shape to a symmetrically bisected truncated cone, each half having a very large groove centered lengthwise on the bisecting face and shaped such that they will effectively compress a flexible interconnection device placed between them in the grooves.
[0019] FIG. 10 is a side view of section Detail ‘C-C’ of FIG. 9 .
[0020] FIG. 11 is a side view of a restraint device which is shaped similar to a round rod.
[0021] FIG. 12 is a side view of section Detail ‘D-D’ of FIG. 11 .
[0022] FIG. 13 is a side view of a restraint device which is similar in shape to a wedge.
[0023] FIG. 14 is a side view of section Detail ‘E-E’ of FIG. 13 .
[0024] FIG. 15 is a view of a restraint device which is an alteration of the basic form of the flexible interconnection device, in this example by forming a knot in the flexible interconnection device.
[0025] FIG. 16 is a side view of a duct grip anchor system which utilizes a flexible interconnection device which is a fibrous rope, a restraint device similar to the knot as illustrated in FIG. 15 , and a terminal object that defines a duct similar to the section detail illustrated in FIG. 2 .
[0026] FIG. 17 is a side view of a duct grip anchor system which utilizes a flexible interconnection device which is a fibrous strap, a restraint device similar to the wedge as illustrated in FIG. 13 , and a terminal object that defines a duct similar to the section detail that is illustrated in FIG. 2 .
[0027] FIG. 18 is a side view of a duct grip anchor system which utilizes a flexible interconnection device which is a chain, a restraint device similar to the rod as illustrated in FIG. 11 , and a terminal object that defines a duct similar to the section detail illustrated in FIG. 2 but which also includes angular features.
[0028] FIG. 19 is a side view of a duct grip anchor system in which the object that defines the duct is neither a terminal anchor object or terminal anchored object but is an intermediate object which is intended to alter the relative weight of a section of the flexible interconnection device while allowing beneficial movement of the flexible interconnection device to which it is fixed.
[0029] FIG. 20 is a side view of a protective sleeve and a fastener that holds it in place when they are applied over a section of a flexible interconnection device that may be prone to damage.
[0030] FIG. 21 is a side view of a protective sleeve fastener device of a type that utilizes Velcro™.
[0031] FIG. 22 is a view of section Detail ‘F’.
DETAILED DESCRIPTION
[0032] A duct grip anchor system will now be described with reference to FIG. 1 through FIG. 7 . A section of a flexible linking component of an anchor system connects two terminal objects. A terminal object has at least one open ended duct with a first duct end with a first cross-section dimension that is larger than a combination that is comprised of a flexible interconnection device and a restraint device in place on the flexible interconnection device. Adjacent to the first duct end is an interior section of the duct that; has a reducing cross-section dimensions section smaller than the first cross-sectional dimension, resembles a flared shape which diminishes in it's cross-section towards the interior of the terminal object and will accommodate a combination within the confines of the duct. The duct also has a second duct end with a second cross-sectional dimension outside of which is a portion of the flexible interconnection device, referred to as a bitter end, that is intended to be attached to a separate terminal object. A force applied to the bitter end that places the combination within the reducing cross-sectional dimension section of the duct and initiates contact between a surface of the larger cross-sectional dimensions of the combination and a surface of the smaller reducing cross-sectional dimension section of the duct is referred to as a tensional force. The forced contact between those two surfaces results in an interaction that causes them to become fixed together while the tensional force exists. A portion of a flexible interconnection device called a reserve component, is that portion which remains outside the first duct end and is intended to aid in the disassembly of the connection, not to form a link to another object. A placement maintaining device that can utilize a placement maintaining feature on a restraint device keeps a restraint device in place on the flexible interconnection device to form a combination independent of contact with the interior portion of the duct. FIG. 7 and FIG. 8 illustrate that the duct grip anchor system is also a functional connection system when it is a minor structure that is demountable from, and an adjunct to, a major structure. FIG. 9 through FIG. 15 illustrate devices and techniques which act as restraint devices. FIG. 16 through FIG. 18 illustrate duct grip anchor system components in place together as they could be when in service. FIG. 19 illustrates an intermediate object which is designed to attach to and alter the relative weight, such as the buoyancy, of selected portions of a flexible interconnection device that forms a link between two terminal objects, such as an anchored object and it's anchor, while still allowing beneficial mobility of the flexible interconnection device to which it is attached. FIG. 20 illustrates a protective sleeve and it's fastening device for a flexible interconnection device. FIG. 21 and FIG. 22 illustrate views of the protective sleeve and it's components.
Structure and Relationship of Parts:
[0033] Referring to FIG. 1 and FIG. 2 the duct grip anchor system includes a flexible interconnection device 22 , such as a rope, connected to terminal objects composed of a material that provides the strength to maintain a specific shape, such as a concrete block being an anchoring terminal object 10 , with an exterior surface 12 and an interior surface 14 that define an open ended duct. The duct has a first end with a first cross-sectional dimension 16 and a second end with a second cross-sectional dimension 18 and an interior portion 20 that will be described into three sections; a reducing cross-sectional dimension section 20 A, a consistent cross-sectional dimension section 20 B and an increasing cross-sectional dimensions section 20 C. A flexible interconnection device 22 , such as a rope, with a restraint device 24 , such as a split cone, in place on it forms a combination 26 . A restraint device 24 may have a placement maintaining feature 36 and utilize a placement maintaining device 38 , such as elastomeric self-adhesive tape, to ensure that a combination 26 can be formed and maintained independent from contact with the interior portion 20 . A tensional force 32 is a force acting on that section of a flexible interconnection device 22 referred to as a bitter end section 28 , which is that portion of the flexible interconnection device 22 that has exited the second duct end with a second cross-sectional dimension 18 and is intended to be connected to a separate terminal object, so as to cause the flexible interconnection device 22 to traverse the interior portion 20 of the duct. The tensional force 32 also places a combination 26 within the confines of an interior portion 20 described as a reducing cross-sectional dimension section 20 A and causes surface contact to occur between the areas of a reducing cross-sectional dimension section 20 A that are smaller in cross-sectional dimension than and the larger cross-sectional dimensions surface areas of a combination 26 . The surface contact pressure causes an interaction between a combination 26 and a reducing cross-sectional dimension section 20 A such that as the contact pressure increases in magnitude due to a tensional force 32 , so does the effectiveness of fixing a combination 26 and a reducing cross-sectional dimension section 20 A together. When a flexible interconnection device 22 does not have a tensional force 32 acting on it or experiences a negating force 34 , which is a force sufficient to withdraw the flexible interconnection device 22 out of the anchoring terminal object 10 through the first duct end with a first cross-sectional dimension 16 , a combination 26 and a reducing cross-sectional dimension section 20 A lose the surface contact between them and thus become unfixed and separable. A portion of the flexible interconnection device 22 remaining outside the first duct end with a first cross-sectional dimension 16 is called a reserve component 30 whose purpose is to readily allow the application of a negating force 34 . A pilot line 40 , which is a readily handled flexible line typically being of a much smaller cross-sectional dimension relative to the flexible interconnection device 22 , may be temporarily attached to the flexible interconnection device 22 to facilitate the installation or removal of a flexible interconnection device 22 from an interior portion 20 . A protective sleeve 44 held in place by a protective sleeve fastener 46 covers and protects a flexible interconnection device 22 from damage, such as where it is within and exits from the increasing cross-sectional dimension section 20 C to outside the second duct end with a second cross-sectional dimension 18 . FIG. 19 illustrates an intermediate object 42 , such as a concrete ovoid form, that alters the relative weight, such as the buoyancy, of a bitter end section on which it is fixed in placed but still allows that bitter end section beneficial movement. A restraint device 24 in place on the bitter end section 28 forms a combination 26 that interacts with an interior portion 20 reducing cross-sectional dimension section 20 A of the intermediate object 42 so as to fix the intermediate object 42 to the bitter end section 28 .
Operation:
[0034] The use and operation of the duct grip anchor system will now be described with reference to FIG. 1 and FIG. 2 . An anchoring terminal object 10 , such as a concrete block anchor, is placed in position. A flexible interconnection device 22 has a restraint device 24 put in place, and if required held in place with a placement maintaining device 38 , such as elastomeric tape, to create a combination 26 . Temporarily attached to what is intended to be a bitter end section 28 of a flexible interconnection device 22 is a pilot line 40 that facilitates the installation of a flexible interconnection device 22 into a duct first end with a first cross-sectional dimension 16 , through an interior portion 20 , out the duct second end with a second cross-sectional dimension 18 and onwards towards a separate terminal object. A tensional force 32 applied to a bitter end section 28 of a flexible interconnection device 22 to ensures the continued traversing movement of a flexible interconnection device 22 brings the surfaces of a combination 26 and an interior portion 20 reducing cross-sectional dimension section 20 A into contact with a resultant interaction so as to fix them together, after which a bitter end section 28 can be secured to a separate terminal object (e.g. anchored terminal object 10 B FIG. 7 ). A pilot line 40 may now be removed from a bitter end section 28 . A tensional force 32 such as that via a dynamic relative position or static tension between two terminal objects maintains a surface contact pressure between a combination 26 and an interior portion 20 reducing cross-sectional dimension section 20 A that is proportional to the tensional force 32 , an interaction and, thus, a connection to fix a flexible interconnection device 22 to an anchoring terminal object 10 . When it is required to disengage a flexible interconnection device 22 from an object that uses the duct grip anchor system, a tensional force 32 is removed or a negating force 34 can be applied to a reserve component 30 . In a situation where the duct grip anchor system utilizes multiple flexible interconnection devices, restraint devices and terminal objects the definitions for shared components may change according to the point of reference and sequence of the discrete actions occurring in the process of the installation of components.
Variations:
[0035] In order for the duct grip anchoring system to be fully understood, some possible variations will be described. When the components are identical, identical reference symbols will be assigned.
[0036] FIG. 3 and FIG. 4 have been included to illustrate that multiple ducts are suitable in a single object. Since one of these ducts is noticeably different, it is assigned different designations. FIG. 3 and FIG. 4 have an object with an exterior surface 12 and interior surface 14 and a second but different interior surface designated 14 . 1 , a duct with an interior portion 20 and a second duct with an interior portion different in size and shape so it is designated interior portion 20 . 1 . Interior portion 20 . 1 has three sections, reducing cross-sectional dimension section 20 . 1 A, consistent cross-sectional dimension 20 . 1 B and increasing cross-sectional dimension 20 . 1 C, and a first end with a first cross-sectional dimension 16 . 1 and a second end with a second cross-sectional dimension 18 . 1 .
[0037] FIG. 5 and FIG. 6 are included to illustrate a type of terminal object that is intended to be an anchor but have minimal inherent weight, so it is shaped to be suitable as an anchor and able to contain extraneous weight so as to be effective as an anchor. The minimum inherent weight facilitates it's movement and placement. The purpose of this object is the same as for the similar anchoring terminal object 10 but the shape and qualities are noticeably different so it is designated minimum weight anchoring terminal object 10 A.
[0038] FIG. 7 illustrates a terminal object that floats and is anchored instead of anchoring, so it is labeled a anchored terminal object 10 B.
[0039] FIG. 8 illustrates a different class of terminal object. Whereas previously a major structure performed additional functions as well as defining an inherent duct, this major structure performs functions but has no inherent duct. Instead, connected to it is a class of terminal object that is a minor structure that defines an inherent duct and that is intended to function solely as a connection system and is attached to and is an adjunct to the major structure, so it is called a terminal minor object 10 C.
[0040] FIG. 9 through FIG. 15 illustrate a variety of restraint devices which may be utilized on flexible interconnection devices. Due to the ubiquitous nature of the rope form, restraint device 24 illustrated in FIG. 9 and FIG. 10 could be in common use. FIG. 11 and FIG. 12 illustrates a rod shaped restraint device 24 A. FIG. 13 and FIG. 14 is included to illustrate the flat wedge shaped restraint device 24 B, which is appropriate in combination with strap forms of flexible interconnection devices. FIG. 15 illustrates a restraint formed by altering the basic form of a section of a flexible interconnection device 22 by contorting that section, in this case by forming a knot, to become restraint device 24 C.
[0041] FIG. 16 through FIG. 18 illustrate restraint devices in place on their compatible flexible interconnection devices, some of which are different than flexible interconnection device 22 . FIG. 16 illustrates the form of a flexible interconnection device 22 that has been altered into a knot, which is restraint device 24 C. FIG. 17 illustrates a wedge shaped restraint device 24 B in place on a fibrous strap that is flexible interconnection device 22 A. FIG. 18 illustrates restraint device 24 A in place on a metallic chain that is flexible interconnection device 22 B. There is also illustrated one section of the interior portion 20 that is different than before as it features an angular form, so it is designated interior portion reducing cross-sectional dimension section 20 . 2 A.
[0042] FIG. 19 illustrates an intermediate object 42 that neither anchors nor is anchored but acts as a method to alter the relative weight, such as by being an ovoid form composed of concrete, of a section of a flexible interconnection device 22 to which the intermediate object 42 has become fixed.
[0043] FIG. 20 through to FIG. 22 are illustrations of a protective sleeve 44 and a protective sleeve fastener device 46 that secures them to flexible interconnection devices.
Advantages/Cautionary Warning:
[0044] Typical anchor systems utilizing flexible interconnection devices have terminal connective components that are peripheral to the main structure of the anchored item and the anchoring item. This peripheral location; makes the terminal connective components prone to impact damage, requires supplementary structural extensions between the primary object of the anchored or anchoring item and the peripheral connective components, inherently have areas of great friction and stress that must be mitigated as they are unwanted and only cause degradation to the connection, makes replacement and repair of degraded connective components frequently difficult, uneconomical and occasionally impossible which would make the anchor and anchoring item useless. When compounding factors such as corrosive environments and abrupt variable stress vector forces are added to the basic detrimental properties of the peripheral location of the connective components, the remedial solutions escalate costs but are usually limited in effectiveness since there must be compromises in the materials used due to design restriction paradigms.
[0045] With the duct grip anchor system as described, the disadvantages of the peripheral location for terminal connective components for flexible interconnection devices are eliminated or minimized. The terminal connective components can be secure and protected within a duct that is integral to a robust structure, friction and stress generated in service are used to benefit the connection, optimal materials can be used, and placement or replacement of consumable components is simple and always possible. Ancillary components are available to allow different and more efficient methods of installation and repair. Examples would be pilot lines attached to bitter ends and reserve components and that are brought up to and secured to the anchored item in a marine application. That would allow the replacement of the flexible interconnection system and restraint device to the anchor without the need for divers, saving effort and money. New installations could have pilot lines utilized while placing new anchors at their service site, then the service flexible interconnection device with it's compatible restraint device could be installed later without the need for divers. Floating anchored items could have; the duct grip anchor system simply and permanently located out of degrading liquid environments, allow the length of the flexible interconnection device to be adjusted conveniently as required, have spare length of the flexible interconnection device kept ready for service, connective components readily accessible to be fixed or unfixed, components that are reusable and are easily replaced. The ducts are always able to accommodate a connection of some sort short of catastrophic degradation to their primary structure.
[0046] Marine anchor system component service life benefits by reducing abrupt impulse forces on the connective components during variable vector tension forces events on the flexible interconnection device by increasing it's weight. This weight may be inherent, such as with metal chain, or extraneous to the flexible interconnection device, such as with securing an intermediate object to a section of a fibrous rope that connects two objects. That weight may also become a problem by adding substantial weight where it contributes nothing to benefit system performance but increases cost and friction on the components or the difficulty to fix it in place without contributing to the degradation of the flexible interconnection device at the area of connection.
[0047] The duct grip anchor system allows for the use of optimal amounts, types of materials and calculated specific placement of beneficial weight for reducing tension impulse loads.
[0048] In this patent document a reference to an element by the indefinite article “a” or “an” does not exclude the possibility that more that more than one of the elements is present or could be added, unless the context requires that there be one and only one of the elements.
[0049] The following claims are to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, and what can be obviously substituted. Those skilled in th art will appreciate that various adaptions and modifications of the described embodiments can be configured without departing from the scope of the claims. The illustrated embodiments have been set forth only as examples and should not be taken as limiting the invention. It is to be understood that, within the scope of the following claims, the invention may be practiced other than as specifically illustrated and described.
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An anchor system including at least one flexible interconnection device. A restraint device is on the at least one flexible interconnection device. The restraint device and the flexible interconnection device form a combination. The anchor system includes a terminal object having an exterior surface and an interior surface that defines a duct for receiving a portion of the flexible interconnection device. The duct has a first end, a second end, and an interior portion. The terminal object includes a metallic-iron-free load-bearing structure that defines a load-bearing surface such that when the flexible interconnection device is positioned through the duct and when a tensional force is applied to the interconnection device, the tensional force urges the combination against the load-bearing surface such that the metallic-iron-free load-bearing structure impedes the combination from traversing the duct in response to the tensional force by bearing the resultant load.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of this invention resides within the field of food dispensing and water dispensing portable kiosks, bars, and related items. It more particularly involves those types of beverage dispensing carts and portable cafes that are used to provide various fast food items in a portable manner. To this extent it involves the washing and maintenance of food service items and the hands and other portions of a food service operator in order to maintain a degree of cleanliness in the dispensing of food.
2. Prior Art
The prior art with regard to food dispensing and cleanliness pertaining thereto has not been addressed with regard to outdoor and portable food dispensing carts. Such food dispensing carts are becoming more popular in such areas as corporate locations, office environments, malls, and shopping areas. Such food carts are sophisticated at this point wherein they can provide multiple prepared foods and beverages as well as limited food preparation on the cart.
In order to provide such food preparation and cleanliness, the health authorities have generally requested and in many cases demanded that the purveyor of such food have access to health facilities and in particular an area where they can wash their hands. Many times to date, the food dispensing carts had to be in an area where a building with restroom facilities or sinks provided such cleaning and sanitary conditions. As can be appreciated, this created an inconvenience and a problem for those dispensing and purveying food.
This invention solves the problem by providing a portable sink for cleanliness and health. The sink specifically has a fresh water source and a reservoir for the used water which is referred to as gray water. The sink has a faucet with hot and cold running water, the hot water being provided through a heater. Additionally thereto, an electrical outlet provides for heating and pumping of the water on a continuum. Further enhancement, of the overall health facilities provided by the sink is enhanced by a towel dispenser and a soap dispenser.
The entire unit is a portable unit and can be moved on casters or wheels. It is of a light weight plastic material which allows for not only portability but ease of handling. Further to this extent, the invention has ease of maintenance and operating capabilities not known in the prior art.
SUMMARY OF THE INVENTION
In summation, this invention comprises a portable sink with hot and cold running water having a fresh water supply, a heater, a pump, and certain regulators and controls for allowing the flow of hot and cold water from a spigot into a sink and for further retention by a reservoir after use.
More specifically, the invention comprises a portable sink mounted on rollers or casters. The housing and mounting includes a separable sink portion and cabinet portion. The sink portion has a sink, soap dispenser, faucets, and a spigot for hot and cold water.
The cabinet is mounted on wheels and houses four tanks of water, two of which are fresh water tanks and the other two are used water or gray water tanks.
In order to heat the water, an electrical inlet provides heat through a switch outlet box to a heater having heater coils and controls. The heater is supplied by water from the fresh water tanks through a pump under pressure. In order to provide for safety, a bypass valve or blow tube compensates for over pressure.
The pump also provides cold water to the spigot outside of the circuit of the water heater for an appropriate mixture of hot and cold water through the spigot.
In order to provide for and compensate as to pressure irregularities and pumping irregularities, a hammer arrester is placed in the line. The hammer arrester leading from the pump allows for absorption of pressure irregularities through the arrester so that a smooth and moderated transit of water takes place as delivered from the pump.
The water heater and controls including the switch outlet and pump are mounted on a water heater rack and control panel. The water heater rack and control panel can be removed for servicing, giving it ready access to a user. Further to this extent, the fresh water tanks and gray water tanks can be moved and rotated from their respective positions in an easy and facile manner by merely opening the front doors of the sink cabinet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a frontal perspective view of the sink and cabinet of this invention.
FIG. 2 shows a front elevation view of the sink and cabinet with the doors opened and fragmented.
FIG. 3 shows a sectional view of the sink and cabinet detailing the area of the water heater controls and other portions as seen in the direction of lines 3 — 3 of FIG. 2 .
FIG. 4 shows a sectioned top plan view of the water tanks and the heater and controls as seen in the direction of lines 4 — 4 of FIG. 1 .
FIG. 5 shows a perspective view, as partially sectioned through one of its walls, of the water heater rack and control rack which can be removed from the cabinet.
FIG. 6 shows a detailed view of the side wall of the cabinet and structure as seen through circle 6 of FIG. 3 .
FIG. 7 shows a line diagram and schematic view of the water and control flow path.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking specifically at FIG. 1 it can be seen that a cart 10 has been shown with a cabinet portion 12 and a sink portion 14 . The cabinet portion 12 and the sink portion 14 can be referred to also as the cabinet module and the sink module.
The cabinet module has two doors 16 and 18 . The two respective doors 16 and 18 are supported on hinge points that can be seen in the way of hinge elements at the upper and lower portions in the form of elements or knuckles 20 and 22 . These respective hinge elements or knuckles have an intermediate hinge portion between them, and on the cabinet itself as opposed to the doors, formed as intervening hinge portions 24 and 26 .
The hinge elements 20 and 22 are supported by a three inch long pin at the bottom namely through hinge portion 22 to the respective cabinet, and with a lock clip. A pivot pin is also inserted through portions 24 and 26 as well as in portion 20 to effectuate a hinge element so that the doors 16 and 18 can be opened and closed.
Doors 16 and 18 are frictionally secured with a hook and striker to allow them to be retained in closed relationship to the cabinet 12 . A pair of opening handles 17 and 19 are cut into the doors 16 and 18 to allow easy access by merely positioning one's hand and pulling the openings.
The cabinet 12 is supported by four wheels or casters, two of which are wheels 30 and 32 . Wheels 30 and 32 are stationary rigid casters. A pair of swivel wheels 34 and a second swivel wheel in a like position which is not seen also supports the cabinet. These respective swivel wheels have a brake element which can be seen in FIG. 2 in the form of the little brake pedal 36 that can be pressed downwardly to prevent the wheels 34 from turning. The wheels and casters can be of any configuration but are shown supported by brackets. These brackets can be substituted, and the wheels 30 and 34 supported in any other suitable manner.
The sink module 14 has a stainless steel two cavity sink 40 that is within the sink module. The sink module has a standard stopper in the form a basket stopper and is drained as will be seen hereinafter through a line to the used or gray water tanks. The sink module incorporates handle areas 42 supported by brackets extending from the sink module 14 . The handle areas 42 can be locked to a kiosk of the type that is shown in Design Patent Application Serial No. 29/091,005 and connected as an entire unit. This effectively allows for a food server and a sink to be placed in connected relationship. Also, the handles 42 can be not only locked to a service cart but can be used independently as a towel rack.
At the back of the sink module 14 is a raised apron 46 . The raised apron 46 circumscribes the sink in part to protect from back splashing as well as supporting a towel rack 48 and a soap dispenser 40 . This allows one to use the sink with soap and water while later drying ones hands. The back splash panel or apron can be formed in any suitable manner such as a cowling or in the U shaped configuration around the sink module 14 as shown.
Attached to the sink module 14 is a spigot 52 and a hot water faucet 54 and cold water faucet 56 both with connections to a source of water. These respective faucets 54 and 56 allow water to pass from the spigot 52 into the sink area for washing ones hands.
Looking more specifically at FIGS. 2 and 3 it can be seen that the sink module 14 and the cabinet 12 have been formed as two respective portions. These two respective portions are formed by rotational molding and then attached at a later point in time. As can be understood, this provides for an ease of molding as well as attachment and dis-attachment of the two respective portions namely sink module 14 and cabinet 12 . It also provides for access downwardly into the interior of the cabinet and the equipment therein.
The respective rotational molding operation is such wherein it provides for a polyeurethane foam as can be seen in FIG. 6 namely urethane foam 60 with a polyethylene surface 62 . The polyethylene surface 62 and foam can be utilized in any particular manner so as to effect a firm and rigid sandwich structure forming the entire cabinet and sink module. Other foam sandwich configurations, wall configurations and materials instead of the polyethylene material for the wall surface can be utilized. Also, it should be understood that the polyeurethane foam core namely polyeurethane foam 60 provides for stiffening as well as insulation and sound absorption.
Looking again more specifically at FIGS. 3, 4 , and 5 it can be seen that the cabinet area has a total of four tanks. Specifically, a pair of fresh water tanks 66 and 68 are shown on the right side of FIG. 2 . Used water tanks 70 and 72 are shown to the left side. The two respective tanks 70 and 72 can be referred to as gray water tanks after use of the water. The respective tanks 66 and 68 are connected for pumping water for cold water usage as well as hot water usage in the manner that will be described hereinafter. The foregoing tanks 66 , 68 , 70 , and 72 comprise the fresh water reservoirs respectively and used water reservoirs and must be filled and removed respectively after their contents have been utilized and filled.
Looking more specifically at FIGS. 2 and 3, it can be seen that a water heater 80 has been shown. The water heater 80 has a control panel 82 with an on/off switch 84 and a dial 86 for purposes of controlling temperature. This respective control panel 82 allows the water heater 80 to maintain hot water in the system.
The water heater 80 can be made of a plastic exterior surface with foam cell material for insulating the heater. It has a heater element interiorly thereof which can be in a metal or stainless container. It can be a metal tank or it can be stainless with the heating element passing therethrough on the interior portion of the heater 80 . The heater element can be a looped wire coil or any other type of known electrical element wherein a passage of water therethrough is heated by either an electric heating element or other means of electrical heating to heat the water passing through the coil.
An inlet connection 90 and outlet 92 is provided for the water passing into the heater 80 to be heated and then passed to the hot water outlet, which is controlled by the hot water faucet and inlet 54 .
In order to control the unit electrically, a switch outlet box 100 is shown having a cord 102 connected thereto and a plug 104 . This provides power to the system. The switch outlet box 100 has a light 106 to indicate when the unit is on and a switch 108 which provides the function of being an on/off switch. Two respective outlets shown as a duplex outlet 110 provide the outlet for plugging in the pump to be referred to hereinafter and the heater 80 .
A pump 112 is shown mounted by four bolts to the water heater and mounting rack 116 . The water heater and mounting rack 116 is shown with a side wall 118 having a lifting handle 120 and a sliding or pulling handle 122 . The rack 116 has two bracing walls 124 and 126 that are connected to a bottom portion 128 .
Pump 112 as previously stated is mounted to the rack 116 and specifically on the wall 118 , by the four respective bolts.
The pump 112 fundamentally is of a diaphragmatic type having an electrically powered diaphragm that is within the general area 130 .
The heater 80 has been provided with what can be referred to as a flow and pressure relief system in the form of a fluid connection 170 . Relief is provided through a tube 172 or conduit that can be referred to as a blow tube that turns downwardly and terminates at an opening 174 . An opening that is indexed thereto namely opening 176 is provided in the rack 116 so that tube 172 can pass therethrough. This allows for overflow or relief of any pressure therein through the tube 172 .
In order to complete the water circuit, a hammer arrester or what can be referred to generally as a flow moderator for variable pressure flows has been provided, namely hammer arrester 180 . The hammer arrester 180 is formed with an inlet 182 that allows the flow from the pump 112 to pass therethrough and then through an outlet 184 . Interiorly of the hammer arrester 180 is a piston and cylinder that moderates the flow of water pressure surges. Water surges are accommodated and the commonly known effect of “hammering” in a water line is diminished.
In order to connect the outlets of tanks such as tanks 66 and 68 , an outlet 190 is provided. These outlets 190 are such wherein they can be connected to hose couplings or other couplings so that flow can pass therethrough to the pump 112 . In order to fill the tanks 66 and 68 , inlets 192 are provided in each tank.
The used water or gray water passes into tanks 70 and 72 through inlets 196 at the top of each tank connected to the outlet of the sink.
In order to lift the tanks 66 and 70 , handles 198 and 200 are provided respectively in tanks 66 and 70 .
Each respective tank and its connections such as connections 192 and 196 can be provided with a threaded coupling or any other means to connect a hose or outlet in the way of a conduit thereto. In particular, looking at FIG. 7, it can be seen that the outlet from tank 66 which is a five gallon fresh water tank is drawn or pumped from its outlet by pump 112 . The outlet of pump 112 is then delivered through the inlet 182 of the hammer arrester 180 . This tends to moderate and limit the line banging or “hammering” which could possibly happen through surges of the pump 112 .
The outlet from the hammer arrester 180 , namely outlet 184 is delivered to a T 220 . The T 220 allows water to flow into the heater 80 while at the same time going to the cold water inlet and faucet 56 . Water from the T 220 can be directed to the cold water connection 222 or to the hot water connection 224 after being heated. Furthermore, T 220 can be equipped with a non-reverse flow valve so that flow will not be allowed to flow back into the system. Also, connections to the tank outlets such as outlet 190 can be provided with a reverse flow function as well as other portions in the lines to prevent flow of any water back into the fresh water system.
The water from the hot portion of the T outlet namely outlet 224 flows into the inlet of the heater inlet 90 . After it is heated it flows from outlet 92 of the heater to the hot water faucet and connection 54 . Both connections obviously 54 and 56 are connected to the spigot 52 . Outlet from the sink 40 can flow by gravitation through sink outlets 230 and 232 to the inlet 196 of the used or gray water tanks 70 . Thus it can be seen that the entire circuit of the respective flow from the fresh water tanks 66 and 68 to the used or gray water tanks 70 and 72 provides for fresh water that can be used for washing purposes.
The unit is controlled and powered through the electrical connector namely electrical connector 100 which is in turn provided with a circuit breaker. It has an on/off switch 108 and a light 106 to indicate the on/off condition. Duplex outlets 110 provide the power to the respective pump 112 and to the heater 80 providing for the complete electrical circuit to allow the system to work.
Various sensors can be utilized to allow initiation of pumping such as when pressure drops, the pump 112 starts to pressurize the outlet as a consequence of pressure dropping through the opening of outlets 54 and 56 when the faucets are turned. Also, other sensors can be utilized to provide discrete inlets to the heater 80 or to the cold water circuit in any suitable manner. Various back flow and pressure relief members can be utilized throughout the system for preventing back flow and over pressurization.
From the foregoing, it can be seen that this invention is a substantial step over the art of providing for a portable sink to be used by the food service industry.
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A portable sink having a sink module and a hot and cold water outlet connected to a spigot and a used water outlet from said sink connected to a cabinet mounted on wheels having at least one door to access the interior thereof. At least one tank for fresh water and a reservoir for used water is mounted in the cabinet. An electrical connection for powering a pump and a heater connected to the outlet of the pump has an outlet connected to the hot water outlet and a connection from the pump to the cold water outlet. A hammer arrester diminishes line surges and fluidic pounding from the pump, and a flow check valve prevents back flow to the fresh water tank.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of Swiss patent application No. 01379/08, filed Aug. 28, 2008, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The invention is related to a device and a method for separating the contents and the package of used capsules which have been used for the preparation of beverages. Furthermore, the invention is related to a press as well as a coffee machine.
PRIOR ART
[0003] It is known to use capsules for the preparation of beverages, particularly the preparation of coffee, containing a contents which is extractable by means of water, and thus especially containing ground coffee, which remains at least partially in the capsule after its usage or in other words after the making of the coffee. The capsules can be made of metal, which is especially advantageous for the conservation of ground coffee contained therein. Such capsules are for example known under the trademark Nespresso®. The embodiment of the capsule of metal makes a reuse of this material desirable, however, the contents remaining in the used capsule after making the beverage may be annoying for the reuse of the metal. Therefore, the manufacturers of such capsules offer recycling collection sites and a central recycling, wherein a big number of capsules are being shredded and metal and coffee grounds are being separated by means of known method steps like sieving.
BRIEF SUMMARY OF THE INVENTION
[0004] It is the task of the invention to provide a further possibility for users of capsules to deliver these to the recycling after use.
[0005] This task is solved by a device for the capsule by capsule separation of the contents and of the package material of used capsules for the making of beverages, said device being adapted for at least partly destroying the capsules so that a large part of the coffee grounds are separated from the package material.
[0006] In particular the device is adapted to destroy the capsule by compressing or crunching and/or cutting open and/or puncturing at least a part of the capsule. Because the device for separating capsule material of the package from the contents of the capsule is intended for and adapted for in such a way that the separation takes place for each capsule separately or piece by piece, respectively, (but wherein several capsules can as well be separable at the same time but each one separately, the separation of individual capsules in package and contents after their use, particularly at home or at the office, can be carried out by the user in a simple way. Thereafter, the package can be delivered to the metal recycling in a known way and the contents can be disposed of separately, in the case of coffee grounds for example can also be composted. The invention provides for a separate, manually actuatable device for the home and office area, or for the incorporation into the machine making the beverage, thus particularly into a coffee machine. The device is adapted for the at least partial destruction of the capsule, in order to thereby separate the contents of the used capsule from the capsule material. Compressing or crunching, a cut to open or a puncture of at least a part of the capsule is meant by at least partial destruction.
[0007] In a first preferred embodiment of the device, it is executed in such a way, that the capsule is compressed at least partially above an opening of the device by means of a crunching means, whereby the contents of the capsule comes out through the opening while the capsule remains above the opening, such that a separation of capsule and contents takes place. This can be executed in different ways for manual or motor-driven actuation and both as separate device or device within a beverage making machine, especially a coffee machine. Within a preferred embodiment, a base having an intake which is intended for holding the capsule in a predefined position above the opening is provided, as well as a crunching means located above the base, by which the crunching force can be applied to a capsule located in position onto the base. This embodiment is equally suitable for a simple manual device and can form the basis for a device within a coffee machine. The opening is preferably arranged respectively dimensioned in such a way, that the capsule is held solely alongside its edge. This yields an as good as possible emptying of the capsule. It became evident that it is preferable to execute the opening with a side wall which enlarges in a conic way towards the capsule, facilitating the taking out of the destroyed, particularly crunched capsule.
[0008] In a preferred embodiment the crunching means is pivotable around an axis and is particularly arranged in a pivotable way at the base, also yielding a simple assembly, particularly if the crunching means is arranged or formed by an arm which is formed in one piece with the base. It is particularly preferred that the crunching means or crunching arm is provided with a crunching body which is substantially formed by a part of a body of revolution. The crunching body can particularly be formed by a part of a paraboloid. In such embodiments, the crunching body is particularly intended for and shaped such as to crunch for example a round cavity into the capsule, and particularly intended and dimensioned to form a crater-shaped cavity into the capsule, wherein its side walls remain partially undeformed as crater walls. It has become evident that a sufficient emptying of a capsule by a small effort by the user of the device is possible by means of such a pressing in of the back side of the capsule into the capsule and at the same time leaving the side wall of the capsule at least partially in place. This is particularly suitable for i.e. Nespresso® capsules, which are impinged by the crunching body from the water inlet side. The effort or necessary force is particularly to be considered within an device which is handled manually and whereby, because of lack of space and for a simple construction only a small lever for the hand force is provided, and particularly also if the device is formed for accommodating more than one capsule at the same time, particularly for two capsules. Depending on the available force, a crunching of substantially the entire capsule can occur and the crunching body can also be formed in a different way, and can for example be a simple plate-shaped part.
[0009] Within an embodiment, a cutting means is provided at the base and particularly at the intake, being intended for forming a partially or entirely circular cut into the capsule, enhancing the crunching and the emptying. Within an embodiment, the crunching means can have at least a positioning element which is intended for adjusting the mutual position of capsule and crunching means respectively for avoiding an evasion of the capsule during the crunching. Within a preferred embodiment, a removal aid for the destroyed capsule is provided, particularly in combination with the opening with conic side wall. The removal aid can be formed as spring means which presses the destroyed capsule out of its intake and/or the removal aid can be provided as recess which facilitates the taking out of the destroyed capsule from the intake.
[0010] For a simple operation of an device which is actuated manually, it can have a flat base for the positioning of the device onto a surface, for example on a table, wherein the opening is disposed at a distance from the surface, particularly by forming a collecting space, particularly a container, for receiving the contents of at least a capsule. The container has preferably provided with a closure. Furthermore, the device can have an opening, for example at the joint between base and crunching means, which allows a hanging of the device to a hook for its storage during non-use.
[0011] Instead of the preferred crunching of the capsule, the separation of package and contents can for example be provided as well by a pulling out of the contents by means of a spiral conveying means and/or by means of a striking means or vibrating means or by means of a detergent for flushing out the contents with water or by means of a blowing means and/or a sucking means. All embodiments of the device can be formed as separate devices or be arranged within a beverage making machine, particularly a coffee machine.
[0012] Thus, the invention is also related to a coffee machine with a device for separating package and contents of a used capsule.
[0013] Furthermore, the task is solved by using a press for the separation of package and contents.
[0014] Furthermore the task is solved by means of the method in which a single capsule is positioned with its extraction side above an opening and is at least partly destroyed, and particularly impinged upon and crunched by a crunching means from the side of intended water ingress into the capsule when extracting a beverage therefrom, such that at least a part of the contents of the capsule exits out of the capsule and falls through said opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings, which show:
[0016] FIG. 1 a graphical view of an embodiment of a device to which the invention relates;
[0017] FIG. 2 a side view of the device of FIG. 1 ;
[0018] FIG. 3 a graphical view of a further embodiment of the device;
[0019] FIG. 4 a side view of the device according to FIG. 3 ;
[0020] FIG. 5 a graphical view of an example of the device with cutting means;
[0021] FIG. 6 a vertical sectional view of the device of FIG. 5 ;
[0022] FIG. 7 a graphical view of an embodiment with removal aid;
[0023] FIG. 8 a vertical sectional view of the embodiment of FIG. 7 ;
[0024] FIG. 9 a graphical view of an embodiment with positioning means at the crunching body;
[0025] FIG. 10 a further embodiment in side view;
[0026] FIG. 11 a further embodiment in graphical view;
[0027] FIG. 12 a further embodiment in graphical view;
[0028] FIG. 13 the embodiment of FIG. 12 in vertical sectional view;
[0029] FIG. 14 schematically an embodiment of the device within a coffee machine;
[0030] FIG. 15 schematically rough an embodiment of the device with a removing of the contents from below; and
[0031] FIG. 16 schematically an embodiment of the device with a removing of the contents by water or compressed air.
DETAILED DESCRIPTION OF THE INVENTION
[0032] In the following, examples of the invention are being shown, wherein same reference numerals are used within the figures for same elements of the different embodiments. In some Figures, the device is shown together with a capsule which contents are supposed to be separated from the package part by means of the device. It can be a capsule containing powder coffee, which is particularly known by the trademark Nespresso®. This capsule has an extraction side which is formed by a thin foil which is partly destroyed during the extraction of the beverage. The device is equally suitable for other capsules, for which a separation of capsule material and contents is desirable.
[0033] FIGS. 1-4 show first embodiments of a device 1 , whereby the contents of the capsule are separated from the package by crunching the capsule, whereby the contents, particularly the coffee grounds, comes out of the already used capsule. In FIG. 1 it is evident that the device 1 has a base 2 , wherein a support or rest, respectively, for the capsule 10 is provided. When the capsule is located within the rest 3 , it comes to lie above an opening which allows the exit of the contents when the capsule is being crunched. This will be explained in the following by referring to FIG. 3 . The capsule 10 normally lies within the rest 3 of the base 2 in such a way, that it comes to lie with its extraction side, not shown in the figure, through which the product extracted from the contents has flown out from the capsule, above the opening of the device. The crunching force then preferably acts upon the side 12 of the capsule 10 which is located opposite of the extraction side, which, in case of the Nespresso®-capsule, is the side by which water enters the capsule for the extraction.
[0034] In the example shown in FIGS. 1 and 2 an elongated element 5 is provided as crunching means, which could serve as plate-shaped crunching means as it is, which however preferably carries an especially formed crunching body 6 . The element 5 and the base 2 are connected with each other by means of a joint 4 and can particularly be executed in one piece out of plastic or metal. For the crunching of the capsule 10 , the element 5 is manually pivoted in the direction of the capsule 10 , to apply a crunching force to the capsule. After the crunching, the element 5 is pivoted back upwards. This can be carried out just by manual actuation by the operator, supported by the reset force of the joint, if it is formed accordingly, and/or a return spring which is not shown in the figures but can additionally be provided, bringing the element 5 in the shown initial position again, wherein the crunched capsule 10 can be removed and wherein a further used capsule can be inserted into the device. Multiple supports or rests, respectively, for the simultaneous but separate separation of multiple capsules, particularly two capsules, could equally be provided.
[0035] FIG. 3 and FIG. 4 show a further embodiment, wherein the base 2 forms itself a cavity underneath rest 3 . In the previous embodiment only the opening was formed in the base 2 , such that the contents of the crunched capsule did exit from the base directly downwards. However, in the embodiment according to FIG. 3 and FIG. 4 , the contents of the capsule enters the cavity 9 in the base 2 , which forms a collecting space, through the opening 8 . The contents or coffee grounds, respectively, can thus be disposed of easier. In FIG. 3 and FIG. 4 the capsule 10 is not shown, giving a better view of the rest 3 and the opening 8 . The rest 3 forms a take-up for the capsule with an edge or rim 13 , respectively, on which the capsule lies with its edge which can be a flange-like edge 11 , as shown in FIG. 1 . Also the embodiment of FIG. 3 and FIG. 4 has an upper element 5 as a crunching means, on which a crunching body 6 is preferably arranged. Here, the joint part 4 between base and upper element 5 is formed in a different way and generates a reset force for the returning of the element 5 into the base position after the crunching movement. The shown joint is particularly suitable for the manufacture of the device out of plastic. The function of the shown devices is such that the capsule 10 , which used contents and in particular the coffee grounds is supposed to be separated from the rest of the capsule, is placed into the rest 3 above the opening 8 . Thereafter, a crunching force is exerted by the arm and crunching body 5 , 6 upon face 12 of the capsule, deforming the metal and thereby forcing the contents out of the capsule through its extraction side that has been partly destroyed and thus weakened during the extraction procedure in the machine for the extraction of the beverage or coffee machine, respectively. The contents of the crunched capsule fall through the opening 8 of the device into its container 9 in the case of the embodiment of FIGS. 3 and 4 and to an area below the base 2 in the embodiment of FIG. 1 and FIG. 2 , i.e. on the surface of a table on which the device has been placed.
[0036] In the shown example, the crunching body 6 is part of a body of revolution with the rotational axis a ( FIG. 4 ). This is a preferred embodiment which, in case of a suitable (adapted to the capsule to be separated) dimensioning of the crunching body, leads to a pressing in of the capsule wall 12 in the direction of the inside of the capsule, while the side wall 14 of the capsule remains at least partly, approximately in its previous shape. Nevertheless, the contents of the capsule are removed to a large extent by pressing in face 12 of the capsule. Thereby, a good separation between the metal of the capsule and the contents of the capsule can be reached, which allows that the metal part can be provided to the metal recycling without problems. This preferred way of crunching by the body 6 reduces the force to be exerted compared to a full crunching of the capsule. However, a stronger crunching inclusive destroying of the side walls can also take place with the crunching body and also a substantially complete crunching can occur.
[0037] In an embodiment, the cavity 9 can be formed in such a way, as to form a container, particularly a container which is closable at the front side of the base by means of a cover. The opening 8 can also be sealable, for example by positioning the crunching means by means of a support in such a way, that it closes the opening at least partly.
[0038] FIG. 5 and FIG. 6 show a further embodiment, for which a cutting means 23 for cutting the capsule on the extraction side is provided within the rest 3 . This can enhance the crunching respectively the emptying of the contents. In the example, the cutting means is shown continuously circular, such that a round part of the capsule can be completely cut out. However, only a partly circular cutting means is preferred, such that the cut part of the capsule stays in contact with the rest of the capsule and is removed from the device with it and is not disposed of through the opening 8 together with the contents.
[0039] FIG. 7 and FIG. 8 show a spring means 15 which, in the shown example, is formed in one piece with the base 2 and has an elevated edge part 17 of the intake 3 being executed in a springy way by the cuts 16 in the base. This spring means counteracts the crunching force and ensures, after the ending of the crunching, that the emptied capsule is again slightly lifted out of the rest 3 , by this facilitating the removal out of the rest 3 . In an embodiment, the spring means 15 can be provided together with the already described cutting means 23 (combined with it or separately). FIG. 9 shows an embodiment, wherein the crunching body 6 has positioning means 26 , which avoid a shifting and an evasion of the capsule 10 when crunching means 5 , 6 acts upon the capsule. The positioning means 26 also can enhance the crunching and cause, in the example shown, a particularly stronger crunching of the side wall 14 of the capsule.
[0040] FIG. 10 shows a further embodiment, wherein the base 2 is formed curved, such that more space for the contents of the capsule is provided underneath the opening 8 , but wherein no cavity 9 is provided for the contents.
[0041] FIG. 11 shows a further embodiment, wherein an actuator 25 is provided at the upper side of the crunching means, which is supposed to facilitate the manipulation and to avoid a glide off of the hand of the operator during the crunching of the capsule.
[0042] Beside the shown manual devices for the separation of the capsule and its contents, also motor driven devices can be provided and also such devices, which provide the separation of capsule and contents in a different way as by crunching. Such devices can particularly be provided within a coffee machine.
[0043] FIG. 12 shows a further embodiment in perspective view, which in FIG. 13 is shown in a sectional view. Thereby it is evident that the side wall 8 ′ of the opening 8 is conically shaped and enlarges towards the capsule and thus towards the rest 3 . This facilitates the removal of the destroyed capsule, which may deform into the opening during destruction. Preferably, a removing aid is further provided, which can be the already described removal aid with spring means 15 - 17 . Instead of or additionally to this embodiment of the removal aid, it can be executed in the form of a recess 47 which extends into the rest 3 , facilitating the gripping of the destroyed capsule. Within the shown embodiment with a base and crunching means connected by means of a joint 4 , the recess 47 is preferably arranged on the side of the intake showing towards the joint.
[0044] FIG. 14 shows in a schematic way only an embodiment, wherein the device is provided in a coffee machine 20 which is not explicitly depicted and of which only a casing part is denoted. This device also has a rest 3 for the capsule which is not shown. The device can be formed in such a way that the used capsule has to be inserted into the intake 3 manually, after the capsule has been removed from the coffee machine. But the device can as well work together with the capsule ejection mechanism of the coffee machine in such a way that after the extraction, the capsule is passed directly from this mechanism of the coffee machine into the rest 3 . In the example shown, a crunching body 6 is now provided for crunching, being movable downwards, for example by means of a mandrel 37 driven by a motor 36 , for the crunching of the capsule, and being movable back upwards after crunching. In this way, the capsule is crunched in a similar way as in the shown manual embodiments, here however by means of a linear movement instead of a pivoting movement of the crunching body, pressing out the contents of the capsule through the opening 8 into the cavity 9 . The separation can additionally be enhanced by means which make the device 1 vibrate or which carry out a striking movement.
[0045] FIG. 15 shows in a rough schematic way an embodiment of the device 1 , which can be provided in a coffee machine or separately as a stand alone device. Thereby, the capsule which is again not shown, is arranged on a rest 3 , however it is held at the upper part, meaning at its face 12 , by a limitation 40 which acts on the face 12 and is fixed for the separation. Limitation 40 can be removable for the insertion of the capsule 10 onto the rest 3 . Also in this example, the capsule can be inserted manually or it is conveyed to the rest 3 by the coffee machine. For the separation of the contents of the capsule from the package, here an element 41 which is movably driven in the direction of the arrow is provided, which has a removal body 42 for the separation of the contents of the capsule, being pressed in from the extraction side of the capsule into the capsule. Thereby, the contents can come out of the capsule and fall into the container 9 through the opening 8 , as soon as the removal body 42 is pulled out of the capsule again. It also can be provided that the driven removal body 42 can rotate around its longitudinal axis and it can have removal rips 43 which are arranged helically wound, feeding out the contents of the capsule. Also in this case vibration means or striking means can additionally be provided, enhancing the separation of the contents from the capsule.
[0046] FIG. 16 shows an embodiment, wherein the capsule gets onto the rest 3 again, either manually or directly by the coffee machine, and wherein a water supply means 50 is inserted into the capsule from the top through the face 12 of the capsule, and subsequently the capsule is rinsed with water. Particularly, the cutting means 23 not shown here can be provided, cutting open the capsule on the extraction side. The mixture of water and contents then gets into the cavity 9 which has water outlet openings 29 at its bottom side, which are formed in such a way, that water can exit out of them downwards, however the contents remains in the cavity 9 . This embodiment is preferably arranged within a coffee machine, wherein a supply for water under pressure is provided. In a modification of this embodiment, air can be blown into the capsule by the way shown or in a similar way, in order to blow out the contents, or air can be sucked out from the capsule in order to suck out its contents.
[0047] While there are shown and described presently preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practised within the scope of the following claims.
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For separating the contents from the package of used capsules ( 10 ) for making beverages, particularly capsules of metal containing coffee, an device ( 1 ) respectively a press, particularly a manual press, is preferably used, by which the capsule is crunchable, such that its contents comes out of the extraction side of the capsule, where it is collected and can be disposed of separately from the capsule.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to provisional application Ser. No. 61/706,177 filed Sep. 27, 2012 hereby expressly incorporated by reference herein.
BACKGROUND
Depth buffering is the standard technique to resolve visibility between objects in a rasterization pipeline. A depth buffer holds a depth value for each sample, representing the current closest depth of all previously rendered triangles overlapping the sample. The depth value, d, can be defined in a number of ways.
In a stochastic rasterizer with many samples per pixel, the depth buffer bandwidth requirements are much higher than usual, and the depth data should be compressed if possible. Most depth buffer compression schemes exploit the fact that the depth values from a triangle can be represented by a plane. Unfortunately, for moving and defocused triangles, this is no longer true.
In a static (2D) rasterizer, the depth function can be expressed as a plane. This is exploited by many depth compression schemes. Plane encoding is different from other algorithms because it exploits information coming directly from the rasterizer, and therefore uses the exact same plane equation representation in the compressor as in the rasterizer. The depth information is stored as a set of planes and a per-sample plane selection mask for each tile. When there are few triangles overlapping a tile, storing the plane equations and selection masks is more compact than simply storing the per-sample depth. However, when too many triangles overlap a tile, the storage cost of multiple depth planes is higher than directly storing the per-sample depth values. For each tile, depth compression may then be disabled, or another compression algorithm applied (which usually cannot compress as well as plane encoding).
While plane encoding is very useful for static, two-dimensional rasterization, it does not suffice to use static planes for higher order rasterization, where the depth function is more complex.
BRIEF DESCRIPTION OF THE DRAWINGS
Some embodiments are described with respect to the following figures:
FIG. 1 is a schematic depiction for one embodiment;
FIG. 2 is a flow chart for a sequence according to one embodiment;
FIG. 3 is a depiction of motion blur for 4×4 pixels with four samples per pixel indicated by four layers;
FIG. 4 is a depiction for defocus blur;
FIG. 5 is a system depiction of one embodiment; and
FIG. 6 is a front elevation view of one embodiment.
DETAILED DESCRIPTION
Plane encoding may be generalized to include stochastic effects, such as motion blur and depth of field. The depth function coefficients are computed in the rasterizer and are passed to the compressor. A standard plane encoding uses three coefficients per depth function (i.e., a plane) on the form d=A*x+B*Y+C, to represent the depth of a triangle. When the triangle undergoes stochastic effects such as motion blur and depth of field, the depth function is no longer a plane. However, we can still derive a depth function on the form d=f(x, y, u, v, t) by storing more coefficients per triangle.
The benefits of this method include, in some embodiments, a compression algorithm that is substantially more efficient than previous methods. This is made possible by providing an analytical representation of the depth function directly from the rasterizer setup, avoiding the cost of finding a lower order representation in the compressor, as in previous methods. Unlike previous plane compression methods, this method is well suited for motion blur and depth of field effects, and does not break down for these cases. Furthermore, since this method operates on an analytical representation, it may work equally well for floating point precision depth buffers in some embodiments.
The mathematical expression for the depth functions may be analyzed in the case of motion blur and depth of field. Although the expressions may appear somewhat complicated, they can be effectively simplified, and compact forms for the depth functions can be used to design algorithms with substantially better average compression ratios for stochastic rasterization.
In general, the compressors and decompressors exist in a depth system. Compression/decompression is applied to a tile, which typically is the set of depth samples inside a rectangular screen-space region.
Suppose we have a triangle with clip space vertex positions p k =(p k x ,p k y ,p k w )), kε{0,1,2}. In homogeneous rasterization, the two-dimensional homogeneous (2DH) edge equation, e k =n k ·x, corresponds to a distance calculation of an image plane position, x=(x, y, 1), and the edge plane, which passes through the origin, with, for example, n 2 =p 0 ×p 1 .
An arbitrary per-vertex attribute, A k , may be interpolated over the triangle. Each of the barycentric coordinates, B 0 , B 1 , B 2 , of the triangle can be found by evaluating and normalizing the corresponding 2DH edge equation, such that
B k = e k e 0 + e 1 + e 2 .
The interpolated attribute, A, for a given sample point, x, can then be found by standard barycentric interpolation:
A ( x , y ) = ∑ A k B k = A 0 e 0 + A 1 e 1 + A 2 e 2 e 0 + e 1 + e 2 ( 1 )
The depth value, d, is formed by interpolating z and w individually, and then performing a division:
d ( x , y ) = z ( x , y ) w ( x , y ) = ∑ z k B k ∑ w k B k = ∑ z k e k ∑ w k e k ( 2 )
If we look at the denominator, we see that:
∑ w k e k = ( ∑ w k p i × p j ) · x = ( 0 , 0 , det ( p k , p i , p j ) ) · ( x , y , 1 ) = det ( p k , p i , p j ) , ( 3 )
which is independent of (x, y). This is six times the signed volume of the tetrahedron spanned by the origin and the triangle, which can be used to detect if a triangle is backfacing.
If we use a standard protection matrix, such that the transformation of (z cam ,1) to clip space (z,w) can be expressed as (c.f., the standard Direct3D projection matrix):
z=az cam +b, w=z cam , (4)
then the depth function can be simplified. The coefficients a and b depend solely on z near and z far . Combining Equations 2 and 4 and simplifying gives us:
d ( x , y ) = z ( x , y ) w ( x , y ) = a + b ∑ e k ∑ w k e k ( 5 )
We have now derived the 2D depth function, which is widely used in rendering systems today. However, Equation 5 can be augmented so that it holds for depth sampled in higher dimensions. For example, adding motion blur and depth of field means that z, w, and the edge equations are functions of shutter time, t, and lens position, (u, v). Thus we can write the depth function on a more general form:
d ( x , y , … ) = a + b ∑ e k ( x , y , … ) ∑ w k ( x , y , … ) e k ( x , y , … ) , ( 6 )
where . . . should be replaced with the new, augmented, dimensions.
For higher-order rasterization, including motion blur and defocus blur, static plane equations are not suitable to represent the depth functions, because the depth functions are much more complex in those cases. For motion blur, the depth function is a cubic rational polynomial, for example. Therefore, the plane encoding method is generalized in order to also handle motion blur and defocus blur.
The generalized plane encoding (GPE) algorithm is nearly identical to static plane encoding, except that the plane equations for motion blurred and/or defocused plane equations use more storage, and that the depth functions are more expensive to evaluate. This can be seen in Equation 6, which is based on more complicated edge equations, e k , and w k -components. However, the required number of coefficients for specific cases can be substantially reduced, which makes it possible to fit more planes in the compressed representation. This in turn makes for higher compression ratios and faster depth evaluation.
Similar to static plane encoding, the compression representation for generalized depth (motion and defocus blur, for example) includes a variable number of generalized plane equations, and a plane selector bitmask per sample. If there are at most n plane equations in the compressed representation, then each sample needs [log n] bits for the plane selector bitmask. Next, we simplify the depth functions for higher-order rasterization.
We begin the depth function derivation for motion blur by setting up time-dependent attribute interpolation on matrix form. Then, we move on to reducing the number of coefficients needed to exactly represent the interpolated depth of a triangle.
One approach to store the depth functions for a motion blurred triangle is to retain all vertex positions at t=0 and t=1, which are comprised of a total of 4×3×2=24 coordinate values (e.g., floating-point). If the projection matrix is known, and can be stored globally, then only 3×3×2=18 coordinate values are needed, as z then can be derived from w, using Equation 4, for example. In the discussion below, we show how the depth function can be rewritten and simplified to contain only 13 values, which enables more efficient storage.
In the derivation below, we assume that vertices move linearly in clip space within each frame. Thus, the vertex position, p k , becomes a function of time:
p k ( t )= q k +td k , (7)
where d k is the corresponding motion vector for vertex k. Since the vertices depend on time, the 2DH edge equations form 2nd degree polynomials in t:
e k ( x,y,t )=( p i ( t )× p j ( t ))· x =( f k t 2 +g k t+h k )· x, (8)
where
h k =q i ×q j , g k =q i ×d j +d i ×q j , f k =d i ×d j . (9)
For convenience, we rewrite the edge equation on matrix form:
e k ( x , y , t ) = t 2 C k x T ,
where
C k = ( - h k - - g k - - f g - ) , ( 10 )
and t 2 =(1, t, t 2 ), x=(x, y, 1), and C k is a 3×3 matrix as shown above.
By combining the matrix notation and Equation 1, we have a general expression of how to interpolate a vertex attribute, A k , over a motion blurred triangle:
A
(
x
,
y
,
t
)
=
t
2
(
∑
A
k
C
k
)
x
T
t
2
∑
C
k
x
T
.
(
11
)
However, if the attribute itself varies with t, e.g., A k (t)=A k 0 +tA k d we obtain a general expression for interpolating a time-dependent attribute over the triangle, with an numerator of cubic degree:
A ( x , y , t ) = t 2 ( ∑ ( A k 0 + t A k d ) C k ) x T t 2 ∑ C k x T = t C A x T t 2 ∑ C k x T ( 12 )
where t=(1, t, t 2 , t 3 ), and the vertex attributes, A k , are multiplied with each C k and summed to form the 4×3 coefficient matrix C A . This form may be used to interpolate the w clip attribute at the pixel center.
To compute the depth function
d = z w ,
we perform barycentric interpolation of the z- and w-components of the clip space vertex positions, which are now linear functions of t, e.g., z(t)=q z +td z and w(t)=q w +td w .
Let us consider the depth function, d(x,y,t):
d ( x , y , t ) = z ( x , y , t ) w ( x , y , t ) = t 2 ( ∑ ( q k z + t d k z ) C k ) x T t 2 ( ∑ q k w + t d k w ) C k ) x T = t C z x T t C w x T , ( 13 )
Where the 4×3 matrix:
C z = ∑ ( q k z [ C k 0 0 0 ] ︸ C _ k + d kz [ 0 0 0 C k ] ︸ C _ k ) , ( 14 )
and the 4×3 matrix C w is defined correspondingly. We now have the depth function on a convenient form, but the number of coefficients needed is no less than directly storing the vertex positions. We will now examine the contents of the coefficient matrixes, C z and C w , in order to simplify their expressions.
Using equation 14 and the definition of C k , we can express the first and last row of C w as:
C w 0 =Σq k w h k =Σq k w q i ×q j =(0,0 ,det ( q k ,q i ,q j )),
C w 3 =Σd k w f k =Σd k w d i ×d j =(0,0 ,det ( d k ,d i ,d j )), (15)
where, in the last step, the terms cancel out to zero for the x and y-components. The two remaining rows look a bit more complex, but with a similar derivation and simplification, we obtain:
C w 1 = ∑ q k w g k + d k w h k = ∑ q k w ( d i × q j + q i × d j ) + d k w ( q i × q j ) = ( 0 , 0 , ∑ det ( d k , q i , q j ) ) ,
C w 2 = ∑ q k w f k + d k w g k = ( 0 , 0 , ∑ det ( q k , d i , d j ) ) .
Using these expressions, we can formulate tC w x T as a quadratic function in t independent of (x, y):
tC w x T =Δ 0 +Δ 1 t+Δ 2 t 2 +Δ 3 t 3 , (16)
where:
Δ 0 =det(q k , q i , q j ), Δ 1 =Σdet(d k , q i , q j ) Δ 2 =Σdet(q k , d i , d j ) Δ 3 =det(d k , d i , d j ).
Expressed differently, the denominator tC w x T is the backface status for the moving triangle, e.g., det(p o (t),p 1 (t), p 2 (t), which is independent of (x, y).
As a result of these simplifications, we reveal that tC w x T has no dependency on x and y and is reduced to a cubic polynomial in t, needing only 4 coefficients. Thus, with this analysis, we have shown that the depth function can be represented by 12 (for C z )+4 (for C w )=16 coefficients, which should be compared to the 24 coefficients needed to store all vertex positions. This formulation is substantially more compact.
If we use a standard projection matrix, according to Equation 4, we can simplify the depth function further. If we return to Equation 14, and insert the constraint from the projection matrix, i.e., q z =aq w +b and d z =z t 1 −z t 1 =ad w , we obtain:
C z =Σ( q k z C k +d k z C k )=Σ(( aq k w +b ) C k +ad k w C k )= aC w +bΣ C k . (17)
We combine this result with Equation 13 to finally arrive at:
d
(
x
,
y
,
t
)
=
t
C
z
x
T
t
C
w
x
T
=
t
(
a
C
w
+
b
∑
C
_
k
)
x
T
t
C
w
x
T
=
a
+
b
t
(
∑
C
_
k
)
x
T
t
C
w
x
T
=
a
+
b
t
2
(
∑
C
k
)
x
T
Δ
0
+
Δ
1
t
+
Δ
2
t
2
+
Δ
3
t
3
(
18
)
As can be seen above, we have reduced the representation of the depth function from 24 scalar values down to 13 (with the assumption that a and b are given by the graphics application program interface (API)).
Next, we consider an extra optimization for the special case of all three triangle vertices with a common motion vector, e.g., pure translation. In the examples below, we assume that a standard projection matrix is used (i.e., Equation 4). The transformed clip space position, p′=(p x ′, p y ′, p w ′), of each triangle vertex is: p′=p+d, where d=(d x , d y ,d w ) is a vector in clip space (xyw).
With all motion vectors equal for the three vertices of a triangle, we can derive a simplified depth function. Note that the coefficients f k =0, and
det(d i , d j , d k )=det(d, d, d)=0 det(q i , d j , d k )=det(q i , d, d)=0.
Furthermore, it holds that:
Σ g k =Σd ×( q j −q i )= d ×Σ( q j −q i )=0. (19)
The depth function can then be simplified as:
d ( x , y , t ) = a + b x · ∑ h k Δ 0 + Δ 1 t ( 20 )
We have reduced the representation of the depth function from 18 scalar values down to 5 (again with the assumption that a and b are given by the graphics API).
There are not as many opportunities to simplify the depth function for defocus blur as there are for motion blur. If we simply store all vertex positions, then 4×3=12 coordinate values are needed. If, however, the projection matrix is known, the number is reduced to 3×3=9. We assume that the camera focal distance and lens aspect are known globally. In the following section, we will show how to reduce the storage requirement of the depth function to 8 scalar coefficients for a defocused triangle.
When depth of field is enabled, a clip-space vertex position is sheared in xy as a function of the lens coordinates (u, v). The vertex position is expressed as:
p=q+cu′, (21)
where c is the signed clip space circle of confusion radius, u′=(u, ξu, 0), and ξ is a scalar coefficient that adjusts the lens aspect ratio. We use these vertices to set up the edge equations:
e k ( x , y , u , v ) = ( p i ( u , v ) × p j ( u , v ) ) · x = ( q i × q j + u ′ × ( c i q j - c j q i ) ) · x = ( h k + u ′ × m k ) · x ,
where we have introduced m k =(c i q j −c j q i ) and h k =q i ×q j to simplify notation. With u=(u, kv, 1), we can write the edge equation on matrix form as:
e
k
(
x
,
y
,
u
,
v
)
=
u
C
k
x
T
,
where
:
(
22
)
C
k
=
[
0
-
m
k
w
m
k
y
m
k
w
0
-
m
k
x
h
k
x
h
k
y
h
k
w
]
(
23
)
Analogous to the motion blur case, we can express the depth function as a rational function in (x, y, u, v) as follows:
d ( x , y , u , v ) = z ( x , y , u , v ) w ( x , y , u , v ) = uC z x T uC w x T , ( 24 )
where C z =Σq k z C k and C w =Σq k w C k . By combining the observation that:
Σ q k w m k w =Σq k w ( c i q j w −c j q i w )=0, (25)
and the top row in Equation 15, C w is reduced to a single column, similar to the motion blur case. Thus, the denominator can be written as:
uC
w
x
T
=
[
0
0
∑
q
k
w
m
k
w
u
0
0
-
∑
q
k
w
m
k
x
ξ
v
0
0
det
(
q
0
,
q
1
,
q
2
)
]
x
T
=
Δ
u
u
+
Δ
v
v
+
Δ
0
,
(
26
)
Again, this is equal to det(p 0 (u, v), p 1 (u, v), p 2 (u, v)), which is also the backface status for a defocused triangle.
If we introduce the restrictions on the projection matrix as in Equation 4, then C z can be expressed in the following manner:
C z =Σq k z C k =Σ( aq k w +b ) C k =aC w +bΣC k . (27)
If we further assume that the clip-space circle of confusion radius follows the lens model, it can be written as c k =αp k w +β. With this, we see that:
∑ m kw = ∑ ( c i p j w - c j p i w ) = ∑ ( ( α p i w + β ) p j w - ( α p j w + β ) p i w ) = α ∑ ( p i w p j w - p j w p i w ) + β ∑ ( p j w - p i w ) = 0 ,
and ΣC k takes the form:
∑
C
k
=
[
0
0
∑
m
k
y
0
0
-
∑
m
k
x
∑
h
k
x
∑
h
k
y
∑
h
k
w
]
(
28
)
With this, we have shown that:
d ( x , y , u , v ) = u C z x T u C w x T = a + b ∑ h k · x + ∑ m k y u - ∑ m k x ξ v Δ u u + Δ v v + Δ 0 ( 29 )
which can be represented with 8 scalar coefficients (given that a and b are known). The denominator is linear in each variable.
The algorithms may be implemented in a software or hardware rasterizer augmented with a depth system containing depth codecs (compressors and decompressors), a depth cache, culling data, and a tile table. To reduce the design space, we chose a cache line size of 512 bits, i.e., 64 bytes, which is a reasonable and realistic size for our purposes. The implication of this choice is that a tile, which is stored using 512·n bits, can be compressed down to 512·m bits, where 1≦m<n in order to gain bandwidth usage. It should be noted that any practical cache line size can be used, and 512 bits is just used as an example.
Thus in some embodiments, a graphics pipeline 10 shown in FIG. 1 may include at least a rasterizer 12 which may be software or hardware based. It provides depth function coefficients to a compressor 14 . The compressor 14 gets depth data from a depth cache 16 and tile information from the tile table 18 . The compressor 14 and rasterizer 12 may be controlled by a control 11 in some embodiments. The control may be a processor or controller as examples.
Even though motion blur is three-dimensional, and defocus blur uses four dimensions, the same tile notation may be used for both these cases in order to simplify the discussion. An explanation of our notation can be found in FIGS. 3 and 4 . In FIG. 3 , motion blur for 4×4 pixels is shown where there are four samples per pixel indicated by the four different layers. In total, there are 4×4×4 samples. If n layers are used as the tile size for compression, then we denote such a tile as 4×4×n. As an example, if each layer is compressed as a separate tile, then we denote these tiles by 4×4×1.
In FIG. 4 , the same notation is used for defocus blur, but with a different meaning. Here, the lens has been divided into 2×2 smaller lens regions, and as before, there are four samples per pixel. Again, indicated by the four layers. However, for defocus blur, 4×4×n means that n layers regions are compressed together as a tile.
Referring to FIG. 2 , the sequence 20 may be implemented in software, firmware and/or hardware. In software and firmware embodiments, it may be implemented by computer executed instructions stored in one or more non-transitory computer readable media such as magnetic, optical or semiconductor storages. For example the control shown in FIG. 1 may be used for this purpose in some embodiments.
The sequence 20 begins by providing a triangle to a rasterizer as indicated at block 22 . The rasterizer set-up computes depth function coefficients which are passed directly to the tile depth compressor, as indicated in block 24 . The stochastic rasterizer computes, for each tile, per sample coverage in depth, as indicated at block 26 . Then the tile depth compressor takes coverage mask, per sample depth and depth function coefficients as inputs. If the sample depths can be represented by a depth function, the tile is stored in a compressed form as indicated in block 28 .
For culling per 8×8×1 tiles, we store z min and z max of the tile using 30 bits each in order to do Z-max culling and Z-min culling. In addition to the min and max values, we also allocated one bit per group of 16 samples, or one cache line worth of uncompressed samples, to indicate whether all of them are cleared. This sums to 4 clear bits per 8×8×1 tile, and so, 64 bits are needed in total per 8×8×1 tile for culling and clear bits.
The tile table, which is accessed through a small cache or stored in an on-chip memory, stores a tile header for each tile. In one embodiment, the tile header may store four bits, where one combination (0000b) indicates that the tile is stored uncompressed, while the remaining 15 combinations are used to indicate different compression modes. These four bits may use a different tile size compared to the culling tile size because the algorithms usually perform quite differently depending on which tile size is used. For example, for depth offset compression algorithms, a smaller tile size is usually advantageous, while larger tile sizes may be better for generalized plane encoding (GPE), which is the method presented in this patent application.
One implementation of the generalized plane encoder is as follows. For the motion blur encoder, we let the rasterizer forward information about the type of motion applied to each triangle. The three different types of motion that we support are static (no motion), only translation, and arbitrary linear per-vertex motion. In addition, the rasterizer forwards a coverage mask, which indicates which sample positions are inside the triangle. The depth is evaluated for these samples, and depth testing is performed. The depth functions of any previously drawn triangles are removed if their sample indices are covered by the incoming triangle's coverage mask. The depth of field encoder works in exactly the same way, except that there are no special types for defocus blur that are forwarded. It should be noted that our method also works for motion blur and depth of field at the same time. However, in this case, the most compact representation is simply to store (x,y,w) per vertex at both time 0 and time 1 for all three vertices of a triangle. While the representation is not optimized, the algorithm works and provides the same advantages as described above.
A new triangle can be added to the compressed representation as follows. A triangle may be rasterized to each covered tile on screen to obtain its per-sample coverage and depth values. Within each tile, the depth test is performed by decompressing the compact representation (to obtain the stored depth values for each covered sample). If any sample passes the depth test, the compressed representation is updated by adding the depth function coefficient for the current triangle and update the bitmask. If no sample passes the depth test, the current compressed representation and bitmask is not updated.
Below, we discuss the case of depth functions for the case of simultaneous motion blur and depth of field. In contrast to the case of only motion blur or only depth of field, the number of coefficients to store the depth function as a function of (x, y, u, v, t) is larger than simply storing the three triangle vertices as t=0 and t=1. Therefore, we do not explicitly derive and simplify the depth function on this form, but work with the vertex data directly.
One way of representing the depth function for the case of simultaneous motion blur and depth of field is to simply store the three triangle vertices at t=0, denoted q i , and t=1, denoted r i . When visiting a tile, the depth value for a given sample can then be obtained from this data by:
1. First evaluate the vertex positions for the sample's (u, v, t) position, e.g., p i (u,v,t)=(1−t)q i +td i +c i (t)(u, ξv, 0) 2. Use these vertex positions to derive a static depth plane equation on the form d(x,y)=Ax+By+C 3. Evaluate the depth plane equation for the sample's (x, y) position
The storage cost for this depth function representation is 2×3×4=24 scalar values, which can be reduced to 2×3×3=18 scalar values if the z-mapping of the projection matrix is known, i.e., z clip =az cam +b, w clip =z cam . As previously shown, if we derive and simplify the depth function for the case of simultaneous motion blur and depth of field, is can be represented with 25 scalar values, which is more expensive in terms of storage.
FIG. 5 illustrates an embodiment of a system 300 . In embodiments, system 300 may be a media system although system 300 is not limited to this context. For example, system 300 may be incorporated into a personal computer (PC), laptop computer, ultra-laptop computer, tablet, touch pad, portable computer, handheld computer, palmtop computer, personal digital assistant (PDA), cellular telephone, combination cellular telephone/PDA, television, smart device (e.g., smart phone, smart tablet or smart television), mobile internet device (MID), messaging device, data communication device, and so forth.
In embodiments, system 300 comprises a platform 302 coupled to a display 320 . Platform 302 may receive content from a content device such as content services device(s) 330 or content delivery device(s) 340 or other similar content sources. A navigation controller 350 comprising one or more navigation features may be used to interact with, for example, platform 302 and/or display 320 . Each of these components is described in more detail below.
In embodiments, platform 302 may comprise any combination of a chipset 305 , processor 310 , memory 312 , storage 314 , graphics subsystem 315 , applications 316 and/or radio 318 . Chipset 305 may provide intercommunication among processor 310 , memory 312 , storage 314 , graphics subsystem 315 , applications 316 and/or radio 318 . For example, chipset 305 may include a storage adapter (not depicted) capable of providing intercommunication with storage 314 .
Processor 310 may be implemented as Complex Instruction Set Computer (CISC) or Reduced Instruction Set Computer (RISC) processors, x86 instruction set compatible processors, multi-core, or any other microprocessor or central processing unit (CPU). In embodiments, processor 310 may comprise dual-core processor(s), dual-core mobile processor(s), and so forth.
Memory 312 may be implemented as a volatile memory device such as, but not limited to, a Random Access Memory (RAM), Dynamic Random Access Memory (DRAM), or Static RAM (SRAM).
Storage 314 may be implemented as a non-volatile storage device such as, but not limited to, a magnetic disk drive, optical disk drive, tape drive, an internal storage device, an attached storage device, flash memory, battery backed-up SDRAM (synchronous DRAM), and/or a network accessible storage device. In embodiments, storage 314 may comprise technology to increase the storage performance enhanced protection for valuable digital media when multiple hard drives are included, for example.
Graphics subsystem 315 may perform processing of images such as still or video for display. Graphics subsystem 315 may be a graphics processing unit (GPU) or a visual processing unit (VPU), for example. An analog or digital interface may be used to communicatively couple graphics subsystem 315 and display 320 . For example, the interface may be any of a High-Definition Multimedia Interface, DisplayPort, wireless HDMI, and/or wireless HD compliant techniques. Graphics subsystem 315 could be integrated into processor 310 or chipset 305 . Graphics subsystem 315 could be a stand-alone card communicatively coupled to chipset 305 .
The graphics and/or video processing techniques described herein may be implemented in various hardware architectures. For example, graphics and/or video functionality may be integrated within a chipset. Alternatively, a discrete graphics and/or video processor may be used. As still another embodiment, the graphics and/or video functions may be implemented by a general purpose processor, including a multi-core processor. In a further embodiment, the functions may be implemented in a consumer electronics device.
Radio 318 may include one or more radios capable of transmitting and receiving signals using various suitable wireless communications techniques. Such techniques may involve communications across one or more wireless networks. Exemplary wireless networks include (but are not limited to) wireless local area networks (WLANs), wireless personal area networks (WPANs), wireless metropolitan area network (WMANs), cellular networks, and satellite networks. In communicating across such networks, radio 318 may operate in accordance with one or more applicable standards in any version.
In embodiments, display 320 may comprise any television type monitor or display. Display 320 may comprise, for example, a computer display screen, touch screen display, video monitor, television-like device, and/or a television. Display 320 may be digital and/or analog. In embodiments, display 320 may be a holographic display. Also, display 320 may be a transparent surface that may receive a visual projection. Such projections may convey various forms of information, images, and/or objects. For example, such projections may be a visual overlay for a mobile augmented reality (MAR) application. Under the control of one or more software applications 316 , platform 302 may display user interface 322 on display 320 .
In embodiments, content services device(s) 330 may be hosted by any national, international and/or independent service and thus accessible to platform 302 via the Internet, for example. Content services device(s) 330 may be coupled to platform 302 and/or to display 320 . Platform 302 and/or content services device(s) 330 may be coupled to a network 360 to communicate (e.g., send and/or receive) media information to and from network 360 . Content delivery device(s) 340 also may be coupled to platform 302 and/or to display 320 .
In embodiments, content services device(s) 330 may comprise a cable television box, personal computer, network, telephone, Internet enabled devices or appliance capable of delivering digital information and/or content, and any other similar device capable of unidirectionally or bidirectionally communicating content between content providers and platform 302 and/display 320 , via network 360 or directly. It will be appreciated that the content may be communicated unidirectionally and/or bidirectionally to and from any one of the components in system 300 and a content provider via network 360 . Examples of content may include any media information including, for example, video, music, medical and gaming information, and so forth.
Content services device(s) 330 receives content such as cable television programming including media information, digital information, and/or other content. Examples of content providers may include any cable or satellite television or radio or Internet content providers. The provided examples are not meant to limit embodiments of the invention.
In embodiments, platform 302 may receive control signals from navigation controller 350 having one or more navigation features. The navigation features of controller 350 may be used to interact with user interface 322 , for example. In embodiments, navigation controller 350 may be a pointing device that may be a computer hardware component (specifically human interface device) that allows a user to input spatial (e.g., continuous and multi-dimensional) data into a computer. Many systems such as graphical user interfaces (GUI), and televisions and monitors allow the user to control and provide data to the computer or television using physical gestures.
Movements of the navigation features of controller 350 may be echoed on a display (e.g., display 320 ) by movements of a pointer, cursor, focus ring, or other visual indicators displayed on the display. For example, under the control of software applications 316 , the navigation features located on navigation controller 350 may be mapped to virtual navigation features displayed on user interface 322 , for example. In embodiments, controller 350 may not be a separate component but integrated into platform 302 and/or display 320 . Embodiments, however, are not limited to the elements or in the context shown or described herein.
In embodiments, drivers (not shown) may comprise technology to enable users to instantly turn on and off platform 302 like a television with the touch of a button after initial boot-up, when enabled, for example. Program logic may allow platform 302 to stream content to media adaptors or other content services device(s) 330 or content delivery device(s) 340 when the platform is turned “off.” In addition, chip set 305 may comprise hardware and/or software support for 5.1 surround sound audio and/or high definition 7.1 surround sound audio, for example. Drivers may include a graphics driver for integrated graphics platforms. In embodiments, the graphics driver may comprise a peripheral component interconnect (PCI) Express graphics card.
In various embodiments, any one or more of the components shown in system 300 may be integrated. For example, platform 302 and content services device(s) 330 may be integrated, or platform 302 and content delivery device(s) 340 may be integrated, or platform 302 , content services device(s) 330 , and content delivery device(s) 340 may be integrated, for example. In various embodiments, platform 302 and display 320 may be an integrated unit. Display 320 and content service device(s) 330 may be integrated, or display 320 and content delivery device(s) 340 may be integrated, for example. These examples are not meant to limit the invention.
In various embodiments, system 300 may be implemented as a wireless system, a wired system, or a combination of both. When implemented as a wireless system, system 300 may include components and interfaces suitable for communicating over a wireless shared media, such as one or more antennas, transmitters, receivers, transceivers, amplifiers, filters, control logic, and so forth. An example of wireless shared media may include portions of a wireless spectrum, such as the RF spectrum and so forth. When implemented as a wired system, system 300 may include components and interfaces suitable for communicating over wired communications media, such as input/output (I/O) adapters, physical connectors to connect the I/O adapter with a corresponding wired communications medium, a network interface card (NIC), disc controller, video controller, audio controller, and so forth. Examples of wired communications media may include a wire, cable, metal leads, printed circuit board (PCB), backplane, switch fabric, semiconductor material, twisted-pair wire, co-axial cable, fiber optics, and so forth.
Platform 302 may establish one or more logical or physical channels to communicate information. The information may include media information and control information. Media information may refer to any data representing content meant for a user. Examples of content may include, for example, data from a voice conversation, videoconference, streaming video, electronic mail (“email”) message, voice mail message, alphanumeric symbols, graphics, image, video, text and so forth. Data from a voice conversation may be, for example, speech information, silence periods, background noise, comfort noise, tones and so forth. Control information may refer to any data representing commands, instructions or control words meant for an automated system. For example, control information may be used to route media information through a system, or instruct a node to process the media information in a predetermined manner. The embodiments, however, are not limited to the elements or in the context shown or described in FIG. 5 .
As described above, system 300 may be embodied in varying physical styles or form factors. FIG. 6 illustrates embodiments of a small form factor device 400 in which system 300 may be embodied. In embodiments, for example, device 400 may be implemented as a mobile computing device having wireless capabilities. A mobile computing device may refer to any device having a processing system and a mobile power source or supply, such as one or more batteries, for example.
As described above, examples of a mobile computing device may include a personal computer (PC), laptop computer, ultra-laptop computer, tablet, touch pad, portable computer, handheld computer, palmtop computer, personal digital assistant (PDA), cellular telephone, combination cellular telephone/PDA, television, smart device (e.g., smart phone, smart tablet or smart television), mobile internet device (MID), messaging device, data communication device, and so forth.
Examples of a mobile computing device also may include computers that are arranged to be worn by a person, such as a wrist computer, finger computer, ring computer, eyeglass computer, belt-clip computer, arm-band computer, shoe computers, clothing computers, and other wearable computers. In embodiments, for example, a mobile computing device may be implemented as a smart phone capable of executing computer applications, as well as voice communications and/or data communications. Although some embodiments may be described with a mobile computing device implemented as a smart phone by way of example, it may be appreciated that other embodiments may be implemented using other wireless mobile computing devices as well. The embodiments are not limited in this context.
The processor 310 may communicate with a camera 322 and a global positioning system sensor 320 , in some embodiments. A memory 312 , coupled to the processor 310 , may store computer readable instructions for implementing the sequences shown in FIGS. 1 and 2 in software and/or firmware embodiments. Particularly the sequences may be implemented by one or more non-transitory storage devices storing computer implemented instructions.
As shown in FIG. 6 , device 400 may comprise a housing 402 , a display 404 , an input/output (I/O) device 406 , and an antenna 408 . Device 400 also may comprise navigation features 412 . Display 404 may comprise any suitable display unit for displaying information appropriate for a mobile computing device. I/O device 406 may comprise any suitable I/O device for entering information into a mobile computing device. Examples for I/O device 406 may include an alphanumeric keyboard, a numeric keypad, a touch pad, input keys, buttons, switches, rocker switches, microphones, speakers, voice recognition device and software, and so forth. Information also may be entered into device 400 by way of microphone. Such information may be digitized by a voice recognition device. The embodiments are not limited in this context.
Various embodiments may be implemented using hardware elements, software elements, or a combination of both. Examples of hardware elements may include processors, microprocessors, circuits, circuit elements (e.g., transistors, resistors, capacitors, inductors, and so forth), integrated circuits, application specific integrated circuits (ASIC), programmable logic devices (PLD), digital signal processors (DSP), field programmable gate array (FPGA), logic gates, registers, semiconductor device, chips, microchips, chip sets, and so forth. Examples of software may include software components, programs, applications, computer programs, application programs, system programs, machine programs, operating system software, middleware, firmware, software modules, routines, subroutines, functions, methods, procedures, software interfaces, application program interfaces (API), instruction sets, computing code, computer code, code segments, computer code segments, words, values, symbols, or any combination thereof. Determining whether an embodiment is implemented using hardware elements and/or software elements may vary in accordance with any number of factors, such as desired computational rate, power levels, heat tolerances, processing cycle budget, input data rates, output data rates, memory resources, data bus speeds and other design or performance constraints.
One or more aspects of at least one embodiment may be implemented by representative instructions stored on a machine-readable medium which represents various logic within the processor, which when read by a machine causes the machine to fabricate logic to perform the techniques described herein. Such representations, known as “IP cores” may be stored on a tangible, machine readable medium and supplied to various customers or manufacturing facilities to load into the fabrication machines that actually make the logic or processor.
The foregoing description of one or more implementations provides illustration and description, but is not intended to be exhaustive or to limit the scope of the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of various implementations of the invention.
The graphics processing techniques described herein may be implemented in various hardware architectures. For example, graphics functionality may be integrated within a chipset. Alternatively, a discrete graphics processor may be used. As still another embodiment, the graphics functions may be implemented by a general purpose processor, including a multicore processor.
References throughout this specification to “one embodiment” or “an embodiment” mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one implementation encompassed within the present invention. Thus, appearances of the phrase “one embodiment” or “in an embodiment” are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be instituted in other suitable forms other than the particular embodiment illustrated and all such forms may be encompassed within the claims of the present application.
While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
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Unlike a static primitive, where the depth function is planar, the depth function for a moving and defocused triangle is a rational function in time and the lens parameters. Compact depth functions can be used to design an efficient depth buffer compressor/decompressor, which significantly lowers total depth buffer bandwidth usage. In addition, this compressor/decompressor is substantially simpler in the number of operations needed to execute, which makes it more amenable for hardware implementation than previous methods.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of U.S. application Ser. No. 09/208,022, filed Dec. 9, 1998, now U.S. Pat. No. 6,673,262, which claims priority from Japanese patent application no. 9-349536, filed Dec. 18, 1997, and Japanese patent application nos. 10-239338 and 10-239339, each filed Aug. 26, 1998.
BACKGROUND OF THE INVENTION
The present invention relates to a gas, that is, a cleaning or etching gas, for removing deposits by a gas-solid reaction and a removal method using the gas.
In thin-film device production process of semiconductor industry, optical device production process, super steel material production process and the like, various thin films, thick films, powders, whiskers and the like are produced, for example, by chemical vapor deposition, (CVD), physical vapor deposition (PVD), sputtering, and sol-gel process. During the production of these materials, unnecessary deposits in the form of film, whisker or powder are inevitably formed, for example, on a reactor's inner wall and a jig for supporting the object, as well as on the object. This may cause the occurrence of unnecessary particles, making it difficult to produce films, powders, whiskers and the like of good quality. Thus, it becomes necessary to occasionally remove the unnecessary deposits, for example, by cleaning gas. Such a cleaning gas is required, for example, to have (1) a high reaction rate at which the cleaning gas reacts with unnecessary deposits to form volatile compounds, (2) a relative easiness to make the exhaust gas of the cleaning unharmful, and (3) a relative unstableness in the atmosphere to make the impact on the global warming smaller. Conventional examples of the cleaning gas are C 2 F 6 , CF 4 , C 4 F 8 , NF 3 and ClF 3 . These compounds, however, have the following defects. Firstly, ClF 3 is highly reactive, and thus may do damage to materials conventionally used for the apparatus, when ClF 3 is used at a high temperature or with the assistance of plasma. Secondly, NF 3 is low in reactivity unless the reaction temperature is at least 300° C., and thus may be impossible to remove unnecessary deposits accumulated in the piping of the apparatus and the outside of the plasma region. Furthermore, it is necessary to have a high temperature in order to make the exhaust gas unharmful. Thus, the cost for conducting the cleaning becomes relatively high. Thirdly, each of C 2 F 6 , CF 4 and C 4 F 8 has the following defects. That is, it may be impossible to remove unnecessary deposits accumulated in the piping of the apparatus and the outside of the plasma region. Furthermore, a fluorocarbon(s) will accumulate by the plasma cleaning. If oxygen is added in order to decrease the amount of the accumulation of the fluorocarbon(s), an oxide(s) will accumulate instead. Since each of C 2 F 6 , CF 4 and C 4 F 8 is a very stable compound, it is difficult to treat the exhaust gas of the cleaning. In other words, these compounds (gases) will be stably present in the environment, and cause adverse impact against the environment due to their high global warming coefficients or factors. Thus, it is necessary to have a high temperature for the treatment of the exhaust gas. This makes the cost of the treatment relatively high.
An etching gas, which is analogous to the above-mentioned cleaning gas, is used for partially removing a thin film material in order to transfer the circuit pattern, for example, of LSI and TFT. Conventional examples of this etching gas are CF 4 , C 2 F 6 , CHF 3 , SF 6 , and NF 3 . These gases have a problem of high global warming coefficient. Furthermore, these gases are relatively stable gases. Thus, it is necessary to use a large amount of energy for generating, for example, CF 3 radicals and F radicals, which are useful as etchant. That is, the electric power consumption becomes large. Furthermore, it is relatively difficult to treat the unreacted etching gases, prior to the discharge into the atmosphere. Therefore, there is an urgent demand for an alternative etching gas(es) that can easily be made unharmful on the global environment and is capable of achieving high precision etching.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a gas for removing deposits, which gas can easily be made unharmful on the global environment after the removal of deposits.
It is a more specific object of the present invention to provide a cleaning gas for efficiently removing unnecessary deposits accumulated, for example, in an apparatus for producing semiconductor devices, which cleaning gas can easily be made unharmful on the global environment after the removal of the deposits.
It is another specific object of the present invention to provide an etching gas for removing, as precisely as originally designed, an unwanted portion of a film deposited on a substrate, for example, for producing thin film devices (e.g., LSI and TFT), which etching gas can easily be made unharmful on the global environment after the removal of the unwanted portion.
It is a still another object of the present invention to provide a method for removing a deposit by the gas.
According to the present invention, there is provided a gas for removing deposits by a gas-solid reaction. This gas comprises a hypofluorite that is defined as being a compound having at least one OF group in the molecule. We unexpectedly found that various deposits can be removed by the gas and that the gas can easily be made unharmful on the global environment after the removal of the deposits. The gas may be a cleaning gas for substantially completely removing the deposits. In other words, this cleaning gas is used for cleaning, for example, the inside of an apparatus for producing semiconductor devices. This cleaning gas comprises 1–100 volume % of the hypofluorite. We unexpectedly found that various unnecessary deposits can efficiently be removed by the cleaning gas. Furthermore, either of plasma-assisted and plasma-less cleanings is made possible by the cleaning gas. Alternatively, the gas according to the present invention may be an etching gas for removing an unwanted portion of a film deposited on a substrate. In other words, the etching gas is used, for example, in pattern transfer operations in the production of semiconductor circuits. We unexpectedly found that the unwanted portion can be removed by the etching gas as precisely as originally designed.
According to the present invention, there is provided a method for removing a deposit by the gas. This method comprises the step (a) bringing the gas into contact with the deposit, thereby to remove the deposit by a gas-solid reaction. The above-mentioned unexpected findings are also obtained by this method.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing a multilayer structure used in the after-mentioned Examples 1–3 and Comparative Example 1, which is prior to an etching of a SiO 2 insulator film with an etching gas; and
FIG. 2 is a view similar to FIG. 1 , but showing the multilayer structure after the etching.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A hypofluorite according to the present invention dissociates more easily than, for example, each of CF 4 , C 2 F 6 , C 4 F 8 , and NF 3 , and is lower than ClF 3 in reactivity. For example, O—F bond of a hypofluorite, that is, trifluoromethyl-hypofluorite (CF 3 O—F), has a bond dissociation energy of 43.5 kcal/mol. This value is lower than that (61 kcal/mol) of N—F bond of NF 3 and higher than that (37 kcal/mol) of Cl—F of ClF 3 . In other words, CF 3 O—F releases active fluorine more easily than NF 3 and is more stable than ClF 3 . Although CF 3 O—F does not have a high fluorination strength as that of F 2 or ClF 3 , it is sufficient to make it possible to conduct a plasma-less cleaning. Furthermore, it is possible to remove deposits (contaminants) accumulated in the outside of the plasma region by using an etching gas comprising a hypofluorite (e.g., CF 3 O—F), although it has been impossible by using conventional plasma cleaning gases (e.g., CF 4 ). It should be noted that the hypofluorite is much smaller than ClF 3 in corrosiveness. That is, the hypofluorite does relatively little damage to general materials used for, for example, an inner wall of the apparatus. The hypofluorite is decomposed in the air, and thus has little to do with the global warming. Furthermore, the cleaning gas or etching gas according to the invention discharged from the apparatus can easily be decomposed by water or an alkali aqueous solution, for example, of alkali scrubber. Thus, the cleaning gas or etching gas itself is not discharged into the environment, nor produces global warming gases (e.g., C 2 F 6 and CF 4 ). Therefore, the cleaning gas or etching gas according to the present invention does not cause substantial environmental problems. The etching gas according to the invention is capable of having a higher etching rate and a higher aspect ratio than those of, for example, CF 4 .
In the invention, examples of the deposit, which can be removed by cleaning with the cleaning gas or by etching with the etching gas, are B, P, W, Si, Ti, V, Nb, Ta, Se, Te, Mo, Re, Os, Ru, Ir, Sb, Ge, Au, Ag, As and Cr, and oxides, nitrides, carbides and alloys of these elements. The deposit, which is partially removed by etching with the etching gas, may be formed on a substrate, such as silicon wafer, metal plate, glass plate, single crystal plate, or polycrystalline plate.
In the invention, the hypofluorite optionally has at least one selected from halogen atoms, ether groups, alcohol groups, carbonyl groups, carboxyl groups, ester groups, amine groups, and amide groups. In general, hypofluorites have very great fluorination strengths. Therefore, it may not be preferable in the invention to use a hypofluorite that has a reducing group or a bond that is unstable in terms of energy level. Preferable examples of the hypofluorite of the invention are CF 3 OF, CF 2 (OF) 2 , CF 3 CF 2 OF, CH 3 COOF, (CF 3 ) 3 COF, CF 2 HCF 2 OF, (CF 3 CF 2 )(CF 3 ) 2 COF, CH 3 OF, CFH 2 OF, CF 2 HOF, CF 3 CF 2 CF 2 OF and (CF 3 ) 2 CFOF. The hypofluorite of the invention may be derived from a halogenated hydrocarbon group, ether, alcohol, carboxylic acid, ester, amine or amide. In the invention, it is optional to use a hypofluorite that has at least two OF groups in the molecule, because this hypofluorite has a reactivity analogous to another hypofluorite having only one OF group in the molecule.
In the invention, it is optional to use a hypofluorite itself as a cleaning gas. That is, this cleaning gas contains 100% of the hypofluorite. This cleaning gas is capable of completely cleaning deposits, which have been deposited on the inside of a chamber and its exhaust pipes. These deposits may be CVD by-products or unnecessary deposits made of materials that are the same as the materials of films formed on, for example, silicon wafer and glass substrates. Furthermore, the cleaning gas of the invention can be used for cleaning a multi-chamber type CVD apparatus, various batch-type CVD apparatuses, a CVD apparatus for epitaxial growth, and the like. The manner of exciting the cleaning gas is not particularly limited. For example, high frequency or microwave may be used for the excitation, depending on the type of the apparatus. It is optional to excite the cleaning gas in the inside of the reaction chamber. Alternatively, it is optional to take a remote plasma method in which the cleaning gas is excited in the outside of the reaction chamber, and then radical or ion is introduced into the reaction chamber.
In the invention, it is optional to prepare a cleaning gas by mixing a hypofluorite with an inert gas (e.g., He, N 2 and Ar) and/or at least one gas component selected from oxygen and oxygen-containing gases (e.g., CO 2 , CO, NO, NO 2 , and N 2 O). In fact, if deposits containing no oxygen are repeatedly removed, a very small amount of an organic fluoride having a white color accumulates on a low temperature portion of the exhaust pipe(s) of the apparatus. This organic fluoride is assumed to be a polymer made from ions and radicals, such as CF 3 O + , CF 3 + and CF 2 + , derived from the hypofluorite. We unexpectedly found that the formation of this organic fluoride is prevented by mixing a hypofluorite with the above-mentioned at least one gas component. Although CO 2 and CO of the at least one gas component each contain carbon, which is an element causing the formation of the organic fluoride, these compounds each contain oxygen in the molecules, too. Therefore, it becomes possible to make F-radicals long in lifetime. This may prevent the formation of the polymer. In particular, it is preferable that the at least one gas component is in an amount from 0.4 to 90 volume %, based on the total volume of the at least one gas component and the hypofluorite. If it is less than 0.4 volume %, carbon may remain on the wall of the reactor or the piping after the cleaning. If it is greater than 90 volume %, the oxidation of the surface of the deposit may occur predominantly. This may lower the cleaning rate too much.
In the invention, as mentioned above, the cleaning gas may be a hypofluorite itself or a mixture of a hypofluorite and the at least one gas component selected from oxygen and oxygen-containing gases. Furthermore, the cleaning gas may be diluted with an inert gas (e.g., nitrogen, argon and helium). A suitable cleaning gas is chosen, depending on the type and thickness of the deposit to be removed, the type of the material of the apparatus, and the like. In case that the cleaning gas is diluted, the hypofluorite concentration of the diluted cleaning gas is preferably at least 1 volume %, more preferably at least 5 volume %, still more preferably at least 10 volume %. If it is less than 1 volume %, the reaction rate may become too low.
In the invention, the cleaning conditions are not particularly limited. The temperature of the cleaning is preferably from 10 to 700° C., more preferably from 20 to 600° C. If it is higher than 700° C., the reactor may corrode too much. If it is lower than 10° C., the reaction rate of the cleaning may become too low. The pressure of the cleaning is not particularly limited. In fact, it is preferably from 0.1 to 760 Torr in plasma-less cleaning and preferably from 1 m Torr to 10 Torr in plasma-assisted cleaning
In the invention, the etching manner and the reaction conditions of the etching, in which the etching gas of the invention is used, are not particularly limited. For example, the etching may be reactive ion etching (RIE) or electron cyclotron resonance (ECR) plasma-assisted etching. Due to the use of a hypofluorite for the etching gas, fluorine radicals reach the surface of a SiO 2 insulator film 2 that is to be partially removed by the etching gas (see FIG. 1 ). Furthermore, CFn ions impinge on the surface of the film 2. With this, the film 2 is etched away in a vertical direction, thereby to form, for example, a contact hole in the film 2, as shown in FIG. 2 . The side walls of the contact hole are protected by the accumulation of a fluorocarbon polymer, thereby to achieve an anisotropic etching. In particular, a large amount of CF 3 + ions are produced, as well as fluorine radicals, in plasma by the hypofluorite. Therefore, the etching gas of the invention is superior in etching efficiency. Furthermore, the etching gas of the invention contains oxygen of the hypofluorite. With this, a fluorocarbon film accumulated on the side walls of the contact hole can efficiently be removed, thereby to conduct an anisotropic etching.
In the invention, the etching can be conducted under various dry etching conditions, for example, of plasma etching, reactive plasma etching, and microwave etching. The etching gas of the invention may be prepared by mixing a hypofluorite with an inert gas (e.g., He, N 2 and Ar) and/or at least one other gas selected from, for example, HI, HBr, HCl, CO, NO, O 2 , CH 4 , NH 3 , H 2 , C 2 H 2 , and C 2 H 6 . In fact, it is preferable to add, to the hypofluorite, at least one first gas component selected from hydrogen and hydrogen-containing gases (e.g., CH 4 , NH 3 , HI, HBr, C 2 H 2 , and HCl), in the preparation of the etching gas, for the purposes of (1) reducing the amount of fluorine radicals, which accelerate isotropic etching, and (2) increasing the reaction selectivity toward SiO 2 over Si. Furthermore, the flow rate ratio of the at least one first gas component to the hypofluorite is preferably not greater than 10:1. If this ratio is greater than 10:1, the amount of fluorine radicals, which are useful for the etching, may become too low. It is preferable to add, to the hypofluorite, at least one second gas component selected from oxygen and oxygen-containing gases (e.g., CO, NO, N 2 O, and NO 2 ), in the preparation of the etching gas, for the purpose of increasing the etching rate of metals over oxides and nitrides. It is particularly preferable that the flow rate ratio of the at least one second gas component to the hypofluorite is not greater than 4:1. If this ratio is greater than 4:1, the amount of fluorine radicals, which are useful for the etching, may become too low.
In the invention, the gas pressure of the etching is preferably not higher than 5 Torr, in order to conduct anisotropic etching. If the gas pressure is lower than 0.001 Torr, the etching rate may become too slow. The flow rate of the etching gas may vary, depending on the reactor capacity of the etching apparatus and the size of wafer, and is preferably from 10 to 10,000 standard cubic centimeters per minute (SCCM). The etching is conducted at a temperature preferably not higher than 400° C. If this temperature is greater than 400° C., the etching may proceed isotropically. This lowers the etching precision, and the resist may be etched away too much. If the etching gas comprises the above-mentioned at least one first and/or second gas component, it becomes possible, for example, to increase the etching rate selectivity toward the silicon oxide film over the silicon film in the preparation of the contact hole.
The following nonlimitative Examples are illustrative of the present invention.
EXAMPLES 1–4
In each of these examples, a test piece was prepared at first by thermally oxidizing the surface of a silicon wafer and then by forming a polycrystalline silicon film having a thickness of 200 μm through a thermal decomposition of SiH 4 . This test piece was put on the lower electrode of a plasma CVD apparatus. Then, the test piece was subjected to an etching for 30 seconds by applying a high frequency or RF (radio frequency) power to the lower electrode and by feeding an etching gas, shown in Table 1, having a pressure of 0.5 Torr, a flow rate of 100 SCCM and a temperature of 20° C. In this etching, the frequency of the high frequency power source was 13.56 MHz, the power applied to the lower electrode was 0.2 W/cm 2 , and the distance between the lower and upper electrodes was 10 mm. The result (etching rate) of the etching is shown in Table 1.
TABLE 1
Etching Gas
Etching Rate (Å/min)
Example 1
CF 3 OF
8,105
Example 2
CF 3 CF 2 OF
7,769
Example 3
(CF 3 ) 3 COF
9,606
Example 4
CF 2 (OF) 2
20,832
EXAMPLES 5–44 & COMPARATIVE EXAMPLE 1
In these examples and comparative example, Examples 1-4 were repeated except in that the etching gas types were changed as shown in Table 2, that the etching gas pressure was 10 Torr in place of 0.5 Torr, that the gas temperature was changed as shown in Table 2, and that the application of a high frequency power was omitted. The results (etching rates) are shown in Table 2.
TABLE 2
Temp.
(° C.)
Etching Gas
Etching Rate (Å/min)
Example 5
20
CF 3 OF
1,040
Example 6
CF 2 (OF) 2
1,953
Example 7
CF 3 CF 2 OF
990
Example 8
(CF 3 ) 3 COF
960
Example 9
CF 2 HCF 2 OF
780
Example 10
(CF 3 CF 2 )(CF 3 ) 2 COF
970
Example 11
CF 3 OF
480
Example 12
CFH 2 OF
660
Example 13
CF 2 HOF
770
Example 14
CF 3 CF 2 CF 2 OF
910
Example 15
(CF 3 ) 2 CFOF
930
Example 16
100
CF 3 OF
3,230
Example 17
CF 2 (OF) 2
4,385
Example 18
CF 3 CF 2 OF
2,780
Example 19
200
CF 3 OF
9,810
Example 20
CF 2 (OF) 2
10,259
Example 21
CF 3 CF 2 OF
6,620
Example 22
300
CF 3 OF
20,500
Example 23
CF 2 (OF) 2
49,853
Example 24
CF 3 CF 2 OF
9,880
Example 25
400
CF 3 OF
32,900
Example 26
CF 2 (OF) 2
59,560
Example 27
CF 3 CF 2 OF
14,700
Com. Ex. 1
CF 4
0
Example 28
500
CF 3 OF
53,600
Example 29
CF 2 (OF) 2
71,265
Example 30
CF 3 CF 2 OF
23,000
Example 31
600
CF 3 OF
78,800
Example 32
CF 2 (OF) 2
98,654
Example 33
CF 3 CF 2 OF
37,100
Example 34
700
CF 3 OF
99,600
Example 35
CF 2 (OF) 2
115,893
Example 36
CF 3 CF 2 OF
45,200
Example 37
(CF 3 ) 3 COF
37,000
Example 38
CF 2 HCF 2 OF
31,000
Example 39
(CF 3 CF 2 )(CF 3 ) 2 COF
34,500
Example 40
CF 3 OF
25,000
Example 41
CFH 2 OF
31,500
Example 42
CF 2 HOF
33,000
Example 43
CF 3 CF 2 CF 2 OF
36,000
Example 44
(CF 3 ) 2 CFOF
35,200
EXAMPLE 45
In this example, a plasma CVD was conducted by using tetraethylsilicate (TEOS) and oxygen as raw materials, in an apparatus for conducing the plasma CVD. With this, SiO 2 having a thickness of about 0.05 to about 20 μm deposited on the wall of the apparatus. The inside of the apparatus was cleaned at 20° C. for 20 min by feeding cleaning gases of CF 3 OF, CF 2 (OF) 2 and CF 3 CF 2 )F by turns and by applying a high frequency power to the lower electrode of the apparatus. Each cleaning gas had a pressure of 1 Torr and a flow rate of 100 SCCM. In this etching, the frequency of the high frequency power source was 13.56 MHz, the power applied to the lower electrode was 0.2 W/cm 2 , and the distance between the lower and upper electrodes was 50 mm. It was found by an observation of the inside of the apparatus that the SiO 2 was completely removed by the cleaning with each cleaning gas.
EXAMPLE 46
A tungsten film was formed by a thermal CVD in a cold wall type apparatus for conducting the CVD. Then, it was found that the temperature in the vicinity of a heater disposed in the reactor was 500° C., that the temperature of a gas diffusion plate was 40° C., and that the temperature of the reactor wall was from 20 to 300° C. Furthermore, it was found that unnecessary tungsten films deposited in many positions in the apparatus. The thickest tungsten film deposited therein had a thickness of about 120 μm. It was further found that a tungsten oxide powder deposited in the piping of the apparatus. After the formation of the tungsten film, a first cleaning was conducted by allowing a cleaning gas of CF 3 OF to flow through the apparatus at a flow rate of 1 standard liter per minute (SLM) for 30 minutes. Then, it was found by an observation of the inside of the apparatus that the tungsten film of the inside of the reactor and the tungsten oxide powder of the piping were completely removed by the first cleaning. Then, a tungsten film was formed again in the same manner as above in the apparatus. After that, a second cleaning was conducted in the same manner as that of the first cleaning except in that CF 3 OF was replaced with CF 3 CF 2 OF Then, a tungsten film was formed again in the same manner as above in the apparatus. After that, a third cleaning was conducted in the same manner as that of the first cleaning except in that CF 3 OF was replaced with (CF 3 ) 3 COF. Similar to the above, it was found by an observation of the inside of the apparatus that the tungsten film of the inside of the reactor and the tungsten oxide powder of the piping were completely removed by the second and third cleanings.
EXAMPLE 47
At first, four test pieces were prepared by a thermal CVD by respectively forming a tungsten (W) film, a WSi film, a TiC film and a Ta 2 O 5 film on four nickel substrates each having a length of 10 mm and a width of 20 mm and a thickness of 2 mm. Each film had a thickness of 50 μm. Then, these four test pieces were put on the lower electrode of a plasma CVD apparatus. Then, an etching was conducted for 10 min at 20° C. by allowing an etching gas of CF 3 OF to flow through the apparatus and by applying a high frequency power to the lower electrode. This etching gas had a pressure of 0.5 Torr and a flow rate of 100 SCCM. In this etching, the frequency of the high frequency power source was 13.56 MHz, the power applied to the lower electrode was 0.2 W/cm 2 , and the distance between the lower and upper electrodes was 50 mm. After the etching, the test pieces were taken out of the CVD apparatus and then analyzed with an X-ray microanalyzer. With this, the peaks of W, Si, Ti and Ta were not found.
EXAMPLE 48
In this example, Example 47 was repeated except in that a Mo film, a Re film and an Nb film, each having a thickness of 50 μm, were respectively formed on three nickel substrates each having the same dimensions as those of Example 47 and that the etching was conducted for 3 min. The peaks of Mo, Re and Nb were not found by an analysis with X-ray microanalyzer.
EXAMPLE 49
In this example, Example 47 was repeated except in that a TiN film and a Ti film, each having a thickness of 5 μm, were respectively formed by sputtering on two nickel substrates each having the same dimensions as those of Example 47. The peak of Ti was not found by an analysis with X-ray microanalyzer.
EXAMPLE 50
In this example, Example 47 was repeated except in that an Au film, an Ag film and a Cr film, each having a thickness of 2 μm, were respectively formed by vacuum deposition on three nickel substrates each having the same dimensions as those of Example 47, that the etching gas flow rate was 10 SCCM, and that the power applied to the lower electrode was 0.315 W/cm 2 . The peaks of Au, Ag and Cr were not found by an analysis with X-ray microanalyzer.
EXAMPLE 51
At first, a nickel vessel was charged with commercial phosphorus (white phosphorus), Ta, As, Ge, Se and B powders, each being in an amount of 5 mg. Then, the nickel vessel was put on the lower electrode of a plasma CVD apparatus. Then, an etching was conducted for 10 min at 20° C. by allowing an etching gas of CF 3 OF to flow through the apparatus and by applying a high frequency power to the lower electrode. This etching gas had a pressure of 1 Torr and a flow rate of 10 SCCM. In this etching, the frequency of the high frequency power source was 13.56 MHz, the power applied to the lower electrode was 0.315 W/cm 2 , and the distance between the lower and upper electrodes was 50 mm. After the etching, it was found by an observation of the vessel and the inside of the apparatus that all the powders were completely removed.
EXAMPLES 52–64
In each of these examples, a silicon film was formed by using SiH 4 as a raw material in an apparatus. After that, there were found in the apparatus silicon and polysilane powders, which were deposited in a reactor of the apparatus, and a polysilane powder, which was deposited in the piping of the apparatus. This piping is outside of the plasma region. Then, a plasma-assisted cleaning was conducted a certain times as shown in Table 3 for 30 min per one time of the cleaning for the purpose of removing these powders of the apparatus. In this cleaning, a cleaning gas of CF 3 OF was allowed to flow through the apparatus at a flow rate of 1 SLM under a pressure of 1 Torr. Furthermore, oxygen and nitrogen were selectively allowed to flow therethrough, as shown in Table 3. During the cleaning, the temperature of the inside of the piping was 20° C., and that of the inside of the reactor was from 40 to 400° C. After the cleaning, the inside of the apparatus was observed, and the result of this observation is shown in Table 3. In Table 3, ◯ means that the powders were completely removed from the inside of the reactor and the piping, and the deposition of an organic fluoride did not occur; Δ means that the powders were completely removed from the inside of the reactor and the piping, but the deposition of an organic fluoride in the form of powder or film was found at an end portion (particularly a low temperature portion) of the piping; and □ means that a silicon oxide formed by oxidation of the polysilane powder deposited. In each of Examples 52–64, at least the inside of the reactor was cleaned.
TABLE 3
O 2
The Number
Observation
Flow Rate
N 2 Flow Rate
of Cleanings
Result after
(SCCM)
(SCCM)
(time(s))
Cleaning
Example 52
0
0
1
◯
Example 53
0
0
2
◯
Example 54
0
0
3
Δ
Example 55
1
0
3
Δ
Example 56
3
0
3
Δ
Example 57
4
0
3
◯
Example 58
4
0
10
Δ
Example 59
100
0
10
◯
Example 60
500
0
10
◯
Example 61
50
50
10
◯
Example 62
5,000
0
10
◯
Example 63
8,000
0
10
◯
Example 64
9,000
0
10
□
EXAMPLES 65–70
In each of these examples, a silicon film was formed in an apparatus by using SiH 4 as a raw material. After that, there were found in the apparatus silicon and polysilane powders, which were deposited in a reactor of the apparatus, and a polysilane powder, which was deposited in a piping of the apparatus. This piping was outside of the plasma region. Then, a plasma-assisted cleaning was repeatedly conducted for 30 min per one time of the cleaning for the purpose of removing these powders of the apparatus. In this cleaning, a cleaning gas of CF 3 OF was allowed to flow through the apparatus at a flow rate of 1 SLM under a pressure of 1 Torr. Furthermore, an oxygen-containing gas shown in Table 4 was allowed to flow therethrough, together with CF 3 OF During the cleaning, the temperature of the inside of the piping was 20° C., and that of the inside of the reactor was from 40 to 400° C. After the cleaning, the inside of the apparatus was observed, and the result of this observation is shown in Table 4. In Table 4, ◯ means the same as that of Table 3 of Examples 52–64.
TABLE 4
Oxygen-
Flow Rate of Oxygen-
containing
containing Compound
Observation Result
Compound
(SCCM)
after Cleaning
Example 65
CO 2
20
◯
Example 66
CO
50
◯
Example 67
NO
20
◯
Example 68
NO
100
◯
Example 69
NO 2
5
◯
Example 70
N 2 O
10
◯
EXAMPLE 71
A thermal CVD was conducted in an apparatus such that a tungsten film having a thickness from 10 to 20 μm was deposited on the wall of a reactor of this apparatus. Separately, a mechanism for exciting a gas with microwave was attached with the reactor via a piping. Then, a remote plasma-assisted cleaning of the apparatus was conducted for 10 min using microwave plasma. In this cleaning, a cleaning gas of CF 3 OF was allowed to flow at a flow rate of 1,000 SCCM under a pressure of 0.1 Torr. The microwave output was 50 W (13.56 MHz), and the substrate temperature was 18° C. After the cleaning, it was found that the inside of the reactor was completely cleaned and that a powder (i.e., a mixture of tungsten and tungsten oxide) deposited in the piping was completely removed.
EXAMPLE 72
In this example, Example 71 was repeated except in that CF 2 (OF) 2 was used as the cleaning gas. After the cleaning, it was found that the inside of the reactor was completely cleaned and that a powder (i.e., a mixture of tungsten and tungsten oxide) deposited in the piping was completely removed.
EXAMPLES 73–75 & COMPARATIVE EXAMPLE 2
In each of these examples and comparative example, as shown in FIG. 1 , a multilayer structure was prepared by forming a SiO 2 insulator film 2 and a resist mask 3 on a single crystal silicon wafer 1 . Then, an opening was formed in the resist mask, as illustrated in FIG. 1 . After that, the multilayer structure shown in FIG. 1 was put into an etching apparatus equipped with a power source for supplying a high frequency power of 13.56 MHz. Then, an etching of an exposed portion of the insulator film 2 was conducted for the purpose of making a contact hole in the insulator film 2 , as shown in FIG. 2 . In the etching, an etching gas shown in Table 5 was allowed to flow through the apparatus at a flow rate of 50 SCCM under a pressure of 0.02 Torr with a RF (radio frequency) power density of 2.2 W/cm 2 . After the etching, the etching rate of this etching, the selectivity of the etching toward the insulator film 2 over the resist 3 , and the aspect ratio were determined, and their results are shown in Table 5. Furthermore, the loss of shoulder portions 4 of the resist 3 (see FIG. 2 ) was checked, and its result is also shown in Table 5.
TABLE 5
Etching
Loss of
Etching
Rate
Aspect
Shoulder
Gas
(Å/min)
Selectivity
Ratio
Portions
Example 73
CF 3 OF
5,453
6
At least 7
No
Example 74
C 2 F 5 OF
4,026
7
At least 7
No
Example 75
CF 2 (OF) 2
7,563
6
At least 6
No
Com. Ex. 2
CF 4
608
4
5
Yes
EXAMPLE 76
In this example, Example 73 was repeated except in that an argon gas with a flow rate of 200 SCCM was added to the etching gas (CF 3 OF) of Example 73 and that the flow rate of CF 3 OF was 10 SCCM.
EXAMPLES 77–84
In each of these examples, Example 73 was repeated except in that a hydrogen-containing gas with a flow rate shown in Table 6 was added to the etching gas (CF 3 OF) of Example 73 and the flow rate of CF 3 OF was changed as shown in Table 6. In fact, the total flow rate of CF 3 OF and the hydrogen-containing gas was adjusted to 100 SCCM in Examples 77–84, as shown in Table 6. The results of the etching rates of the insulator film 2 , which is made of SiO 2 , and the silicon wafer 1 , which is made of Si, are shown in Table 6. It is understood from Table 6 that the etching rate of the silicon wafer 1 has decreased drastically with the increase of the flow rate of the hydrogen-containing gas, and in contrast the etching rate of the SiO 2 insulator film was relatively stable even with the increase of the flow rate of the hydrogen-containing gas. In other words, it is understood that the SiO 2 insulator film can selectively be etched away by adding a hydrogen-containing gas into the etching gas (i.e., hypofluorite), over the silicon wafer. Furthermore, similar results of the etching rates were also obtained by respectively using CH 4 , HI, HCl and HBr as hydrogen-containing gases.
TABLE 6
Flow Rate of
Etching Rate
Flow Rate
Hydrogen-
Hydrogen-
(Å/min)
of CF 3 OF
containing
containing
Insulator
Silicon
(SCCM)
Gas
Gas (SCCM)
Film
Wafer
Example
100
H 2
0
5,560
40,856
77
Example
99.9
H 2
0.1
5,560
38,856
78
Example
99
H 2
1
5,560
18,856
79
Example
90
H 2
10
5,260
5,189
80
Example
70
H 2
30
5,240
889
81
Example
60
H 2
40
5,060
11
82
Example
10
H 2
90
3,596
0.5
83
Example
60
C 2 H 2
40
5,010
9
84
EXAMPLE 85
In this example, a first etching was conducted by etching a tungsten film in the same way as that of Example 73. The etching rate of the first etching was 39,554 Å/min. A second etching was conducted in the same way as that of the first etching except in that oxygen with a flow rate of 10 SCCM was added to the etching gas (CF 3 OF). The etching rate of the second etching was 400,259 Å/min. A third etching was conducted in the same way as that of the first etching except in that the tungsten film was replaced with a SiO 2 film. The etching rate of the third etching was 5,453 Å/min. A fourth etching was conducted in the same way as that of the third etching except in that oxygen with a flow rate of 10 SCCM was added to the etching gas (CF 3 OF). The etching rate of the fourth etching was 9,865 Å/min. It is understood from the etching rates of the first to fourth etchings that the etching rate of a metal film (tungsten film) increases more greatly by adding oxygen to an etching gas, than that of an oxide film (SiO 2 ) does.
The entire disclosure of each of Japanese Patent Application Nos. 9-349536 filed on Dec. 18, 1997, 10-239338 filed on Aug. 26, 1998, and 10-239339 filed on Aug. 26, 1998, including specification, claims, drawings and summary, is incorporated herein by reference in its entirety.
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The invention relates to a gas for removing deposits by a gas-solid reaction. This gas includes a hypofluorite that is defined as being a compound having at least one OF group in the molecule. Various deposits can be removed by the gas, and the gas can easily be made unharmful on the global environment after the removal of the deposits, due to the use of a hypofluorite. The gas may be a cleaning gas for cleaning, for example, the inside of an apparatus for producing semiconductor devices. This cleaning gas comprises 1–100 volume % of the hypofluorite. Alternatively, the gas of the invention may be an etching gas for removing an unwanted portion of a film deposited on a substrate. The unwanted portion can be removed by this etching gas as precisely as originally designed, due to the use of a hypofluorite. The invention further relates to a method for removing a deposit by the gas. This method includes the step (a) bringing the gas into contact with the deposit, thereby to remove the deposit by a gas-solid reaction.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/662,975 filed on Oct. 29, 2012, which is a continuation of U.S. patent application Ser. No. 11/402,319 filed on Apr. 11, 2006, which claims the benefit of U.S. Provisional Application No. 60/680,851, filed on May 13, 2005. The entire disclosures of each of the above applications are incorporated herein by reference.
FIELD
[0002] The present teachings relate to an apparatus for the correction of chest wall deformities, and more specifically to a pectus bar stabilizer.
BACKGROUND
[0003] To correct chest wall deformities, a pectus bar may be fixedly mounted to supporting structure, typically cartilage, using a stabilizer plate, which generally includes a single plate having a recess through a central portion and apertures therein for receiving and fixedly attaching a pectus bar thereto. A pectus bar stabilizer may also include a series of apertures on distal portions for fixedly securing the stabilizer plate to the supporting structure. To remove or adjust the pectus bar, screws securing the pectus bar to the stabilizer plate must be removed. But the screws are often difficult to access and remove due to surrounding tissue or bone growth.
SUMMARY
[0004] A pectus bar stabilizer assembly generally includes a pectus bar, a retainer assembly, a first base part and a second base part. The first and second base parts are separable from one another to facilitate removal and combinable to define a channel therebetween. The pectus bar is received by the channel and the retainer assembly retains the pectus bar in the channel. A portion of the retainer assembly may be removed, allowing the pectus bar to be removed or adjusted.
[0005] Further areas of applicability of the present teachings will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present teachings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present teachings will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0007] FIG. 1 is a perspective view of a first pectus bar stabilizer assembly shown partially assembled and partially exploded;
[0008] FIG. 2 is a front perspective view of one base part of a pectus bar stabilizer;
[0009] FIG. 3 is a rear perspective view of the base part of FIG. 2 ;
[0010] FIG. 4 is a sectional view of the base parts of the pectus bar stabilizer as cut along line IV-IV of FIG. 1 ;
[0011] FIG. 5 is a plan view of the tool and stopping member;
[0012] FIG. 6 is a partial plan view of the tool and stopping member;
[0013] FIG. 7 is a perspective view of a pectus bar stabilizer assembly shown partially assembled and partially exploded;
[0014] FIG. 8 is a front perspective view of one base part of the pectus bar stabilizer shown in FIG. 7 ;
[0015] FIG. 9 is a rear perspective view of the base part of FIG. 8 ;
[0016] FIG. 10 is a perspective view of a pectus bar stabilizer assembly shown partially assembled and partially exploded;
[0017] FIG. 11 is a front perspective view of one base part of the pectus bar stabilizer shown in FIG. 10 ;
[0018] FIG. 12 is a rear perspective view of the base part of FIG. 11 .
[0019] FIG. 13 is a perspective view of a pectus bar stabilizer assembly shown partially assembled and partially exploded;
[0020] FIG. 14A is a front perspective view of one base part of the pectus bar stabilizer shown in FIG. 13 ;
[0021] FIG. 14B is an additional front perspective view of the base part of FIG. 14A ;
[0022] FIG. 15A is a rear perspective view of the base part of FIG. 14 .
[0023] FIG. 15B is an additional front perspective view of the base part of FIG. 15A ;
[0024] FIG. 16 is a front perspective view of one base part of the pectus bar stabilizer shown in FIG. 13 having an additional feature;
[0025] FIG. 17 is a rear perspective view of the base part of FIG. 16 ;
[0026] FIG. 18 is a perspective view of a pectus bar stabilizer assembly shown partially assembled and partially exploded;
[0027] FIG. 19 is a perspective view of the pectus bar stabilizer of FIG. 18 ; and
[0028] FIG. 20 is a sectional view of the pectus bar stabilizer of FIG. 19 taken at line 20 - 20 .
DETAILED DESCRIPTION
[0029] FIGS. 1-4 show a pectus bar stabilizer assembly 10 generally includes a pectus bar 12 and a pectus bar stabilizer 14 . The pectus bar stabilizer 14 retains the pectus bar 12 and may be fixedly attached to an external structure, such as cartilage.
[0030] The pectus bar 12 may have a longitudinally extending bar of generally uniform thickness, a generally rectangular cross-section, and an end portion 24 opposite a second end portion 26 . The first and second end portions 24 , 26 may include an arcuate periphery and an aperture 25 . A series of apertures 28 , 30 , which may include internal threads, may be disposed inwardly from the end portions 24 , 26 .
[0031] The pectus bar stabilizer 14 may include first and second base parts 20 , 22 and a retainer assembly 78 . The first and second base parts 20 , 22 may be generally similar to one another, with minor differences that will be discussed below. For simplicity in the description, first base part 20 will be discussed in detail.
[0032] The first base part 20 may include a body portion 32 and a leg 34 extending therefrom. The body portion 32 may include an inner body wall 36 , a top body surface 38 , a lower body surface 40 and an outer body surface 42 . The top body surface 38 may include three main sections 44 , 46 , 48 . The first section 44 is generally planar and includes a series of notches 50 . The second section 46 is contoured and slopes downward from the first section 44 to the third section 48 . The third section 48 is generally planar and extends from the second section 46 . The lower body surface 40 is generally planar and generally parallel to the first and third sections 44 , 48 of the top body surface 38 . The outer body surface 42 connects the top body surface 38 , the lower body surface 40 and the inner body wall 36 .
[0033] The inner body wall 36 may include two sections 56 , 58 . The first section 56 is generally rectangular and has a width L 1 and a height L 2 . The second section 58 is generally rectangular and has a width L 1 and a height L 3 . The height L 3 of the second section 58 is less than the height L 2 of the first section 56 . A recess 60 , defined below the second section 58 and proximate the first section 56 , extends into the body portion 32 a depth of L 4 and has a width L 1 and a height L 5 .
[0034] A leg 34 extends generally perpendicularly from the first section 56 of the inner body wall 36 . The leg 34 may have a width generally equal to the width L 1 of the first section 56 of the inner body wall 36 and may be divided into a first leg portion 62 and a second leg portion 64 . The first leg portion 62 , which is located proximate the body portion 32 , may have a generally rectangular cross-section and a height less than the height L 5 of the recess 60 in the body portion 32 . The first leg portion 62 of the first and second base parts 20 , 22 may also each include an arcuate recess 63 at an inner edge portion 65 as shown in FIGS. 7-9 . The second leg portion 64 may have a generally rectangular cross-section and may be sized to generally fit within the recess 60 , having a height, length and width generally corresponding to the dimensions L 5 , L 4 , L 1 of recess 60 .
[0035] A series of apertures may be located in the first base part 20 . A first aperture 52 may be located at a distal end 54 of the body portion 32 , passing through the third section 48 of the top body surface 38 and the lower body surface 40 . The first aperture 52 allows the first base part 20 to be coupled to a supporting structure, such as cartilage. A series of pin apertures 66 , 68 , 70 , 72 may be provided in the first and second base parts 20 , 22 . The pin apertures 66 , 68 extend partially into the first base part 20 . The first pin aperture 66 extends into body portion 32 through the recess side wall 74 in the recess 60 of body portion 32 . The second pin aperture 68 extends into the second leg portion 64 through the second leg portion side wall 76 . The pin apertures 70 , 72 in the second base part 22 may be positioned similarly to those in the first base part 20 , and may extend completely through the second leg portion 64 and the body portion 32 of the second base part 22 , as shown in FIG. 4 . Alternatively, the base parts 20 , 22 may not include any pin apertures, eliminating the need for pins as shown in FIGS. 7-9 .
[0036] The retainer assembly 78 may include a series of pins 80 , a series of retaining bars 82 and a stopping member assembly 84 . The pins 80 may be generally cylindrical members, sized to be located within the pin apertures 66 , 68 , 70 , 72 . The pin may include a first portion 81 and a main portion 83 generally extending therefrom. The first portion 81 of the pin 80 may have a diameter greater than the diameter of the main portion 83 of the pin 80 . The main portion 83 of the pin 80 may be smaller in diameter than the pin apertures 66 , 68 , 70 , 72 . The main portion 83 may be first inserted into the pin apertures 66 , 68 , 70 , 72 . The first portion 81 may have a diameter similar to the diameter of the pin apertures, resulting in retention of the pin within the pin apertures 66 , 68 , 70 , 72 , due to friction between the first portion 81 and pin apertures 70 , 72 .
[0037] The retaining bars 82 may include a first end portion 86 opposite a second end portion 88 . The retaining bars 82 may generally have flattened, substantially rectangular cross-sections with rounded edges at the first and second end portions 86 , 88 . The retaining bars 82 may have a generally uniform thickness throughout their length. The first and second ends 86 , 88 of the retaining bars 82 may be located in the notches 50 in the body portions 32 of the base parts 20 , 22 .
[0038] The stopping member assembly 84 , shown in FIGS. 5 and 6 , may include a tool 90 , a neck portion 92 and a stopping member 94 . The tool 90 is generally cylindrical and may include a knurled surface 96 to facilitate grasp by a user. A distal end 98 of the tool 90 may be generally conical, having a greater diameter at a first end 100 and a reduced diameter at a second end 102 . A neck portion 92 may generally extend from the distal end 98 of the tool 90 to the stopping member 94 . The neck portion 92 may be substantially smaller in diameter than both the tool 90 and the stopping member 94 and provides a mechanism to separate the tool 90 from the stopping member 94 . The separation feature may be a necked-down portion facilitating separation by bending or twisting the tool 90 relative to the stopping member 94 , or may include a torque-limiting feature to sever the tool 90 from the stopping member 94 upon meeting a predetermined torque limit during insertion. The neck portion 92 diameter may be one-tenth of the diameter of the tool 90 and less than one-half of the diameter of the smallest diameter of the stopping member 94 . A variation may include a separate tool and stopping member.
[0039] The stopping member 94 may include a hexagonal head 104 and a body portion 106 generally extending therefrom. The hexagonal head 104 may be attached to the neck portion 92 . The body portion 106 may include an unthreaded portion 108 and a threaded portion 110 . The unthreaded portion 108 may be located proximate the hexagonal head 104 and the threaded portion 110 may be located at the end of the body portion 106 distal from the hexagonal head 104 .
[0040] The pectus bar stabilizer assembly 10 may retain the pectus bar 12 through the first and second base parts 20 , 22 and the retainer assembly 78 . The two base parts 20 , 22 may be placed proximate one another, inserting the second leg portion 64 of the first base part 20 into the recess 60 of the second base part 22 and inserting the second leg portion 64 of the second base part 22 into the recess 60 of the first base part 20 . In this configuration, the first and second base parts 20 , 22 define a channel 112 bound by the inner body wall 36 of the first base part 20 , the inner body wall 36 of the second base part 22 and the first leg portions 62 of the first and second base parts 20 , 22 . In this configuration, the pin apertures 66 , 68 , 70 , 72 of the first and second base parts 20 , 22 are in respective alignment.
[0041] Once the first and second base parts 20 , 22 have been arranged to define the channel 112 , pins 80 may be inserted into the pin apertures 66 , 68 , 70 , 72 . The pins 80 may extend completely through the first base part 20 and partially into the second base part 22 , securing the first and second base parts 20 , 22 to one another in a transverse direction relative to the axis of the pins 80 . Next, the retaining bars 82 may be placed over the channel 112 . The first and second ends 86 , 88 may be located within the notches 50 in the body portion 32 of the first and second base parts 20 , 22 and welded in place. The retaining bars 82 secure the first and second base parts 20 , 22 to one another in a transverse direction relative to the bars 82 .
[0042] Once the first and second base parts 20 , 22 are fixedly attached to one another, a first end portion 24 of the pectus bar 12 may be inserted into the channel 112 below the retaining bars 82 . After the first end portion 24 is located within the channel 112 , one of the apertures 28 in the first end portion may be aligned between the retaining bars 82 . After the desired aperture 28 is located between the retaining bars 82 , the stopping member 94 may be secured in the aperture 28 . Once the stopping member 94 is securely in place, the tool 90 is separated from the stopping member 94 at the neck portion 92 . The hexagonal head 104 may provide retention of the pectus bar 12 . The body portion 106 of the stopping member 94 may be attached to the aperture 28 in the pectus bar 12 and the hexagonal head 104 may extend above the pectus bar 12 , preventing the pectus bar 12 from translating axially beyond the retaining bars 82 .
[0043] In FIGS. 1-3 , the stopping member 94 is shown only passing through the pectus bar because the channel 112 has no aperture therethrough. As shown in FIGS. 7-9 the channel may have an aperture allowing for passage of the stopping member 94 therethrough, providing further retention. The stopping member 94 may include an additional portion extending beyond the threaded portion 110 . This additional portion may be unthreaded, as shown in FIG. 7 , or may be threaded.
[0044] Other stopping members may be used for retention of the pectus bar 12 within the pectus bar stabilizer 14 . One such example is a rivet, which may be applied to an aperture 28 in the pectus bar 12 , leaving a head portion exposed above the pectus bar 12 and retaining the pectus bar 12 within the pectus bar stabilizer 14 as described above.
[0045] The pectus bar 12 may be removed from the pectus bar stabilizer 14 without removing any of the stopping members 94 . One of the retaining bars 82 located distal from the retained end portion 24 , 26 may be removed allowing the pectus bar 12 to translate axially in a direction free of the bars 82 . Both bars 82 may also be removed to eliminate retention of the pectus bar 82 within the pectus bar stabilizer 14 .
[0046] The pectus bar stabilizer 14 may generally be attached to an external structure, such as cartilage. The pectus bar stabilizer 14 may be attached using the apertures 52 located in the distal portions of the first and second base parts 20 , 22 . The attachment may be made using any suitable method including sutures, screws or some other form of attachment.
[0047] A typical pectus bar stabilizer assembly 10 may include two pectus bar stabilizers 14 , as shown in FIG. 1 . The second pectus bar stabilizer 14 may be identical to the first pectus bar stabilizer 14 , as described above. A second end portion 26 of the pectus bar 12 may be attached to the second pectus bar stabilizer 14 through a second series of apertures 30 in a manner similar to that described above.
[0048] An additional pectus bar stabilizer assembly 210 is shown in FIGS. 10-12 and generally includes a pectus bar 12 and a pectus bar stabilizer 214 . The pectus bar stabilizer 214 retains the pectus bar 12 and may be fixedly attached to an external structure, such as cartilage.
[0049] The pectus bar stabilizer 214 may include first and second base parts 220 , 222 and a retainer assembly 278 . The first and second base parts 220 , 222 may be generally similar to one another. For simplicity in the description, only first base part 220 will be discussed in detail with the understanding that the second base part 222 is similar in structure.
[0050] The first base part 220 may include a first end 232 , a second end 234 and a channel 212 disposed therebetween. The first and second ends 232 , 234 are generally similar and only the first end 232 will be discussed in detail. The first end 232 may include an channel wall 236 , a top body surface 238 , a lower body surface 240 and an outer body surface 242 . The top body surface 238 may include three main sections 244 , 246 , 248 . The first section 244 is generally planar and includes a series of notches 250 . The second section 246 is contoured and slopes downward from the first section 244 to the third section 248 . The third section 248 is generally planar and extends from the second section 246 . An arcuate recess 252 is formed through the third section 248 of the top body surface 238 . The arcuate recess 252 aligns with a similar arcuate recess 252 on the second base part 222 , generally forming an aperture through the first end 232 thereof. The lower body surface 240 is generally planar and generally parallel to the first and third sections 244 , 248 of the top body surface 238 . The outer body surface 242 connects the top body surface 238 , the lower body surface 240 and the channel wall 236 .
[0051] The channel walls 236 define the width of the channel 212 and the middle portion 262 defines the lower structure of the channel 212 . A series of channel notches 268 are located in the channel walls 236 and the first section 244 of the top body surface 238 . A threaded arcuate recess 266 may be formed on the inner surface of the middle portion 262 . When the first and second base parts 220 , 222 are assembled the threaded arcuate recesses 266 of each align, forming a threaded aperture.
[0052] The retainer assembly 278 may include a series of retaining bars 282 and a stopping member assembly 284 . The retaining bars 282 may include a first end portion 286 opposite a second end portion 288 . The retaining bars 282 may generally have flattened, substantially rectangular cross-sections with rounded edges at the first and second end portions 286 , 288 . The retaining bars 282 may have a generally uniform thickness throughout their length. The first and second ends 286 , 288 of the retaining bars 282 may be located in the notches 250 in the first and second ends 232 , 234 of the base parts 220 , 222 .
[0053] The stopping member assembly 284 may include a tool 90 , a neck portion 92 and a stopping member 94 similar to that described above. The stopping member 94 may include an additional threaded portion extending beyond the threaded portion 110 , as shown in FIG. 10 .
[0054] The pectus bar stabilizer assembly 210 may retain the pectus bar 12 through the first and second base parts 220 , 222 and the retainer assembly 278 . The two base parts 220 , 222 may be placed proximate one another defining a channel 212 bound by the channel walls 236 and middle portion 262 . In this configuration, the notches 250 of the first and second base parts 220 , 222 are in respective alignment.
[0055] Once the first and second base parts 220 , 222 have been arranged to define the channel 212 , the retaining bars 282 may be placed along the sides if the channel 212 . The first and second ends 286 , 288 may be located within the notches 250 in the first and second ends 232 , 234 of the first and second base parts 220 , 222 and welded in place. The retaining bars 282 secure the first and second base parts 220 , 222 to one another in both a transverse direction and an axial direction relative to the bars 282 .
[0056] Once the first and second base parts 220 , 222 are fixedly attached to one another, a first end portion 24 of the pectus bar 12 may be inserted into the channel 212 . After the first end portion 24 is located within the channel 212 , one of the apertures 28 in the first end portion may be aligned with the aperture formed by the threaded arcuate recesses 266 in the middle portion 262 . After the desired aperture 28 is located above the aperture formed by the threaded arcuate recesses 266 , the stopping member 94 may be threaded into the aperture 28 and through the aperture formed by the threaded arcuate recesses 266 as well. Once the stopping member 94 is securely in place, the tool 90 is separated from the stopping member 94 at the neck portion 92 . The hexagonal head 104 may provide retention of the pectus bar 12 . The body portion 106 of the stopping member 94 may be attached to both the aperture 28 in the pectus bar 12 and the aperture formed by the threaded arcuate recesses 266 . The hexagonal head 104 may extend above the pectus bar 12 , providing for removal of the stopping member 94 from the pectus bar 12 if desired.
[0057] Other stopping members may be used for retention of the pectus bar 12 within the pectus bar stabilizer 14 . One such example is a rivet, which may be applied to an aperture 28 in the pectus bar 12 , leaving a head portion exposed above the pectus bar 12 to retain the pectus bar 12 within the pectus bar stabilizer 214 as described above.
[0058] The pectus bar 12 may be removed from the pectus bar stabilizer 214 without removing any of the stopping members 94 . The retaining bars 282 located distal from the retained end portion 24 , 26 may be removed allowing one of the base parts 220 , 222 to be removed. The pectus bar 12 may then translate axially in a direction free of the aperture formed by the threaded arcuate recesses 266 . The stopping member 94 may also be removed, freeing the pectus bar 12 from the pectus bar stabilizer 214 .
[0059] The pectus bar stabilizer 214 may generally be attached to an external structure, such as cartilage as previously discussed.
[0060] A further example of a pectus bar stabilizer assembly 310 is shown in FIGS. 13-15 and may generally include a pectus bar 12 and a pectus bar stabilizer 314 . The pectus bar stabilizer 314 retains the pectus bar 12 and may be fixedly attached to an external structure, such as cartilage.
[0061] The pectus bar stabilizer 314 may include first and second base parts 320 , 322 and a retainer assembly 378 . The first and second base parts 320 , 322 may be generally similar to one another. For simplicity in the description, only first base part 320 will be discussed in detail with the understanding that the second base part 322 is similar in structure.
[0062] The first base part 320 may include a body portion 332 and a leg 334 extending therefrom. The body portion 332 may include an inner body wall 336 , a top body surface 338 , a lower body surface 340 and an outer body surface 342 . The top body surface 338 may include three main sections 344 , 346 , 348 . The first section 344 is generally planar and includes a retainer recess 350 .
[0063] The retainer recess 350 may include a first recess 350 a forming a channel in the first section 344 that is generally parallel to the inner body wall 336 . The first recess 350 a may extend the entire width of the first section 344 . The first recess 350 a may be defined by an outer wall 351 and an inner wall 353 located opposite one another. The inner wall 353 may include two discrete sections 353 a, 353 b forming an opening 350 b therebetween.
[0064] The second section 346 is contoured and slopes downward from the first section 344 to the third section 348 . The third section 348 is generally planar and extends from the second section 346 . The lower body surface 340 is generally planar and generally parallel to the first and third sections 344 , 348 of the top body surface 338 . The outer body surface 342 connects the top body surface 338 , the lower body surface 340 and the inner body wall 336 .
[0065] The inner body wall 336 may include two sections 356 , 358 . The first section 356 is generally rectangular and has a width L 31 and a height L 32 . The second section 358 is generally rectangular and has a width L 31 and a height L 33 . The height L 33 of the second section 358 is less than the height L 32 of the first section 356 . A recess 360 , defined below the second section 358 and proximate the first section 356 , extends into the body portion 332 a depth of L 34 at the outer body surface 342 and has a height L 35 . The recess 360 may include an upper recess 360 a and a lower recess 360 b. The upper recess 360 a is defined by a first recess wall 361 , an upper recess surface 367 , a lower recess surface 369 , and the plane of the second section 358 . The first recess wall 361 may have a generally curved profile and extends from the outer body surface 342 to the first section 356 . The lower recess 360 b is located below the upper recess 360 a and extends into the body portion a distance L 37 at the outer body surface 342 . The lower recess 360 b is defined by a second recess wall 371 , the plane of the lower recess surface 369 , the plane of the lower body surface 340 , and the plane of the second section 358 . The second recess wall 371 may have a generally curved profile and extends from the outer body surface 342 to the first section 356 .
[0066] A leg 334 extends generally perpendicularly from the first section 356 of the inner body wall 336 . The leg 334 may be divided into a first leg portion 362 and a second leg portion 364 . The first leg portion 362 , which is located proximate the body portion 332 , may have a generally rectangular cross-section and a height less than the height L 36 defined between the second section 358 and the lower body surface 340 . The first leg portion 362 of the first and second base parts 320 , 322 may also each include an arcuate recess 363 at an inner edge portion 365 as shown in FIGS. 16-17 . The arcuate recess 363 may be optionally threaded (not shown). The second leg portion 364 may include a generally stepped arrangement having an upper portion 364 a and a lower portion 364 b. The upper portion 364 a may have a shape similar to the shape of the upper recess 360 a and the lower portion 364 b may have a shape generally similar to the lower recess 360 b, thereby allowing the second leg portion 364 to generally fit within the recess 360 .
[0067] A series of apertures may be located in the first base part 320 . A first aperture 352 may be located at a distal end 354 of the body portion 332 , passing through the third section 348 of the top body surface 338 and the lower body surface 340 . The first aperture 352 allows the first base part 320 to be coupled to a supporting structure, such as cartilage.
[0068] The retainer assembly 378 may include a retainer bar arrangement 382 and a stopping member assembly 384 . The retainer bar arrangement 382 may include a series of legs 386 interconnected by a series of cross bars 387 extending between the legs 386 and generally perpendicular thereto, forming a channel 389 between the legs 386 and cross bars 387 . The legs 386 may have end portions 391 extending beyond the cross bars 387 . The legs 386 may generally have flattened, substantially rectangular cross-sections. The cross bars 387 may also generally have flattened, substantially rectangular cross-sections similar to those of the legs 386 . The retainer assembly 378 may have a generally uniform thickness throughout its length. The legs 386 are located within the first recess 350 a, extending generally parallel to the channel 312 . The cross bars 387 may extend across the channel 312 and pass through the openings 350 b in the inner wall 353 .
[0069] The stopping member assembly 384 may include a tool 90 , a neck portion 92 and a stopping member 94 similar to that described above. The pectus bar apertures 28 , 30 may be threaded or the aperture 363 in the base parts 320 , 322 may be threaded. If threading exists in either of these parts a screw may be used as the fastener and engage the threaded aperture. The stopping member 94 may include an additional portion extending beyond the threaded portion 110 . This additional portion may be unthreaded to mate with recess 363 in FIGS. 16 and 17 .
[0070] The pectus bar stabilizer assembly 310 may retain the pectus bar 12 through the first and second base parts 320 , 322 and the retainer assembly 378 . The two base parts 320 , 322 may be placed proximate one another defining a channel 312 bound by the channel walls 336 and middle portion 362 . In this configuration, the retainer recesses 350 of the first and second base parts 320 , 322 are in respective alignment.
[0071] Once the first and second base parts 320 , 322 have been arranged to define the channel 312 , the retainer bar arrangement 382 may be placed in the retainer recess 350 , thereby extending across the channel 312 . The retainer bar arrangement 382 may then be welded in place. The retainer bar arrangement 382 secures the first and second base parts 320 , 322 to one another in both a transverse direction and an axial direction relative to the retainer bar arrangement 382 .
[0072] Once the first and second base parts 320 , 322 are fixedly attached to one another, a first end portion 24 of the pectus bar 12 may be inserted into the channel 312 . After the first end portion 24 is located within the channel 312 , one of the apertures 28 in the first end portion may be aligned with the channel 389 . After the desired aperture 28 is located below the channel 389 , the stopping member 94 may be threaded, or otherwise fixedly secured, into the aperture 28 . Once the stopping member 94 is securely in place, the tool 90 is separated from the stopping member 94 at the neck portion 92 . The hexagonal head 104 may provide retention of the pectus bar 12 . The body portion 106 of the stopping member 94 may be attached to the aperture 28 in the pectus bar 12 . The hexagonal head 104 may extend above the pectus bar 12 , providing for removal of the stopping member 94 from the pectus bar 12 if desired.
[0073] Other stopping members may be used for retention of the pectus bar 12 within the pectus bar stabilizer 314 . One such example is a rivet, which may be applied to an aperture 28 in the pectus bar 12 , leaving a head portion exposed above the pectus bar 12 to retain the pectus bar 12 within the pectus bar stabilizer 314 as described above.
[0074] The pectus bar 12 may be removed from the pectus bar stabilizer 314 without removing any of the stopping members 94 . The retainer bar arrangement 382 may either partially or entirely removed. The pectus bar 12 may then translate axially free from the retainer bar arrangement 382 . The stopping member 94 may also be removed, freeing the pectus bar 12 from the pectus bar stabilizer 314 .
[0075] The pectus bar stabilizer 314 may generally be attached to an external structure, such as cartilage as previously discussed.
[0076] An additional example of a pectus bar stabilizer assembly 410 is shown in FIGS. 18-20 and may generally include a pectus bar 12 , a one-piece pectus bar stabilizer 414 , and a stopping member assembly 484 . The pectus bar stabilizer 414 retains the pectus bar 12 and may be fixedly attached to an external structure, such as cartilage.
[0077] The pectus bar stabilizer 414 may be machined as a single piece and include outer portions 416 , 418 and a central recessed portion 420 . The pectus bar stabilizer 414 may include inner body walls 436 defining central recessed portion 420 . Pectus bar stabilizer 414 may further include top, lower, and outer body surfaces 438 , 440 , 442 . Top body surface 438 may include three main sections 444 , 446 , 448 . First section 444 may be generally planar. Second section 446 may be contoured and slope downward from first section 444 to third section 448 . Third section 448 may be generally planar and extend from second section 446 . Lower body surface 440 may be generally planar and parallel to first and third sections 444 , 448 of top body surface 438 . Outer body surface 442 may connect top body surface 438 , lower body surface 440 , and inner body wall 436 . Central recessed portion 420 may additionally include a threaded or unthreaded aperture extending therethrough generally similar to the aperture created by unthreaded recess 63 in FIG. 9 or threaded recess 266 in FIG. 10 .
[0078] A series of retaining bars 482 may be integrally formed with and extend between end portions 416 , 418 and over central recessed portion 420 . The retaining bars 482 may have flattened, generally rectangular cross-sections. The retaining bars 482 may have a generally uniform thickness throughout their length.
[0079] A series of apertures 452 , 454 may be located in outer portions 416 , 418 , passing through third section 448 of top body surface 438 and lower body surface 440 . Apertures 452 , 454 allow pectus bar stabilizer 414 to be coupled to a supporting structure, such as cartilage.
[0080] A channel 422 may be located in pectus bar stabilizer 414 . Channel 422 may have a starting point 424 located below and generally between ends of retaining bars 482 . As shown in FIG. 19 , starting point 424 may extend through inner body wall 436 . An end point 426 of channel 422 may extend through lower body surface 440 . Channel 422 may take the form of a variety of paths allowing separation of outer portions 416 , 418 once retaining bars 482 are severed, as discussed below. Channel 422 may be formed in a variety of ways, such as wire electrical discharge machining (EDM).
[0081] Stopping member assembly 484 may include a tool 90 , a neck portion 92 and a stopping member 94 similar to that described above. Stopping member 94 may include an additional portion extending beyond threaded portion 110 , similar to that shown in FIGS. 7 and 10 . This additional portion may be threaded for mating with a threaded aperture or unthreaded to pass through an unthreaded aperture in central recessed portion 420 .
[0082] A first end portion 24 of pectus bar 12 may be inserted into recessed portion 420 below retaining bars 482 . After first end portion 24 is located within central recessed portion 420 , one of apertures 28 may be located between retaining bars 482 , stopping member 94 may then be threaded, or otherwise fixedly secured, into aperture 28 . Once stopping member 94 is securely in place, tool 90 may be separated from stopping member 94 at neck portion 92 . Hexagonal head 104 may provide retention of pectus bar 12 . Body portion 106 of stopping member 94 may be attached to aperture 28 in pectus bar 12 . Hexagonal head 104 may extend above pectus bar 12 , providing for removal of stopping member 94 from pectus bar 12 if desired.
[0083] Other stopping members may be used for retention of pectus bar 12 within pectus bar stabilizer 414 . One such example is a rivet, which may be applied to an aperture 28 in pectus bar 12 , leaving a head portion exposed above pectus bar 12 to retain pectus bar 12 within the pectus bar stabilizer 414 as described above.
[0084] Pectus bar 12 may be removed from pectus bar stabilizer 414 without the removal of stopping members 94 . Retaining bars 482 may be severed resulting in outer portions 416 , 418 being separated from one another due to channel 422 . Pectus bar 12 may then be removed from pectus bar stabilizer 414 while still having stopping member 94 therein.
[0085] The description is merely exemplary in nature and, thus, variations are not to be regarded as a departure from the spirit and scope of the present teachings.
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An assembly for surgically treating a chest-wall deformity may include an implantable stabilizer member, an implantable pectus bar and an implantable stopping member. The implantable stabilizer member may include first and second base parts and a channel defined by the first and second base parts. The stabilizer member may include first and second retaining bars extending between the first and second base parts and traversing the channel. The first and second base parts may be adapted to be secured to tissue of the chest wall. The implantable pectus bar may be receivable within the channel of the stabilizer member. The implantable stopping member may be adapted to be engaged with the pectus bar between the first and second retaining bars after the pectus bar is inserted into the channel to restrict movement of the pectus bar relative to the tissue.
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FIELD OF THE INVENTION
[0001] The invention relates generally to veterinary pharmaceutical compositions and formulations that control the release of the active compound therein to the animal. More specifically, the present invention discloses actives in a dual formulation that stimulates growth and weight gain in domestic animals.
BACKGROUND OF THE INVENTION
[0002] There have been many recent advances in the veterinary sciences and veterinary pharmacology that have resulted in the growth and development of larger, healthier and heartier, bovine, porcine, ovine and equine species. Particularly with respect to the bovine, ovine and porcine groups, the need to feed the world's population through the production of meat provides the impetus to raise domestic animals that grow as quickly and as large as possible.
[0003] Anabolic agents, are widely used to promote the growth of cattle and other domestic animals and stimulated growth promotion is desirable among the cattle farmers because it maximizes both rate of weight gain and the absolute amount of weight gain per average amount of food consumed, which is termed feed efficiency. Generally, steroids are supplied to the animal in the form of a bio-degradable or non-biodegradable, implantable, time release pellet(s) which is injected under the skin using an implant device. These have been proven to be successful; however, the animals may have to be implanted 2-4 times during their growth period.
[0004] The implant devices used for the subcutaneous delivery of these steroid pellets consist of a housing in the shape of a pistol with a handle, a hollow needle for injecting the pellet into the body of the animal located at the front side of the housing, and a push-rod. The push-rod can be slid into this hollow needle and is supported in the housing so as to be displaceable longitudinally. A chamber is provided in the housing and is attached to the needle. A magazine containing the pellets is inserted and displaceable therein. A longitudinally displaceable press-back device (spring ejector) is arranged in the housing parallel to the push-rod and hollow needle in the housing. The push-rod and press-back device are moved by a driving mechanism which is similarly provided in the housing and which can be set in motion by the operating lever (trigger) fastened to the handle. This engages the driving mechanism and press-back device via a toothed segment coupled with the operating lever and a toothed wheel engaging the press-back device and push-rod. Such a device design is described, for example, in U.S. Pat. No. 5,514,101.
[0005] Zeranol (Formula I, CAS Registry Number: 2653844-3) is an anabolic agent which has shown impressive results in the promotion
[0006] of weight gain and growth in cattle. Zeranol, a resorcylic acid lactone derivative, has shown to be a positive influence on dynamic protein metabolism. However, during the growth and development of the cattle, current formulations containing zeranol or other such anabolic agent must be administered at least twice over the 170 day growth and development period for optimal results. Obviously, this necessitates bringing cattle in from the fields, reinjecting the implant and transporting them out again which is a laborious and time-consuming process.
[0007] It has been determined that zeranol and other anabolic agents provide the best growth and weight gain results when administered early on and throughout the animal's growth cycle. This would require a dual immediate-release/sustained-release formulation which has been hereinbefore not possible.
[0008] U.S. Pat. No. 5,643,595 to Lewis discloses and claims a delivery system for veterinary growth promotants consisting of a biodegradable polymeric matrix that contains a steroid growth promotant and an antibiotic. The steroid growth promotant may consist of zeranol which is formulated within sustained-release microparticles consisting of homopolymers or copolymers of lactic and/or glycolic acid. Other biodegradable polymers used in the sustained-release formulations include polycaprolactone, polydioxonene, polyorthoesters, polyanhydrides, waxes, casein and mixtures thereof.
[0009] U.S. Pat. No. 5,427,796 also to Lewis discloses a method for increasing animal growth comprising the administration of an anabolic steroid such as zeranol in a biodegradable microparticle delivery system that releases the drug in a multiphasic manner. Drug delivery duration allegedly lasts up to 200 days. The same polymers are used in Lewis's other patents noted above and below.
[0010] U.S. Pat. Nos. 5,419,910 and 5,288,496 to Lewis also disclose and claim a microparticulate sustained-release delivery system for promoting growth in animals. The microparticles are comprised of a biodegradable polymeric matrix such as poly-d,l-lactic acid, polyglycolic acid and the like. The microparticles separately encapsulate a steroid growth promotant and an antibiotic. Zeranol, among other anabolic steroids, is disclosed as one of the useful actives that result in increased bulk weight and growth.
[0011] U.S. Pat. No. 4,874,612 to Deasy discloses a multi-component implant for the sustained-release, long-term delivery of pharmaceutical agents to humans and animals for the treatment of vitamin deficiencies, hormone replacement therapy, cancer therapy, infection and the like. Preferably, the biodegradable polymers comprising the implants are used to deliver animal growth promotants which contain anabolic steroids such as zeranol as well as their combinations. The matrix used to make the implants consists of lactic acid/glycolic acid copolymers.
[0012] U.S. Pat. No. 4,191,741 to Hudson et al discloses and claims polymeric implants for the long-term sustained-release of anabolic agents to ruminant animals. The steroids can be administered alone or in combination, one of which is estradiol. Zeranol is not specifically disclosed as one of these agents.
[0013] In fact, the use of biodegradable particles for the long-term, sustained-release of anabolic steroids and other pharmaceutical actives is known in the art. See for example, U.S. Pat. Nos. 4,683,288; 4,677,191; 4,675,189; 4,542,025; 4,530,840; 4,489,055 and 4,389,330.
[0014] Unfortunately, not all of the prior art delivery systems enable zeranol to be administered in a way that maximizes the growth and weight gain potential that exists. Whereas zeranol and other anabolic agents must be administered two to four times during the growth phase of the animal, it would be most advantageous to provide a formulation that need only be administered once.
[0015] It is an object of the present invention to provide an anabolic implant formulation for increased growth and weight gain significantly greater than that achieved by animals given other steroid therapies and those given none at all. It is a further object of the present invention to provide an anabolic implant formulation that is given only once during the growth phase of the animal yet provides both immediate and sustained, long-term administration of the drug throughout the growth period for optimal growth and weight gain.
SUMMARY OF THE INVENTION
[0016] The above-noted objects and others are addressed by aspects of the present invention which provides a method and an anabolic implant formulation for stimulating increased rate of growth, greater amount of growth and greater feed efficiency in cattle. The inventive method comprises administering to the animal an implant composition (or implant as is commonly called) which comprises: (i) an immediate-release formulation containing an anabolic agent, and (ii) a controlled-release formulation containing an anabolic agent with a controlled-release agent, wherein the immediate-release formulation and the controlled-release formulation cooperate to effect the desired stimulation of growth and weight gain. The immediate-release formulation and the controlled-release formulation may be simultaneously administered, or one immediately followed by the other in quick succession in whichever order the administrator chooses, to the animal. Applicants have found that the inventive method of administering a dual formulation surprisingly results in growth and weight gain in the animal much higher than when either formulation (i) or (ii) is implanted without the other.
[0017] The present invention further discloses a method of preparing the above-noted dual formulation, an anabolic implant composition comprising a dual formulation, as well as a method for stimulating growth and weight gain in animals using such compositions.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In one embodiment, this invention discloses a method for stimulating increased rate of growth, greater amount of growth and greater feed efficiency in animals, sometimes generally referred to as cattle in this application. The method comprises administering an anabolic implant composition which is a dual formulation comprising (i) an immediate-release formulation containing an anabolic agent, and (ii) a controlled-release formulation containing an anabolic agent and a controlled-release agent. The immediate-release formulation and the controlled-release formulation cooperate in the cattle to effect the desired stimulation of growth and weight gain. Even though the dual formulation may be administered as one composition by simultaneous administration of both (i) and (ii) above in one administrating (injecting) device, or administered one formulation followed by the other in quick succession in whichever order the administrator prefers, the following description, for simplicity sake, describes the invention as a single step simultaneous administration method.
[0019] The present invention concerns a method of stimulating increased rate of growth, greater amount of growth and greater feed efficiency in food animals which comprises providing to such animals biodegradable and non-biodegradable compressed tablets loaded with an anabolic agent. The method of the present invention provides advantages over methods known in the art such as, inter alia, increased weight gain, a biodegradable or nonbiodegradable system, an implant system, the ability to mix tablets (pellets) containing different drugs and the ability to program the release rate (multiphasic release patterns).
[0020] In a preferred embodiment, administration of the growth promotant to food animals by the method of the invention is achieved by a single administration of the growth promotant loaded into compressed shapes such as, for example, tablets which release the active anabolic agent into the animal in a constant or pulsed manner and eliminates the need for repetitive injections. Some of the tablets contain the active anabolic agent with no controlled-release agent, while the other tablets contain the active anabolic agent with a controlled-release agent, as described later in the Examples. Thus, the former acts as the immediate-release formulation while the latter acts as the controlled formulation.
[0021] The anabolic agent used in the two formulations may be the same or different. Illustrative anabolic agents suitable for and useful as growth promotants in the present invention include zeranol, estradiol and its derivatives such as, for example, estradiol benzoate, trenbolone acetate (Formula II, CAS Registry Number: 10161-34-9, available from Pharmacia & Upjohn Company, Kalamazoo, Mich.), somatotrophin and its derivatives, testosterone and its derivatives such as, for example, testosterone propionate, salbutamol, progesterone, its derivatives and combinations thereof.
[0022] In the immediate-release formulation, the anabolic agent may be used as it is or optionally formulated with minor amounts of other materials such as, for example, diluents, excipients, tabletting agents and the like that are suitable for insertion under the skin. Examples of some of these materials include lactose as a diluent, magnesium stearate as a lubricant, silica as a glidant and the like. For example, the commercially available Ralgro® is formulated with lactose. Other diluent materials include, for example, mannitol, sorbitol, sucrose, dextrose, starches, hydrolyzed starches, and the like.
[0023] In the controlled-release formulation (also referred to as sustained-release formulation in this application), generally the controlled-release agent is a polymer matrix. The polymeric matrix material must be biocompatible. The term biocompatible is defined as a polymeric material which is not toxic to an animal and is not carcinogenic. Whereas the matrix material is biodegradable, the polymeric material should degrade by bodily processes to products readily disposable by the body and should not accumulate therein. When the matrix is non-biodegradable, it is still biocompatible and may remain within the animal at the site of implantation indefinitely. Suitable examples of polymeric matrix materials useful in the present invention include poly(D,L-lactide-co-glycolide) copolymer, ethyl cellulose, methyl acrylate-methyl methacrylate copolymer, methylcellulose, hydroxyethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethyl cellulose, and the like. As in the immediate-release formulation, the anabolic agent and the polymer matrix material in the controlled-release formulation may be optionally formulated with minor amounts of other materials such as, for example, diluents, excipients, tabletting agents and the like, that are suitable for insertion under the skin. Examples of some of these materials include lactose as a diluent, magnesium stearate as a lubricant, silica as a glidant and the like.
[0024] The implant is generally in the shape of a cylindrical tablet. The tablet will generally have a diameter of from about 2.0 mm to 6.0 mm and a length of from about 1.0 mm to about 4.0 mm. The implants for the controlled-release are generally prepared by a procedure wherein the active anabolic agent is mixed with the poly(D,L-lactide-co-glycolide) copolymer or the ethyl cellulose together with the other optional materials and this is then compressed in the die of a tabletting press as is known in the art. Suitable illustrative procedures to make such implants with biodegradable polymer and with non-biodegradable polymer are described later in this application.
[0025] The rate of release of the anabolic agent in the controlled-release formulation can be controlled by a variety of measures. With respect to the poly(D,L-lactide-co-glycolide) copolymer, the rate of degradation of the carrier matrix can be increased by decreasing the size and consequently the molecular weight of the polymer chains. Increasing the amount of the active anabolic agent and consequently reducing the active copolymer weight ratio will increase rate of release. The incorporation of additional plasticizers and other excipients may even speed up the degradation and release. Such modifications will be obvious to those skilled in the art.
[0026] The preparation of the implants containing a biodegradable polymer such as, for example, the poly(D,L-lactide-co-glycolide) copolymer, may be achieved utilizing any number of methods known in the art. An illustrative procedure is as follows. Preferably the anabolic active is first dissolved in a suitable solvent that will also solubilize, emulsify or disperse the poly(D,L-lactide-co-glycolide) copolymer. Suitable solvents include organic solvents such as acetone, chloroform, methylene chloride, other aromatic hydrocarbons, cyclic ethers, esters, alcohols and the like and mixtures thereof. The polymer matrix material is also dissolved or dispersed in the solvent and the emulsion or solution formed thereby may be mixed into a continuous phase. A surfactant may be added to the solution to prevent agglomeration.
[0027] The solvent is then removed, generally by the application of heat, the application of reduced pressure or both. The temperature employed is not critical but it should not be so high as to result in a degradation of either the active compound or the implant biodegradable matrix material. Once the solvent is removed, the solid dose implants may then be prepared using a standard tabletting die press as is known in the art.
[0028] Preferably, the anabolic agent useful in the formulation of the present invention is zeranol. A commercially available formulation of zeranol is Ralgro® (from Schering-Plough Corporation, Terre Haute, Indiana) which additionally contains some lactose. The zeranol content in the present formulation is in an amount of from about 50 wt. % to 95 wt. % preferably from about 55 wt. % to about 85 wt. % and most preferably from about 60 wt. % to about 80 wt. %, based on the total weight of the implant composition (including both the immediate-release part and the controlled-release part).
[0029] The poly (D,L,-lactide-co-glycolide) copolymer is incorporated in the sustained-release formulation in amounts ranging from about 1.0 wt. % to about 10 wt. % and preferably from about 1.0 wt. % to about 5.0 wt. %. If ethyl cellulose is used as the agent in place of the poly(D,L-lactide-co-glycolide) copolymer, greater amounts may be used such as from about 1.0 wt. % to 8.0 wt. % and preferably from about 2.0 wt. % to about 7.0 wt. %.
[0030] The other optional materials may be added to the formulation according to the length of drug delivery desired, but for the most part these will be added in standard amounts as is known in the art. For example, a diluent or excipient may be added in amounts of from about 20 wt. % to 40 wt. %, preferably in an amount of from about 25 wt. % to 40 wt. %, and typically in amounts of from about 25 wt. % to 30 wt. %. Coloring dyes for foods, drugs & cosmetics (“FD & C”), and the like may be incorporated into the formulations in amounts of from 0.1 wt. % to 2.0 wt. % as is known in the art.
[0031] Implants containing non-biodegradable polymer such as, for example, ethyl cellulose, may be prepared by procedures known in the art. An illustrative procedure is as follows: The anabolic agent such as zeranol is mixed with a diluent such as, for example, lactose, and optionally a suitable dye in a planetary mixer. In a separate mixer, an aqueous dispersion of ethylcellulose commercially available as Aquacoat ECD-30® (available from FMC Corporation, Philadelphia, Pa.) is mixed with a suitable plasticizer such as triacetin, or dibutyl sebacate, etc. The plasticized ethyl cellulose is then blended with the anabolic agent/lactose mixture and granulated. The granules are dried at a temperature of from about 50° C. to 70° C. until the formulation is characterized by a moisture level of from about 0.2 wt. %-0.6 wt. % based on the total weight of the formulation. The dried granules are then sized through a sieve, such as, for example, the Fitzmill sieve or its equivalent, and then lubricated with an appropriate lubricant such as magnesium stearate and a glidant such as, for example, silicon dioxide. The granules are then compressed into pellets of the desired size and hardness.
[0032] Without being bound to any theory, it is believed that ethyl cellulose which is a pseudolatex matrix is distributed evenly throughout the wet mass. Upon drying, the matrix particles become finely blended with the active anabolic agent and the excipients. Compression in the tablet die further condenses the ingredients together.
[0033] A heating or curing step is important as this seems to fuse or coalesce the ethyl cellulose particles forming a true matrix structure about the active. This results in the active anabolic agent/excipient blend being fully entrapped by the ethyl cellulose chains.
[0034] For the immediate-release formulation, compositions such as the commercially available zeranol product, such as, for example, Ralgro®, may be used and compressed into suitable size tablets. Any optional ingredients such as, for example, dye and the like, may be mixed in before compressing into tablets.
[0035] The inventive dual formulation is prepared by taking a certain number of thus-prepared tablets containing the controlled-release formulation and a certain number of thus-prepared immediate-release formulation (including Ralgro® which is zeranol plus lactose) tablets in the injection device. The number of each kind is determined based on the total amount of zeranol one desires to inject into the animal. For comparison purposes, the dual formulation injection may be compared with injection of either the controlled formulation tablets alone or the zeranol tablets alone such that the total amount of zeranol would still match with the total zeranol in the inventive dual formulation. The growth enhancement implant pellets are generally subcutaneously injected into the cattle, or other domesticated animal under the ear. After administration, water diffuses into the tablet from the tissue of the animal and is driven by hydration of the lactose and to a small extent by hydration of the anabolic agent. The dissolved active then diffuses out of the matrix structure and into the animal's systemic circulation. As the EXAMPLES demonstrate, Applicants found that the inventive dual formulation tablets surprisingly resulted in a higher increase of growth and weight gain in the test animals than either the controlled- release tablets alone or the zeranol tablets alone.
[0036] Another embodiment of the present invention discloses anabolic implant compositions and formulations for stimulating increased rate of growth, greater amount of growth and greater feed efficiency in cattle. The inventive composition is a dual release formulation which comprises: (i) an immediate-release formulation containing an anabolic agent, and (ii) a controlled-release formulation containing an anabolic agent and a controlled-release agent, wherein the immediate-release formulation and the controlled-release formulation cooperate to effect the desired stimulation of growth and weight gain. The types and examples of (i) and (ii) are described above.
[0037] A further embodiment of the present invention discloses a method of stimulating increased rate of growth, greater amount of growth and greater feed efficiency in cattle, whose growth, weight gain and feed efficiency need to be improved, by administering to said cattle an anabolic implant composition which is a dual release formulation which comprises: (i) an immediate-release formulation containing an anabolic agent, and (ii) a controlled-release formulation containing an anabolic agent and a controlled-release agent, wherein the immediate-release formulation and the controlled-release formulation cooperate to effect the desired stimulation of growth and weight gain. The types and examples of (i) and (ii) are described above.
[0038] A still further embodiment of the present invention concerns a method for stimulating increased rate of growth, greater amount of growth and greater feed efficiency in an animal. The method comprises: preparing an immediate-release formulation comprising an anabolic agent such as, for example, the agents described above, in a shaped object suitable for loading into a device such as, for example, pellets, tablets and the like, which device is suitable for administration of said shaped object into the animal (such as, for example, the pistol described earlier); preparing a controlled-release formulation containing an anabolic agent and a controlled-release agent, in a shaped object similar to above and suitable for loading into the device in step (a), wherein said anabolic agent in step (a) and said anabolic agent in step (b) may be the same or different; loading the device with the shapely object in step (a) and the shapely object in step (b) in a ratio such that the total anabolic agent is in the 50-95 weight percent range based on the combined weight of the two formulations (i.e. the formulation in step (a) and the formulation in step (b)); and administering the shaped objects into the animal, wherein said immediate-release formulation and said controlled-release formulation cooperate to effect the desired stimulation. Suitable controlled agents and methods for making the formulations are described above.
[0039] The following EXAMPLES are provided to more fully describe how to make and use the implants of the present invention, as well as to demonstrate the superior results attained thereby. It should be noted however that the examples are for illustrative purposes only and that minor changes or variations may be made in the amounts and/or methods that are not covered therein. It should also be noted that to the extent any such changes or variations that do not materially alter the composition or effects of the final product are deemed as falling within the spirit and scope of the present invention as later recited in the claims.
Examples
Example 1
Comparison of Weight Gain with Zeranol as Immediate-release Formulation to a Formulation Containing Zeranol as Controlled-release Formulation
[0040] The following zeranol matrix base formulations were prepared to compare controlled-release formulations containing zeranol with Ralgro® and a placebo (an ineffective control). As stated earlier, Ralgro® is a commercially available product of zeranol and lactose.
Formulation Composition A Controlled-release Formulation: zeranol/poly (D,L- lactide-co-glycolide copolymer; 50:50 wt %) (180 mg total zeranol) B Controlled-release Formulation: zeranol/ethyl cellulose (50:50 wt %, 180 mg total zeranol) C Ralgro ® (36 mg zeranol) D Placebo: no Zeranol
[0041] The implants were prepared as follows. For formulation A, the poly (D,L-lactide-co-glycolide 50:50, 3.991 g) was placed in an Erlenmeyer flask and dissolved in 50 grams of ethyl acetate. Separately, the zeranol and lactose (26.606 g) were mixed together dry in a mortar to which the FD & C coloring dyes (0.44 g) were added. The solvent comprising D,L-lactide-co-glycolide and ethyl acetate was then added to the zeranol/dye/lactose mixture. The composition was then heated to 40-45° C. to complete dryness and granulated and sized through a 25 mesh screen. A Cab-O-Sil® silica glidant (0.665 g) was added along with magnesium stearate (1.33 g) which was added as a lubricant. The compositions were then compressed in a tabletting die to obtain solid implants (26.606 mg each implant) with a hardness of 12-20 Strong Cobb units. Formulation B was prepared in a similar manner using ethyl cellulose as the polymer matrix and Aquacoat ECD-30 instead of ethyl acetate. For formulation C, Ralgro® was made into similar size tablets using procedures known in the art. And formulation D, the control with no zeranol was made into tablets similar to in formulation C.
[0042] The implants were administered to twenty (20) steers subcutaneously under the ear. In order to properly compare the formulations of the present invention with those of the prior art, formulation C was administered twice, once at day 0 and again at day 70, each dose containing 36 mg of zeranol. Each steer was weighed at selected time periods during its development and the average body weight for each group given a particular formulation A to D was calculated for each date and are as follows:
TABLE 1 Treatment Day Day Day Day Day Day Day Day Day 0 28 56 70 84 112 140 168 182 A 339 423 483 544 562 616 693 765 803 B 337 426 492 558 568 631 701 780 806 C 339 431 506 562 578 644 716 812 838 D 342 420 473 531 536 593 645 709 742
Example 2
Comparison of Weight Gain with Inventive Dual Formulation versus Weight Gain with Immediate Formulation alone, or with Controlled Formulation alone
[0043] The effects of implanting the dual immediate-release/controlled-release pellets of the present invention on weight and growth gain were studied and compared with zeranol (as Ralgro®) alone, with controlled-release formulation alone and with a non-effective placebo control. That could be done by replacing certain controlled-release tablets of Example 1 with Ralgro® tablet(s). The administered dosages were as follows. The total weight administered is shown in brackets.
Formulation Composition E Placebo control; no zeranol F Ralgro ® (36 mg zeranol; 3 pellets 12 mg each) G Zeranol immediate-release (1 pellet of 18 mg zeranol) + Zeranol controlled-release-poly (D,L,-lactide-co-glycoside) (80 mg zeranol; 4 pellets of 20 mg each) [98 mg total zeranol] H Zeranol immediate-release (1 pellet of 18 mg zeranol) + Zeranol controlled-release/poly (D,L-lactide-co-glycolide) (160 mg zeranol; 8 pellets of 20 mg zeranol each) [178 mg total zeranol] I Zeranol immediate-release (1 pellet of 18 mg zeranol) + Zeranol controlled-release/ethyl cellulose (160 mg zeranol; 8 pellets of 20 mg zeranol each) [178 mg total zeranol] J Zeranol immediate-release (1 pellet of 18 mg zeranol) + Zeranol controlled-release/ethyl cellulose (80 mg zeranol; 4 pellets of 20 mg zeranol each) [98 mg zeranol total]
[0044] As can be seen, to prepare the inventive dual formulations H and I, one zeranol immediate-release pellet and 8 zeranol controlled-release pellets were taken in the device. Similarly, to prepare the inventive dual formulations G and J containing just half the amount of the controlled-release formulation, one zeranol immediate-release pellet and 4 controlled-release pellets were taken in the device. The immediate-release pellets and control release pellets were formulated as in Example 1 and administered to six groups of cattle in a similar fashion, i.e., subcutaneously under the ear. Again, in order to compare the improved formulations with the prescriptions currently followed in the veterinary art, formulation F was administered twice, once (36 mg) at day 0 and again (36 mg) at day 70. Each steer was weighed at different intervals during its development and the average weight for each group given a particular formulation was averaged for each date. The formulations and average weight gain results for each are as follows:
TABLE 2 Average Body Weight (in kilograms) Treatment Day Day Day Day Day Day Day Formulation (-1) 0 28 56 84 112 140 E 309 303 352 389 425 461 491 F 309 300 356 398 435 477 511 G 308 301 354 401 444 485 525 H 309 302 358 404 445 485 525 I 309 302 357 408 451 494 533 J 309 302 356 402 443 481 518
[0045] As is evidenced by the results shown for formulations G-J, superior growth and weight gains were observed with the inventive dual release formulations. Thus, when one (out of nine) of the controlled-release formulation pellets was replaced with one immediate-release pellet (formulations H and I), the weight gain became significantly higher than the results observed following the standard immediate re-implant program (formulation F) above. Such improvement was also noticed even when the controlled-release fraction was reduced by half (from 160 to 80 mg or 8 to 4 pellets) as shown in formulations G and J.
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An improved weight and growth stimulant for domesticated animals such as cattle, pigs and sheep is comprised of an anabolic agent that is subcutaneously administered in the form of a dual release implant formulation. Increased gains are particularly improved when zeranol is administered in an immediate-release and controlled-release formulation which allows for a one-time dosage injection.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the design of position indicator displays for elevators. More particularly, the present invention relates to the circuitry used to drive a segmented display in the applications of an elevator position indicator.
2. Description of the Prior Art
Elevator position indicator displays are the displays that inform a person of the floor location of a particular elevator car at a particular moment in time. Elevator position indicator displays are commonly located in the lobby of buildings and within the actual cars of the elevator. The elevator position indicator display in the lobby of a building informs people in the lobby of the position and direction of the elevator car. In this manner they can gauge how long the wait will be before the elevator reaches the lobby. The elevator position indicator display within the elevator car informs a person of the floor level of the elevator so they know when to disembark the elevator car.
There are many different types of elevator position indicator displays, and there are no standards for their design. Additionally, different elevator systems operate at different supply voltages. Many elevator systems operate with twenty four volt power supplies. Other elevator systems are powered by one hundred and twenty volt power supplies. To further complicate matters, some elevator systems operate with alternating current, while others operate with direct current.
In addition to the wide range of power requirements used by various elevator systems, there is an equally large variety of position indicator displays in use. Although many of these position indicator displays use a segmented display to create alpha-numeric characters, the display drive circuits used to drive the segmented displays vary widely. The prior art of display diver circuits are exemplified by U.S. Pat. No. 5,644,326 to Lauzon, entitled, Display Device With Electrically Interconnected Display Elements; U.S. Pat. No. 5,703,607 to Tai, entitled Drive Circuit For Displaying Seven Segment Decimal Digit; U.S. Pat. No. 5,969,628 to Andre, entitled, Display Device For A 7-Segment Font; and U.S. Pat. No. 3,146,436 to Crow, entitled, Arabic Numeral Display Having Binary Code Conversion Matrix. Due to the complex designs of many display drive circuits, many displays are expensive to manufacture and complicated to repair.
Since elevators systems have different power requirements and vary in design, it is often difficult to repair or replace the elevator position indicator display used within that system. A need therefore exists in the art for a low cost versatile elevator position indicator display that can be retroactively added to most any elevator, regardless of the power specification used by that elevator. A need also exists for a simplified elevator position indicator display that uses a minimal amount of wiring and is easily maintained and repaired. These needs are met by the present invention as it is described and claimed below.
SUMMARY OF THE INVENTION
The present invention is a position indicator display system for an elevator. The elevator position indicator has a segmented display capable of producing alpha-numeric characters. The segmented display operates in a predetermined power range that may or may not match the operational voltage used by the rest of the elevator's systems. Within the elevator position indicator, a display driver is coupled to the segmented display. The display driver receives a location signal from the systems controller of the elevator. The display driver arranges the location signal to drive the segmented display and produce an alpha-numeric character indicative of the location signal. Since the elevator's operational voltage may differ from that of the elevator position indicator, a power conditioning circuit is provided. The power conditioning circuit selectively alters the power of the location signal so that the location signal falls within the operational power range of the segmented display.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference is made to the following description of an exemplary embodiment thereof, considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic of an elevator system having an elevator position indicator;
FIG. 2 is a schematic of a seven segment display;
FIG. 3 is a schematic of a sixteen segment display;
FIG. 4 is a schematic of an elevator position indicator that utilizes twelve possible location signals;
FIG. 5 is a schematic of an elevator position indicator that utilizes three possible location signals; and
FIG. 6 is a schematic of a segment of display drive circuit that uses connector ports that receive voltage steering devices.
DETAILED DESCRIPTION OF THE INVENTION
Although the present invention device can be adapted to drive segmented displays in a variety of application, the present invention device is particularly well suited to drive segmented displays that are part of an elevator position indicator. Accordingly, in order to present the best mode contemplated for the present invention device, the device will be described embodied as part of an elevator position indicator.
Referring to FIG. 1, there is shown a schematic of an overall elevator system 11 as it relates to the elevator's systems controller 16 and the elevator position indicator. The elevator position indicator contains a digital segmented display 12 which is comprised of either seven separate segments or sixteen separate segments. The segmented display 12 itself can be either a back-lit liquid crystal display or a light emitting diode array, as is typical for segmented displays.
The elevator system 11 detects the position of the elevator car using various elevator sensors 14 that are positioned in the elevator shaft. The sensors read the position of the elevator car to the elevator systems controller 16 . The elevator systems controller 16 sends signals to the elevator position indicator 10 so that the segmented display 12 will show the floor location of the elevator car using an alpha-numeric character.
A seven segment display is all that is required if the floor locations of the elevator include a lobby and numerically numbered floors. The sixteen segment display is required if alphabetic characters such as “G” for garage or “M” for mezzanine are to be displayed.
The overall elevator system 11 operates at some operational voltage and current type. The present invention position indicator 10 provides a display that can function at multiple operational voltages and current types. As such, the elevator position indicator 10 can be added to a variety of existing elevator systems.
Referring to FIG. 2, a schematic is shown for the seven segment display 12 . The seven segment display 12 has seven segments. The seven segments are labeled with the labels a, b, c, d, e, f and g, respectively. Each segment of the display is either an LED or an energizable segment of an LCD, depending upon the type of display used. To create the number “1”, segments b and c are energized. To create the number “2”, segments a, b, d, e and g are energized. Other letters and numbers can be created by referring to the following table, where the x's indicate the segments that are energized.
TABLE 1
Segment
Number
a
b
c
d
e
f
g
1:
X
X
2:
X
X
X
X
X
3:
X
X
X
X
X
4:
X
X
X
X
5:
X
X
X
X
X
6:
X
X
X
X
X
X
7:
X
X
X
8:
X
X
X
X
X
X
X
9:
X
X
X
X
X
X
0:
X
X
X
X
X
X
L:
X
X
X
P:
X
X
X
X
X
Referring to FIG. 3, a schematic is shown for the sixteen segment display 15 . The sixteen segment display 15 has sixteen segments. The sixteen segments are labeled with the labels a, b, c, d, e, f, g, h, i, j, k, l, m, n, o and p, respectively. Such a sixteen segment display 15 is capable of producing any alpha-numeric character. For example, to produce the letter “M”, segments c, d, h, g, i and k are energized. To produce the letter “G” segments a, b, d, e, f, g, h, and p are energized.
The sixteen segment display 15 can be used. However, for the sake of simplicity, it will be assumed that the seven segment display of FIG. 2 is being used in the remaining description of the present invention.
Referring now to FIG. 4, a wiring schematic is shown that illustrates the major components of the elevator position indicator. The elevator position indicator preferably includes a rectifying circuit 20 that receives either AC or DC signals from the systems controller 16 of the overall elevator system. The rectifying circuit 20 converts the signals into direct current in a manner which will later be explained with reference to FIG. 5 . If the signals received from the systems controller 16 of the overall elevator system are already using direct current, the rectifying circuit 20 need not be present.
The signals produced by the elevator systems controller are position signals that indicate the position of an elevator car in the elevator system. After location signals from the elevator's system controller are rectified, the location signals pass into a display drive circuit 22 . The purpose of the display drive circuit 22 is to drive the segmented display 12 and ensure that the segmented display 12 displays the proper alpha-numeric character as instructed by the received location signal.
The display drive circuit 22 contains seven vertical lines 24 which correspond to the seven segments of the segmented display 12 . Also shown in FIG. 4 are twelve horizontal lines 26 that correspond to the twelve possible display commands that can be produced by the elevator's system controller 16 . The display commands are the numerals “0” through “9” and the letters “P” and “L” as is listed above in Table 1.
Disposed between the various vertical lines 24 and horizontal lines 26 of the drive circuit 22 are diodes 28 that control the direction of current flow. In FIG. 4, it can be seen that the horizontal line for the received location signal for the number “1” is coupled with diodes to vertical line “b” and vertical line “c”. This shows that to produce the number “1” the “b” and “c” segments (FIG. 2) in the seven segment display 12 are to be lit. As such, it will be understood that the drive circuit 22 of FIG. 4 corresponds to Table 1 with regard to what segments of the seven segment display 12 are to be energized to produce different alpha-numeric characters.
After the drive circuit 22 directs the various location signals to the proper pathways, as represented by the vertical lines 24 , the location signals pass through a power conditioning circuit 30 . The power conditioning circuit. 30 ensures that the current of the location signals is not above the capacity of the segmented display 12 . The details of the power conditioning circuit 30 will later be described with reference to FIG. 5 .
Lastly, the location signals are received by the segmented display 12 . Depending upon which of the twelve possible location signals are received, the segmented display will produce one of the twelve alpha-numeric characters listed in Table 1.
The wiring schematic shown in FIG. 4 would be used on an elevator operating in a building having a parking garage, a lobby and ten floors. This would provide the twelve possible command signals listed in Table 1. However, the system can be used for elevator systems having any other number of floors.
Referring to FIG. 5, the present invention system is configured for an elevator that services only three floors. The elevator has three levels represented by “L” for the lobby, “2” for the second floor and “3” for the third floor. As such, the systems controller of the elevator produces one of three location signals depending upon the position of the elevator car. Those three signals are “L”, “2” and “3”. A control wire 50 is, provided for each of the possible location signals.
If the location signal produced by the systems controller of the elevator is a direct current signal, then the signal need not be rectified. However, if the position signals are in alternating current, the signals must be rectified. In FIG. 5, an exemplary embodiment of a rectifying scheme is shown. In the embodiment of FIG. 5, a full wave bridge rectifier 52 is provided along each control wire 50 . The full wave bridge rectifiers 52 rectify the A/C location signals. In circuit design, there are many circuits that perform the same function as a full wave bridge rectifier, and such circuits can be substituted for the full wave bridge rectifiers shown.
The output voltages of each of the full wave bridge rectifiers 52 lead to the display driver 22 . Previously in FIG. 4, a display driver was shown that was capable of producing twelve alpha-numeric characters. In FIG. 5, the display driver 22 is capable of producing only three alpha-numeric characters because the elevator system only has three floor levels. In FIG. 5, the first row of the display driver is configured to produce the letter “L” on a seven segment display 12 . The second row of the display driver is configured to produce the number “2” on a seven segment display 12 . Lastly, the third row of the display driver 22 is configured to produce the number “3” on a seven segment display 12 .
The display driver. 22 has seven outputs so as to drive a seven segmented display 12 . The outputs of the display driver lead into a power conditioning circuit 30 . In the shown embodiment, the power conditioning circuit utilizes a zener diode 32 , a plurality of resistors 34 and dip switches 36 in series with each of display driver outputs. The zener diodes are illustrated within the a seven segmented display 12 but should be considered part of the power conditioning circuit 30 . The dip switches 36 change which of the resistors 34 are in series with the outputs of the display driver 22 . The resistors 34 have different resistance values. As such, by using the dip switches 36 , a resistor can be selected that reduces the voltage of the display signals into the operational range of the seven segment display 12 . Consequently, by altering the dip switch settings, the system can be altered to operate within a wide range of supply voltages.
The outputs of the power conditioning circuit 30 lead into the seven segment display 12 . The seven segment display 12 produces an “L”, “2” or “3” depending upon the location signal received by from the elevator's systems controller.
In the schematics shown in FIG. 4 and FIG. 5, it appears that the various diodes 28 in the display drive circuit 22 are hard wired to the vertical lines 24 (FIG. 4) and horizontal lines 26 (FIG. 4 ). This need not be the case in all applications. Referring now to FIG. 6, a segment of a display drive circuit 22 is shown having vertical lines 24 and horizontal lines 26 . Each and every horizontal line 26 is interconnected to each and every vertical line 24 through use of a junction line 60 . A diode plug connector 62 is disposed within each junction line 60 . The diode plug connectors 62 are sized to selectively receive and retain a diode 28 . When no diode is present in a diode plug connector 62 , no current flows through the junction line 60 that supports that diode plug connector. However, when a diode 28 is present within the diode plug 60 , current flows through both the junction line 60 and that diode 28 .
As such, it will be understood that by selectively placing different diodes. 28 into different diode plug connectors, a technician can customize the display driver circuit to produce a wide variety of different alpha-numeric characters in response to different incoming signals from the elevator's systems controller 16 (FIG. 4 ).
The present invention elevator position indicator can be used in a wide range of voltages and in applications with either alternating current or direct current. The elevator position indicator uses commonly available parts. As such, the elevator position indicator can be manufactured very inexpensively and can be readily repaired.
It will be understood that the specifics of the elevator position indicator described above illustrates only exemplary embodiments of the present invention. A person skilled in the art can therefore make numerous alterations and modifications to the shown embodiment utilizing functionally equivalent components and circuit layouts to those shown and described. All such modifications are intended to be included within the scope of the present invention as defined by the appended claims.
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A position indicator display system for an elevator. The elevator position indicator has a segmented display capable of producing alpha-numeric characters. The segmented display operates in a predetermined power range that may or may not match the operational voltage used by the rest of the elevator's systems. Within the elevator position indicator, a display driver is coupled to the segmented display. The display driver receives a location signal from the systems controller of the elevator. The display driver arranges the location signal to drive the segmented display and produce an alpha-numeric character indicative of the location signal. Since the elevator's operational voltage may differ from that of the elevator position indicator, a power conditioning circuit is provided. The power conditioning circuit selectively alters the power of the location signal so that the location signal falls within the operational power range of the segmented display.
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BACKGROUND OF THE INVENTION
This invention relates to a storage apparatus for identifiable single articles, capable of being chosen singly at random, particularly storage containers, and comprising at least one conveyor, a receiving station, and a delivery station.
Storage apparatus of the aforedescribed type are known in the field in varying constructions, and such known apparatus are furnished with various conveyor devices in which case large storage needs require a very large space. Furthermore, storage apparatus capable of accepting large amounts of goods and having great density of storage have the disadvantage of requiring a large access or retrieval time.
Accordingly, an object of the present invention is to provide a storage apparatus, for instance an intermediate storage for industrial production flow, having a high capacity and a high storage density concurrent with relatively short access or retrieval times, and facilitating a simple surveyable feed and issue processes as well as storage processes adapted to be controlled by a computer.
This objective is achieved according to the present invention by providing a storage apparatus having an endless circulating conveyor which, in at least on one plane, is formed in loops, lying parallel in generally side-by-side relationships, and which include a plurality of take-out devices, such take-out devices being located at the frontal or inner arcs of the loops and being operatively associated with the delivery stations.
Thus the area of storage is determined by an endlessly circulating conveyor, which may be formed in any desired conventional form, for instance as a belt conveyor, a chain conveyor or a roll conveyor and which assures that the complete contents of the storage apparatus is continually moved while delivering the goods. This movement provides, together with one-way characteristics of the conveyor, an exceedingly simple and easily surveyable condition for receiving goods or articles because one single receiving station may be utilized to feed the entire storage apparatus.
Although such a conveyor consisting of loops disposed in side-by-side relationships in a sinuous manner covers most of the area and needs minimal space for its construction proper, the resulting density of storage does not cause large access or retrieval time despite the resulting storage density even at large filling rates of the apparatus. The individual articles are located at storage sites along the conveyor, and the conveyor brings all the storage sites after a limited time to the frontal side of the loops, the time being a function of the sequence of the storage sites.
Each loop is preferably furnished with a take-out device at its front, although of course, when no immediate delivery is desired, only part of the loops may be furnished with take-out devices.
Basically the storage apparatus may be built in its simplest embodiment upon one plane only. However, for higher storage capacities, a conveyor may be provided which runs through a plurality of planes lying one above the other. In such a case the loops may be built congruently in all planes and run in identical directions. This leads to a very simple support construction and drive mechanism, but will result in relatively long oblique connections between the planes. The planes may also alternatingly be run through in opposite directions resulting in extremely short connections between the planes because the conveyor faces at the ending edge of each plane, the beginning of the next plane simply by moving upwardly or downwardly.
A particular advantage of the apparatus lies in the possibility to regulate and coordinate the access according to the take-out devices. Thus the serial order resulting automatically in an endless conveyor makes it possible to identify individual goods according to their position and to expel them when needed. Marked single goods, containers, for example, may basically be taken out once they are identified and their position upon the conveyor is identified, as soon as they have reached the respective position of a take-out device upon the frontal side of the loop. A computer, for instance, is capable of determining the desired take-out time, when the starting position of a part is given and when the running time and running path are evaluated. The computer can also find a stored item wherever it might be upon the apparatus.
Preferably though the apparatus is furnished with readers, allocated to the take-out devices for coding of loaded parts, so that an individual part or a part of a defined kind may be retrieved by using its code and may be ejected by the take-out device whenever such an individual part reaches the take-out device.
Preferably a process control computer may be used for storage of withdrawal demands, for the reading of code numbers, for the choice of a take-out device in the case where a plurality of identical goods can reach a take-out position, and for regulating time or sequence demanded by delivery processes. The process computer may also possess additional control and regulating functions, for instance, control of input and running control of inventory.
Other features which are considered characteristic of the invention are set forth in the appended claims.
Although the invention is illustrated and described in relationship to specific embodiments, 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 operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a storage device according to one embodiment of the present invention;
FIG. 2 is a sectional view taken along the line II--II in FIG. 1;
FIG. 3 is a view looking in the direction of the arrow III in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The storage apparatus in the drawings consists of an endlessly circulating conveyor 1. The details of construction of the conveyor 1 are not shown but mainly the principal parts are shown. The conveyor 1 may be formed in any known manner, for instance as a belt or chain conveyor or a roller conveyor, and may not necessarily consist of identical parts, but may consist of different elements in various sections, for example some driven and some idling. The conveyor 1 is capable of accepting a large number of single items or articles, particularly packaged articles, such as boxes and containers, at a high density of storage, and is capable of retaining them in a steadily moving transport. For this purpose the conveyor 1 is arranged, as shown in FIG. 1, in loops running back and forth, for example, in a sinuous fashion such as heating coils or heating wires might be arranged.
Due to the fact that the floor space at disposal is occupied mostly by parallel track sections which may be laid at minimal distances from each other, a most advantageous use of floor space results with such an arrangement. This loop design may easily be closed to form an endless line-loop by an external return track connecting the first and the last loop. In this manner the design shown in the top view of FIG. 1 could also be used for a storage device occupying one plane only.
A good use of space is preferably obtained with a higher storage density when the storage apparatus extends over a plurality of planes 3 in which case the conveyor runs through one plane after the other. The schematic of connections is readily perceived in FIG. 2.
Thus the planes 3 are crossed consecutively from the top downwardly by the conveyor in which case the conveyor arriving at the end of one plane moves along oblique sections 4 to the next lower plane. These oblique sections 4 lie congruently under each other. After crossing the bottom most plane, the conveyor returns to the beginning of the top most plane along a correspondingly steeper oblique section 5. This results in an exceedingly simple method of conveying because the parallel loops are designed congruently in planes lying one above the other and because they all run in the same direction. Such a design permits a simple, strong, space saving and easily overseen construction of conveyors.
Nevertheless, the construction of a storage device according to the invention is not fixed upon such routes of the conveyors. When the conveyor loops of the planes lying one above the other are arranged such as in FIG. 1 but run oppositely from plane to plane, a very short connection between the planes arises because the beginning track and ending track of a neighboring underlying plane lie above each other.
In case a relatively steep ascension of the conveyor 5 has to be avoided or prevented, an interleaving sequence of the planes may be provided where a conveyor, for instance, runs along every second plane in descension and runs at the interleaving planes on its ascension.
The basic concept of a storage device constantly recirculated by an endlessly circulating conveyor provides for very simple receiving of goods because it suffices at first to reach any point of conveyor 1 in order to feed it completely. There is no need for a multibranched or movable feeder system in order to reach individual storage places. The storage places pass the receiving station and are thus accessible. In order to increase the effectiveness of receiving goods, a plurality of feeding stations may be provided which are disposed at distances corresponding to the length of the conveyor, but, on the other hand, retain the possibility to subsist on a single input station for a relatively large storage flow.
In the illustrated embodiment a receiving station 6 consists of a receiving conveyor 7 and a receiving reader 8. The receiving conveyor 7 enters or operatively leads to the conveyor 5 and 9 and thereafter passes to the first loop of the uppermost plane in order to run the storage in a planar manner from the top down. Thus newly fed-in wares or articles will run at first through all loops of the uppermost plane (see FIG. 2) from left to right and then in the same direction through the planes disposed below one under the other. This sequence is not the only one, inasmuch as the endless conveyor allows feeding at any desired and accessible spot.
The input reader 8 may be any controlling device having varied functions, and in the illustrated embodiment it is a code reader, which reads codings, particularly strip coding of containers, checks its legibility and brings the coded input to a non-illustrated computer. An illegible (based on conventional test numbers) or obviously wrongly coded load may be stopped or ejected. Otherwise the goods enter the conveyor whereby the input is stored in the computer as an addition to the inventory, and when so desired, with its position and time of addition. Thus the computer is capable of constantly recording the inventory of the storage apparatus.
While stores of high capacity and storage density usually have the disadvantage of long delivery or retrieval times, the delivery or retrieval time of the storage apparatus according to the present invention is relatively short, in other words equal to the run of the conveyor along one loop (maximum), thus to the run along two tracks. The average delivery time amounts to approximately the running time of the conveyor along one track. Means are present to make the conveyor accessible at the end of each loop and to remove goods therefrom.
For that purpose a take-out device 10, shown symbolically in FIG. 1, is associated with each loop at its frontal arc. This take-out device 10 makes it possible to eject any individual goods which are desired to be delivered or retrieved, and which pass the take-out device 10 on the conveyor. A vertical conveyor 11 allocated commonly to the loops disposed one above the other is capable of accepting the ejected goods and to set it upon one of two selected retrieving conveyors 12, 13 which run one above the other.
The construction of the delivery of single articles may be varied according to known transportation techniques. Thus, for example, a delivery station may be provided which is allocated in common to the loops arranged one on top of the other and connected to the vertical conveyor 11 instead of stationary delivery stations allocated to the individual loops. The take-out devices 10 may also influence the arrangement of horizontal or oblique conveyors, and this technique allows numerous variations. In such cases a plurality of take-out devices may be provided which are equally distributed along the conveyor forming the storage. These take-out devices are capable of acting at each position of the storage apparatus within maximum or average time spans, respectively and thereby upon each individual article and thereby effect its delivery.
Control of delivery of a desired article due to a called order may, for instance, be actuated by a computer which identifies the selected article and its serial position on the conveyor and the position of the conveyor itself in order to signal on time the nearest take-out device to be reached by the selected article. There are, of course, factors to be considered and conditions for correct functioning particularly relating to the well defined position of the goods upon the conveyor, the synchronisation of the conveyor, and the synchronisation of the computer with the conveyor.
Therefore, it is preferable to allocate to each take-out device a delivery reader 14 which reads the codes of the passing articles. These codes are transmitted to a computer which regulates and controls the take-out devices. In the simplest case, the computer will store the code of a called-for stored article and then effect operation of the take-out device closest to the reader once the reader transmits the respective code.
The computer can furthermore provide a central regulating function in such a manner that it choses one individual take-out device when several of the ancillary readers announce a coding of the demanded kind. Thus, the computer is capable of choosing when more than one article is ready to be taken out.
Such a computer is also capable to control the delivery of an article in a correct sequence when a plurality of articles are on their way to be delivered. It may be planned additionally that since the vertical conveyor 11 has one single acceptance device, there may be furnished between the vertical conveyor 11 and the conveyor or storage device, respectively, a storage device or at least an intermediate place of deposit. Difficulties caused by simultaneous delivery of goods from different planes can be prevented thereby. The vertical conveyor may deposit the selected article upon one of the two horizontal conveyors 12 or 13 running one above the other. The computer may now decide which one of the conveyors 12 and 13 and at what time it is to receive the article. The conveyors 12 and 13 may also run at different speeds. In such a case the problem of differing delivery pathways arises which may cause that article called for at a later time to arrive before the earlier called-for article. The reason may be, that such article may sit upon a plane closer to the conveyors and/or that it reaches the conveyors 12 and 13 relatively farther downstream. By choosing a deposition upon the two horizontal conveyors, in some cases by regulating the conveying speed or by disposing interlocks on the conveyors, such errors of delivery may be corrected. The construction of two or more horizontal conveyors permits goods to pass each other.
It is thought that the invention and many of its attendant advantages will be understood from the foregoing description and that it will be apparent that various changes may be made in the form, construction, and arrangements of the parts without departing from the spirit and scope of the invention or sacrificing all of its material advantages. The form heretofore described being merely a preferred embodiment.
The take-off devices 10 may consist of pushing mechanisms which extend a pusher element onto the conveyor over the U-shaped portions to push the article from its position on the U-shaped portion of the conveyor onto the conveyor element 11. After the article has been pushed off the conveyor, the pusher element is retracted. The pusher element may be pneumatically or hydraulically actuated, utilizing a conventional cylinder and piston arrangement.
The process computer 15 is not shown in the drawing but, in the drawings, it would be represented by a box having connecting lines to the readers 8 and 14. 9n
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Storage apparatus for articles capable of being retrieved includes at least one conveyor disposed generally in at least one plane and arranged in a generally sinuous manner formed by a plurality of joined loops each having generally U-shaped portions and generally straight portions with the straight portions being disposed side-by-side in generally parallel array. A receiving station receives articles and transfers them to the conveyor, and a take-off device takes off articles from the conveyor, the take-off device being arranged within at least one of the U-shaped portions for taking off the articles from the conveyor as the article is disposed in at least one U-shaped portion of the conveyor.
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BACKGROUND OF THE INVENTION
The invention relates to improvements in powered roller conveyors and, in particular, to a novel drive sprocket arrangement for the rollers of such conveyors.
PRIOR ART
Power driven roller conveyors are used in process equipment for conveying materials such as wet slurrys, mats, and so forth, through dewatering and/or drying stations. By way of example, wet or water laden materials conveyed by such conveyors are processed into wall board, ceiling tile, and the like as is known in the art. Commonly, the rollers of the conveyor are each driven through a sprocket fixed to its shaft. The sprockets are typically driven by a common endless chain. The service conditions in which the sprockets operate are adverse, often with no practical way for sealing the materials being processed away from the sprockets and for lubricating the sprockets. The operating conditions typically result in a wear rate that requires replacement of the sprockets every year or so and, in any event, far more routinely than an entire conveyor is replaced.
Sprocket replacement is expensive in terms of both the cost of parts and labor. The sprockets typically occupy a crowded space and it is not easy to separate them from their respective shafts after they have been in service for any significant period. It is common for a mechanic to break the sprockets off, by striking blows with a hammer, rather than pulling them off, since it is difficult to grip them with a puller and it is not unusual for them to be tightly locked onto their shafts as a result of corrosion and the build-up of dirt and debris on the shafts.
SUMMARY OF THE INVENTION
The invention provides a novel sprocket arrangement for a powered roller conveyor useful in a hot air dryer or like processing equipment. The sprocket arrangement of the invention comprises mating hub and sprocket plate elements that allow ready replacement of the sprocket plate after its service life has been exhausted while allowing the hub to remain fixed on its associated roller shaft. The invention departs from the time honored practice of replacing worn out integrated sprocket and hub units. By only replacing that part of a sprocket and hub drive unit that experiences significant, and in practice, inevitable wear, the invention affords substantial savings in both material and labor.
Since only about half of the combined material of the sprocket and hub assembly is replaced, there can be significant savings in material costs. Moreover, the labor to replace a worn sprocket plate, in accordance with the invention, is considerably less than that involved in removing a prior art unitary sprocket and hub, typically frozen on to the roller shaft and difficult to reach because of obstructions posed by adjacent sprockets and other parts of the conveyor.
The disclosed sprocket plate and hub elements have unique mating configurations that allow the sprocket plate to apply torque to the hub through abutting surfaces that are generous in size and effective radius so as to transfer forces by low compressive stresses rather than at concentrated points by shear forces. In one embodiment, the torque coupling between the sprocket plate and hub is isolated from machine screws used to hold these components together. Consequently, these fastener elements or screws can be of moderate size, thereby saving costs and effort needed for their original assembly and eventual removal when a sprocket must be replaced. In another embodiment, the sprocket and hub are configured to be coupled together without separate fasteners.
The disclosed sprocket plate and hub arrangement solves a problem of removing a sprocket from an operational position where the hub has a maximum outside diameter larger than a minimum inside diameter of the sprocket plate.
Still further, in one disclosed preferred embodiment, the sprocket plate is configured as a ring with a large open center to permit it to be removed, when worn out, by slipping it over its associated roller thereby affording flexibility in the steps that can be taken for sprocket plate replacement. This flexibility in the manner in which the sprocket plate can be removed allows a mechanic to choose the easiest way, off either end of a roll assembly for its removal, while still avoiding the removal of the sprocket hub. The ring-like structure of a sprocket plate significantly reduces its material content over that compared with integrated sprocket and hub units thereby reducing the cost of manufacture of replacement parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified fragmentary elevational view of a roller conveyor fitted with one embodiment of the sprocket arrangement of the invention;
FIG. 1A is an elevational end view of the relationship of a sprocket plate to its associated roller in the arrangement of FIG. 1 ;
FIG. 2 is a fragmentary plan view of the conveyor arrangement of FIG. 1 ;
FIG. 3 is a fragmentary exploded perspective view of the conveyor of FIG. 1 ;
FIG. 4 is a side elevational view of a sprocket plate in accordance with a second embodiment of the invention;
FIG. 5 is a cross-sectional view of a “half” sprocket plate taken in the plane 5 - 5 indicated in FIG. 4 ;
FIG. 6 is a cross-sectional view of a “full” sprocket plate taken in the plane 6 - 6 indicated in FIG. 4 ;
FIG. 7 is a side elevational view of a hub in accordance with the second embodiment of the invention;
FIG. 8 is an edge view of the hub of FIG. 7 ;
FIG. 9 is a side view of a sprocket and hub assembly in accordance with the second embodiment of the invention;
FIG. 10 is a fragmentary view, on an enlarged scale, of the sprocket and hub assembly where the sprocket plate is the “half” style of FIG. 5 ; and
FIG. 11 is a fragmentary view like FIG. 10 , showing the “full” style sprocket plate of FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the figures, there is shown a partial area of a roller conveyor 10 of the type used, for example, in dryers employed in the manufacture of drywall, particle, flake or chipboard, ceiling tile, and like products that are formed by drying a slurry or wet intermediate product. The conveyor 10 has cylindrical rollers 11 carried on respective concentric round shafts 12 mounted in bearings 13 as is conventional. Normally, a large number of rollers 11 are used in a conveyor but for simplicity only three are shown in the figures. It will be understood that a bearing 13 is provided at each end of each roller 11 . The rollers 11 are arranged parallel to one another in a common horizontal plane, typically, with a uniform center-to-center spacing. The rollers 11 can be mounted close to one another to adequately support the material being conveyed which is often in a weak state incapable of supporting itself across a significant span.
Ordinarily, in a typical dryer, there are several vertically spaced layers or decks of rollers 11 . The rollers 11 of each level or deck are all driven in the same direction of rotation by a common chain 14 , which may be of the conventional roller type. Customarily, the chain 14 contacts only one or a limited number of teeth 16 of a sprocket 17 associated with a respective roller 11 at any given time. Usually, the rollers 11 of a level or deck are driven by a single chain at one side of the conveyor 10 .
The sprockets 17 , in accordance with the invention, are assemblies of a sprocket plate 18 on which are formed the teeth 16 , and a hub 19 that is mounted on a roller shaft 12 . As will be described, the sprocket plate 18 and hub 19 are specially configured to interfit or mate with one another for a positive rotational drive between these elements and, alternatively, for passage of the sprocket plate axially completely over the hub. More particularly, the sprocket plate 18 has a spider-like internal bore 21 while the hub has a complementary external spider profile, characterized by radially extending legs or spokes 22 that can fit through the bore.
Each hub 19 is preferably a metal body with a plurality of three internally radially extending legs or spokes 22 . The hubs 19 can be formed of any suitable material such as a ferrous metal like cast iron, cast steel, or hot roll steel. A bore 26 of the hub 19 is sized to fit the shaft 12 of a respective roller 11 which shaft typically is 1-¼ inch in diameter.
The sprocket bore 26 includes an internal keyway 27 for receiving a key 28 . The key 28 is also received in an external keyway in the shaft 12 as is conventional. A set screw 29 threaded into a radial hole 31 in the hub 19 locks against the key 28 and releasably fixes the hub 19 onto the shaft 12 .
The sprocket assemblies 17 along the conveying direction alternate between two constructions or styles, one 36 lying outside, with reference to a zone occupied by the rollers 11 , of an imaginary vertical plane passing through the middle width of the chain 14 , and the other 37 lying to the inside of this imaginary plane. In other words, the inside and outside designations of these sprocket assembly styles 36 , 37 is made with the understanding that parts on the side of the imaginary vertical mid-plane of the chain adjacent the rollers 11 are “inside” and parts on the other side of this imaginary plane are “outside”. To the extent that the features of the sprocket plates and hubs are the same or similar in shape or function, the same reference numerals will apply. The sprocket plates of both styles 36 , 37 have essentially the same axial profile, including number of teeth and outside diameter.
The sprocket assemblies 17 , as mentioned, are all driven in the same rotational direction so that their respective rollers 11 also revolve in this same direction. Adjacent leading edges of the hub legs or spokes 22 , with reference to their direction of rotation, are radially extending lugs or stops 41 . The lugs 41 are formed with abutment surfaces 42 that facing rearwardly with reference to their rotational direction, preferably lie in radial planes that are parallel to and pass through the center of rotation or axis of the hub 19 . The abutment surfaces 42 extend radially outward from an imaginary cylinder concentric with the hub axis and coincident with cylindrical surface segments 43 at the base or radially inward ends of the legs 22 . The abutment surfaces 42 terminate radially outwardly at cylindrical outer surface segments 45 of the legs 22 on a common imaginary cylinder concentric with the bore 26 and forming the major outside hub diameter.
The sprocket plates 18 have asymmetric unidirectional teeth 16 that are shaped to provide a positive drive from limited tangential engagement of the chain 14 . Tips 56 of the teeth 16 represent the outside maximum diameter of the sprockets 17 . The sprocket plates 18 have central bores 57 . Arcuate surface areas 58 of the bore 57 , represent a major diameter area and three intervening arcuate surface areas 59 represent the minor diameter of the bore 57 . The internal sprocket legs 23 are equally angularly spaced and form the minor diameter areas 59 at their inner ends. As seen, the legs 23 span the arcuate space between the major diameter arcuate surfaces 58 . Leading abutment faces 61 , with reference to the direction of rotation of the sprocket assemblies 17 , extend between the inside diameter and outside diameter bore surfaces 58 , 59 and preferably lie in flat planes that are radial to, pass through, and are parallel to a central axis of the sprocket plate 18 .
In the illustrated embodiment, the hub legs 22 of either sprocket style 36 or 37 , are three in number and the sprocket plate legs 23 are of the same number. The arcuate extent of each hub leg 22 is slightly less than an arcuate gap 44 between the internal legs or spokes 23 of the internal sprocket plate bore 21 . This arcuate geometry of the hub and sprocket plate legs as well as the limited radial extent of these legs results in an outer hub profile that is complimentary to and slightly smaller than the interior bore 57 of the sprocket plate thereby enabling a sprocket plate to pass completely over a hub.
A face 47 of the hub 19 lies in a flat radial plane transverse to the hub axis and serves as a seat or abutment surface against which the sprocket plate 18 is secured by machine screws 62 , 63 . The sprocket plates 18 are removably assembled on corresponding hubs with the axes of these elements coincident and held in place by a set of the machine screws 62 or 63 . In the case of the outside style of sprocket assembly 36 , the sprocket plate 18 is held to the hub 19 with socket head machine screws 62 threaded into the sprocket plate and in the case of the inside style of sprocket 37 the sprocket plate 18 is held to the hub 19 by flat head machine screws 63 threaded into the hub. The screws 62 , 63 , hold the respective sprocket plates 18 in abutting contact with the radial hub face 47 . It is this surface 47 from which the hub lugs 41 axially project. When mounted on a hub 19 , radial sprocket surfaces 61 abut the radial lug or abutment surfaces 42 enabling the torque developing forces imposed by the chain 14 to be transmitted to the hub with low compressive stresses imposed on these surfaces as a result of being relatively large and being disposed radially outwardly significantly from their rotational axis. Non-threaded clearance holes 66 , 67 , that receive the machine screws 62 , 63 in the hubs of the respective outside sprocket styles 36 or in the sprocket plates of the inside sprocket style 37 , ensure that the torque transmitted from the sprocket plate 18 to the hub 19 is isolated from the screws, it being understood that this torque is developed by the abutment surfaces 61 , 42 .
As seen in FIG. 2 , and as discussed, the inside and outside styles 37 , 36 of the sprocket assembly 17 can alternate along the feed direction of the conveyor 10 to permit a relatively large sprocket diameter to be used in proportion to the center-to-center distance of the shafts 12 . By offsetting the sprocket assemblies 17 to either side of a center plane of the chain 14 , the sprocket plate 18 of one assembly does not interfere with the sprocket 18 or hub 19 of an adjacent sprocket assembly even where, as shown, the center-to-center distance of adjacent shafts 12 is less than the combined radius of a sprocket and a radius of essentially any part of the sprocket hub on the adjacent shaft. This geometry thereby allows relatively large sprockets to be used and, in turn, reduces the forces required of the chain on the sprocket teeth to develop a given level of torque.
At least the sprocket plates 18 on the outer sprocket assemblies 36 , and preferably the sprocket plates on the inner sprocket assemblies 37 , are able to be passed completely over their associated hubs 19 for purposes of removal and replacement.
The sprocket plates 18 can experience relatively high wear rates due to their operating environment and from time-to-time may need to be replaced. Both the inside and outside sprocket plates can be changed without removal of their associated hubs. Moreover, removal and replacement of these plates can be readily accomplished because the machine screws 62 , 63 securing these plates on their respective hubs can be conveniently reached from the outside, i.e. the space outward of the chain 14 , with the convention that the conveyor rollers 11 are to the inside.
With the invention, replacing each of the sprocket plates 18 is a simple matter of removing three screws 62 or 63 , and separating the plate from its hub. The need for breaking the hub loose from its fit on a shaft 12 is eliminated. Prior to assembly, the screws 62 , 63 , can be coated with a suitable protective sealant so that the risk of corrosion in the threaded holes in the sprocket plate 18 , or hub 19 is reduced. The torque between the sprocket plate and hub developed by the chain force is transmitted between the radial abutment faces 42 and 61 and is preferably isolated from the screws by appropriately dimensioning the parts and especially as mentioned, the clearance holes. Typically, where desired, the shaft 12 can be lifted slightly for access to any of the machine screws 63 on the inside sprocket plates. FIG. 4 shows that a sprocket plate 18 can be removed by sliding it axially over the respective roller 11 . This optional method of removal is permitted where, as shown, the minor inside diameter of the sprocket plate is slightly larger than the diameter of the roller. This geometry can be used on the inside sprocket assembly 37 enabling the inside sprocket to be removed, for example, while the adjacent outside sprockets remain in place or can be used on both inside and outside sprocket assemblies for greater flexibility in maintenance or replace operations.
In many instances, the rollers 11 can be spaced apart far enough to allow the sprockets of each roller to be in-line, i.e. in a common plane without interference. In this case, the width or thickness of a sprocket plate can be double that shown in the figures, while still using the illustrated chain and the axial sprocket plate profile can be the same as that of the described and shown sprocket plates. Such a wide or full width sprocket plate is conveniently used with the inside sprocket style hub illustrated in FIG. 2 .
FIGS. 4-11 illustrate a second embodiment of a sprocket assembly 70 that has structure and function analogous to that of the assembly 17 described in connection with FIGS. 1-3 . The sprocket assembly 70 comprises a sprocket plate 71 and a hub 72 each of which is made from a suitable material such as steel or other ferrous metal. The sprocket plate 71 and hub 72 can be cast, stamped, forged, machined or otherwise made into their respective shapes as desired. The sprocket plate 71 has peripheral unidirectional teeth 73 , distributed about its geometric center, to cooperate with the roller chain 14 like that shown in FIGS. 1 and 3 . The hub 72 has a keyed cylindrical bore 74 with an associated set screw 76 for locking a key 77 onto a shaft such as the shaft 12 shown in FIGS. 1 and 3 . When assembled on the hub 72 , the ring-like sprocket plate 71 has its teeth 73 concentrically disposed about the axis of the bore 74 .
The hub 72 has a central core 78 with a generally circular exterior surface 79 concentric with the bore 74 and with a plurality of three equally angularly spaced legs 81 extending radially outwardly from this core surface 79 . The legs 81 have radially outer surfaces 82 lying on a common imaginary cylinder concentric with the bore 74 . Between the legs 81 are arcuate spaces 83 . As shown in FIGS. 8 , 10 and 11 , the legs 81 each have a slot 84 at mid-length in the axial direction of the bore 74 . Each hub leg slot 84 is open at one arcuate side of the leg 81 and adjacent the cylindrical surface 82 . Each slot 84 has a bottom 86 concentric with the bore 74 on a radius equal or larger than the radius of the core 78 . In an angular direction with respect to the axis of the bore 74 the slot 84 ends to form a generally radially oriented abutment surface 87 that can be semi-cylindrical or otherwise somewhat rounded, when viewed in a plane transverse to the radial direction, for ease of manufacture.
The sprocket plate 71 is ring-like in form and has a plurality of three radially inwardly extending equally angularly spaced legs 89 . The legs have inner surfaces 91 on a common imaginary cylinder concentric with the geometric center of the body of the sprocket plate 71 . Arcuate spaces or gaps 92 between each sprocket plate leg are larger in profile than the profile of a hub leg 81 . The sprocket plate legs 89 have leading edges 93 in a rotational sense that are generally radial with respect to the center of the sprocket plate 71 . As indicated in FIG. 5 , showing a sprocket of “half” thickness, the legs 89 lie in a plane that is offset from the plane of the peripheral teeth 73 a distance that preferably is at least equal to the thickness of the sprocket in the base area of the teeth. The spaces 92 are radially bounded by surfaces 94 lying on a common imaginary cylindrical surface concentric with the center of the sprocket plate 71 . The surfaces 94 form the major inside diameter or bore of the sprocket plate while the surfaces 91 form the minor inside diameter of the sprocket.
As the case with the sprocket and hub shown in FIGS. 1-3 , the major and minor inside diameters of the sprocket plate 71 are at least as large as the major and minor outside diameters of the hub 72 . This relationship, in addition to the gaps between the sprocket legs 89 being larger than the arcuate widths of the hub legs 81 enables the sprocket plate 71 to pass completely over the hub 72 .
The sprocket plate 71 is assembled on the hub 72 by angularly aligning its legs 89 with the hub spaces 83 and slipping it onto the hub until the plane of the legs 89 is coincident with the plane of the hub grooves or slots 84 . The sprocket plate 71 is then rotated relative to the hub 72 in a manner similar to a bayonet connection such that the sprocket plate becomes rotationally coupled to the hub with the radial edge abutment faces 93 on the sprocket legs 89 abutting respective end walls or abutment surfaces 87 at the arcuate ends of the hub slots 84 . The sprocket plate 71 can be releasably locked in position on the hub 72 with a roll pin 95 received in holes drilled through the hub and sprocket plate parallel to their axis.
FIGS. 5 and 10 illustrate a “half” width sprocket that can be used as described earlier where the roller shaft centers are close and inside and outside half width sprockets are alternately mounted from shaft-to-shaft. The sprocket of FIG. 5 can be an outside sprocket and a complementary inside sprocket can be configured as a mirror image of it. A “full” sprocket useful when the conveyor roller spacing is large is illustrated in FIGS. 6 and 11 . It is desirable to proportion the hub 72 widthwise in the manner shown such that its axial length is three times the nominal thickness of a half sprocket at the base of the teeth or 1-½ times the width of a full sprocket at the base of its teeth and it is symmetrical about a mid-plane perpendicular to the axis of the bore 74 . This length permits the hub 72 to be used with both inside and outside style sprockets without interference with an adjacent sprocket as well as with full width sprockets.
It will be understood that sprocket plates of the style illustrated in FIG. 4 can be readily removed from a hub for replacement while the hub remains locked on a shaft. Removal of a sprocket plate 71 only requires the roll pin 95 to be knocked out and the sprocket plate to be rotated in a reverse direction relative to the hub until its legs 89 are aligned with the spaces 83 between the hub legs 81 and then moved axially off of the hub.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. For example, in the embodiment of FIGS. 1-3 , the sprocket plate can be retained against the hub by elements other than machine bolts such as a wedge or a horseshoe clip. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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A sprocket assembly for a roller conveyor comprising a hub and a sprocket plate, the hub having a central cylindrical bore for fitting onto a round shaft of a roller, the hub having provisions for rotationally and axially locking it on a shaft in a manner adequate to transmit torque to the shaft and rotationally drive the roller, the sprocket plate having peripheral teeth adapted to be interengaged with a drive chain and a central bore capable of receiving the shaft, the sprocket plate and hub being constructed and arranged to be removably joined together with the centers of their respective bores coincident, said hub and sprocket plate having complementarily shaped radially extending abutting surfaces enabling the sprocket plate to develop torque on the hub by compressive forces developed by the radially extending sprocket plate surfaces against the radially extending hub surfaces.
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[0001] The invention was made with Government support under Contract DE-AC05-76RL0-1830, awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
TECHNICAL FIELD
[0002] This invention relates to nanocomposite materials with unique and useful electrochemical properties. These nanocomposite materials are formed of graphene and metal oxides. The invention has particular utility when used in batteries and particularly in lithium ion batteries.
BACKGROUND OF THE INVENTION
[0003] There have been a number of examples of methods for forming nanomaterials using graphene and metal oxides to take advantage of the unique electrochemical properties of graphene. For example, U.S. patent application Ser. No. 12/462,857 filed Aug. 10, 2009 describes nanocomposite materials having at least two layers. Each layer consists of one metal oxide bonded to at least one graphene layer. The nanocomposite materials will typically have many alternating layers of metal oxides and graphene layers, bonded in a sandwich type construction and will be incorporated into a electrochemical or energy storage device.
[0004] U.S. patent application Ser. No. 12/553,527 filed Sep. 3, 2009 describes a nanocomposite material formed of graphene and a mesoporous metal oxide having a demonstrated specific capacity of more than 200 F/g with particular utility when employed in supercapacitor applications. These nanocomposite materials by forming a mixture of graphene, a surfactant, and a metal oxide precursor and then precipitating the metal oxide precursor with the surfactant from the mixture to form a mesoporous metal oxide. The mesoporous metal oxide is then deposited onto a surface of the graphene.
[0005] These and other prior art devices typically form the nanocomposite materials using a metal oxides in a salt form, such as lithium titanate (Li 4 Ti 5 O 12 ) as a precursor material. While this Li 4 Ti 5 O 12 material has been shown to work well in these applications, it is expensive and thus may not be suited for certain high volume applications.
[0006] Many of these metal oxides are widely known as inexpensive materials, but are also widely known as poor electrical conductors. For example, titania of the form TiO x in its common forms of its anatase or rutile is widely known as an inexpensive material, but is also widely known as a poor electrical conductor. Therefore, those of ordinary skill in the art have not used these metal oxides, such as titania, as an anode material, or in applications where it would be a precursor to an anode material.
[0007] Accordingly, there exists a need for low cost metal oxides that can be successfully utilized as an anode material, or as a precursor to an anode material in applications where it would be combined with graphene. The present invention fulfills that need.
SUMMARY OF THE INVENTION
[0008] The present invention is therefore a method for forming a nanocomposite material using low cost commodity chemicals as starting materials. The present invention proceeds by first providing metal oxide and graphene in a solvent to form a suspension. The suspension is then applied to a current collector. The solvent is then evaporated to form a nanocomposite material which has at least one metal oxide in electrical communication with at least one graphene layer. Preferably, the solvent is an organic solvent, the metal oxide is titania, and the titania is provided in a particle form wherein the particles have an average diameter below 50 nm, and more preferably below 10 nm.
[0009] In one embodiment, the present invention is a method for forming a nanocomposite material that includes the steps of providing metal oxide and graphene in a solvent to form a suspension. The suspension is then applied to a current collector. The solvent is then evaporated to form an anode. The anode is connected to a cathode having lithium ions and an electrolyte to form a battery. The anode is then electrochemically cycled to form a nanocomposite material of at least one metal oxide in electrical communication with at least one graphene layer.
[0010] In another embodiment, the present invention is a nanocomposite material formed by providing metal oxide and graphene in a solvent to form a suspension. The suspension is then applied to a current collector. The solvent is then evaporated to form an anode. The anode is connected to a cathode having lithium ions and an electrolyte to form a battery. The anode is then electrochemically cycled to form a nanocomposite material of at least one metal oxide in electrical communication with at least one graphene layer. Preferably, the solvent is an organic solvent, the metal oxide is titania, and the titania is provided in a particle form wherein the particles have an average diameter below 50 nm, and more preferably below 10 nm. The nanocomposite material of the forgoing embodiment may further be formed by the steps of connecting the anode to a cathode having lithium ions and an electrolyte to form a battery and electrochemically cycling the anode.
[0011] In another embodiment, the present invention is a battery formed by providing metal oxide and graphene in a solvent to form a suspension. The suspension is then applied to a current collector. The solvent is then evaporated to form an anode. A cathode and an electrolyte are then provided in electrical communication with the anode. The anode is connected to a cathode having lithium ions and an electrolyte to form a battery. The anode is then electrochemically cycled to form a nanocomposite material of at least one metal oxide in electrical communication with at least one graphene layer. Preferably, the solvent is an organic solvent, the metal oxide is titania, and the titania is provided in a particle form wherein the particles have an average diameter below 50 nm, and more preferably below 10 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The following detailed description of the embodiments of the invention will be more readily understood when taken in conjunction with the following drawing, wherein:
[0013] FIG. 1 is a graph of the cycling performance of TiO2/Graphene composite electrodes made by one embodiment of the present invention at various C rates using 2.6 micron graphene.
[0014] FIG. 2 is a graph of the charge/discharge voltage profiles of TiO2/Graphene composite electrode at various C rates of between C/10 and 10C using 2.6 micron graphene.
[0015] FIG. 3 is a graph of the cycling performance of TiO2/Graphene composite electrodes made by one embodiment of the present invention at various C rates using 11.6 micron graphene.
[0016] FIG. 4 is a graph of the charge/discharge voltage profiles of TiO2/Graphene composite electrode at various C rates of between C/10 and 10C using 11.6 micron graphene.
[0017] FIG. 5 is a graph of the cycling performance of TiO2/Graphene composite paper electrodes prepared from an aqueous suspension.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitations of the inventive scope is thereby intended, as the scope of this invention should be evaluated with reference to the claims appended hereto. Alterations and further modifications in the illustrated devices, and such further applications of the principles of the invention as illustrated herein are contemplated as would normally occur to one skilled in the art to which the invention relates.
[0019] Several experiments were conducted to demonstrate various alternative embodiments of the present invention. In the first of these experiments, an aqueous method using a film type application was shown for forming titania/graphene composites of 90/10 wt % and 72/28 wt % (P-25).
[0020] To prepare the 90:10 (wt %) titania:graphene suspensions, 23 mg graphene (Vorbeck Materials LLC) was dispersed in 50 ml H2O using 2.3 mg (10 wt %) CTAB (cetyl trimethylammonium bromide) surfactant and ultrasonicated for 15 minutes. For the 72:28 (wt %) titania:graphene suspensions, 77.8 mg of graphene (Vorbeck Materials LLC) was dispersed in 50 ml H2O using 7.78 mg CTAB (cetyl trimethylammonium bromide) surfactant and ultrasonicated for 15 minutes. In a second container, 200 mg nanosized titania powder (Degussa P25) was dispersed in 50 ml H2O by stirring and ultrasonic mixing for 10 minutes then slowly added to the graphene suspension. The final suspension was then mixed for an additional 4 hours. After mixing, the titania:graphene suspension is filtered, air dried then calcined at 400° C. in a H2/Ar atmosphere for 3 hours.
[0021] To prepare test electrodes, 0.5 ml of poly(vinylidene fluoride) (PVDF) binder dispersed in N-methylpyrrolidone (NMP) solution (0.5 g/20 ml) was added to 0.1125 g of the composite powder and homogenized for 10 minutes. The final slurry was then coated on an Al current collector using a roll applicator to a thickness of approximately 60 microns. Slurry rheology was adjusted using NMP content and viscosities in the range of approximately 1000-5000 cps, which produced good quality films. After drying on a hot plate for 5 minutes, circular test electrodes were made using a 9/16″ punch. The half-cells (2325 coin cell, National Research Council, Canada) with polypropylene membrane separator (Celgard, Inc.), Li metal anode and reference in 1M LiPF6 in EC/DMC (1:1 v/v) (ethyl carbonate/dimethyl carbonate) electrolyte were assembled in a glove box (Mbraun, Inc.) filled with ultra highly purity (UHP) argon. The electrochemical performance of the TiO2/graphene anode was then evaluated using an Arbin Battery Tester BT-2000 (Arbin Inst., College Station, Tex.) at room temperature. The half-cell was tested between 3V and 1V vs. Li at various C rate current based on a theoretical capacity of 168 mAh/g (i.e., 1C=168 mAh·g−1) for anatase. In the next set of these experiments, an aqueous method using a tape application was shown for forming titania/graphene composites of 90/10 wt % and 72/28 wt % (P-25).
[0022] To prepare the 90:10 (wt %) titania:graphene suspensions, 23 mg graphene (Vorbeck Materials LLC) was dispersed in 50 ml H2O using 2.3 mg (10 wt %) CTAB (cetyl trimethylammonium bromide) surfactant and ultrasonicated for 15 minutes. For the 72:28 (wt %) titania:graphene suspensions, 77.8 mg of graphene (Vorbeck Materials LLC) was dispersed in 50 ml H2O using 7.78 mg CTAB (cetyl trimethylammonium bromide) surfactant and ultrasonicated for 15 minutes. In a second container, 200 mg nanosized titania powder (Degussa P25) was dispersed in 50 ml H2O by stirring and ultrasonic mixing for 10 minutes then slowly added to the graphene suspension. The final suspension was then mixed for an additional 4 hours. After mixing, the titania:graphene suspension was filtered, air dried then calcined at 400° C. in a H2/Ar atmosphere for 3 hours.
[0023] For the preparation of P-25/graphene tapes (90 wt % P-25), 222.2 mg of graphene was dispersed in 250 mL H2O using 23 mg of CTAB surfactant and sonicated for 15 min. In a separate container, 2.0 g P-25 was dispersed in 100 mL water by sonication (10 min) The P-25 suspension was slowly added to the graphene dispersion upon stirring and stirred for 4 h. The slurry was filtered, air-dried, and calcined at 400° C. in a H2/Ar for 3 h.
[0024] To prepare P-25/graphene composite tapes, the calcined powder was first dispersed in water and 7 wt % of PTFE suspension (65 wt % in water, Aldrich) was added upon stirring. After 3 additional hours stirring, the mixture was filtered and dried at 90° C. for 30 min. The powder/PTFE green body was then calendared to the desired thickness (˜1-100 microns) using a three-roll mill.
[0025] Circular test electrodes were made using a 9/16″ punch and dried overnight at 110° C. in a vacuum oven. The half-cells (2325 coin cell, National Research Council, Canada) with polypropylene membrane separator (Celgard, Inc.), Li metal anode and reference in 1M LiPF6 in EC/DMC (1:1 v/v) (ethyl carbonate/dimethyl carbonate) electrolyte were assembled in a glove box (Mbraun, Inc.) filled with ultra highly purity (UHP) argon. The electrochemical performance of the TiO2/graphene anode was then evaluated using an Arbin Battery Tester BT-2000 (Arbin Inst., College Station, Tex.) at room temperature. The half-cell was tested between 3V and 1V vs. Li at various C rate current based on a theoretical capacity of 168 mAh/g (i.e., 1C=168 mAh·g−1) for anatase.
[0026] FIG. 5 shows the cycling performance of the titania/graphene composite anodes produced using the aqueous film method. The anode shows a good initial capacity of approximately 120 mAh/g and approximately 20% capacity fade after 100 cycle at a C/5 rate.
[0027] In the next set of these experiments, a non-aqueous method also using a film application was shown for forming titania/graphene composites of 90/10 wt % and 72/28 wt % (P-25).
[0028] Nanosized titania powder (Degussa P25) and graphene (Vorbeck Materials LLC) were dispersed in NMP using ultrasonic mixing (30 min) in 90:10 and 72:28 wt % ratios. Total solids loadings between approximately 3-12 wt % were typically used in preparing the initial suspensions. To these slurries 10 wt % (relative to the solids content) of PVDF binder was added and the mixture stirred 5-16 h and homogenized if needed. Slurry rheology was adjusted using NMP and viscosities in the range of approximately 1000-5000 cps, which produced good quality films.
[0029] The final slurry was then coated on an Al current collector using a roll applicator at a thickness of approximately 60 microns. After drying on a hot plate for 5 minutes, circular test electrodes were made using a 9/16″ punch. The half-cells (2325 coin cell, National Research Council, Canada) with polypropylene membrane separator (Celgard, Inc.), Li metal anode and reference in 1M LiPF6 in EC/DMC (1:1 v/v) (ethyl carbonate/dimethyl carbonate) electrolyte were assembled in a glove box (Mbraun, Inc.) filled with ultra highly purity (UHP) argon. The electrochemical performance of the TiO2/graphene anode was then evaluated using an Arbin Battery Tester BT-2000 (Arbin Inst., College Station, Tex.) at room temperature. The half-cell was tested between 3V and 1V vs. Li at various C rate current based on a theoretical capacity of 168 mAh/g (i.e., 1C=168 mAh·g−1) for anatase.
[0030] FIGS. 1-4 show the measured specific capacity at various C rates and voltage profiles for the half cells prepared using this method. FIGS. 1 and 2 were measured on titania/graphene composites made from graphene with an average particle size of 2.6 μm. The samples had high initial capacity (>170 mAh/g at C/10) and good rate capability (>100 mAh/g at 2C). Less that 5% capacity fade occurred after 200 cycles at 1C, after which the fading rate increased slightly. The sample retained a specific capacity of approximately 100 mAhr/g after 400 hours cycling at 1C.
[0031] The data in FIGS. 3 and 4 was collected on titania/graphene composites made from graphene with an average particle size of 11.6 μm. These samples had even better specific capacity, rate performance and cycling stability than those prepared using the smaller (2.6 μm) graphene particles. Negligible fade occurs after 400 cycles at 1C in these samples. While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. Only certain embodiments have been shown and described, and all changes, equivaλents, and modifications that come within the spirit of the invention described herein are desired to be protected. Any experiments, experimental examples, or experimental results provided herein are intended to be illustrative of the present invention and should not be considered limiting or restrictive with regard to the invention scope. Further, any theory, mechanism of operation, proof, or finding stated herein is meant to further enhance understanding of the present invention and is not intended to limit the present invention in any way to such theory, mechanism of operation, proof, or finding.
[0032] Thus, the specifics of this description and the attached drawings should not be interpreted to limit the scope of this invention to the specifics thereof. Rather, the scope of this invention should be evaluated with reference to the claims appended hereto. In reading the claims it is intended that when words such as “a”, “an”, “at least one”, and “at least a portion” are used there is no intention to limit the claims to only one item unless specifically stated to the contrary in the claims. Further, when the language “at least a portion” and/or “a portion” is used, the claims may include a portion and/or the entire items unless specifically stated to the contrary. Likewise, where the term “input” or “output” is used in connection with an electric device or fluid processing unit, it should be understood to comprehend singular or plural and one or more signal channels or fluid lines as appropriate in the context. Finally, all publications, patents, and patent applications cited in this specification are herein incorporated by reference to the extent not inconsistent with the present disclosure as if each were specifically and individually indicated to be incorporated by reference and set forth in its entirety herein.
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A method for forming a nanocomposite material, the nanocomposite material formed thereby, and a battery made using the nanocomposite material. Metal oxide and graphene are placed in a solvent to form a suspension. The suspension is then applied to a current collector. The solvent is then evaporated to form a nanocomposite material. The nanocomposite material is then electrochemically cycled to form a nanocomposite material of at least one metal oxide in electrical communication with at least one graphene layer.
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RELATED APPLICATIONS
The present application claims the benefit under Title 35, United States Code, Section 119E of the United States Provisional Patent application Ser. No. 60/079,654, filed Mar. 27, 1998 entitled “Crankshaft and Method for achieving Improved Low RPM Operation of an Internal Combustion Engine Designed for Marine Trolling Applications”.
BACKGROUND
Gasoline marine engines used in small water craft are typically of two types. A first type is an inboard mounted engine which drives a propulsion unit which may be an outboard mounted propeller or jet. A second type of gasoline marine engine used in small water craft is an outboard engine that mounts high on the transom of the boat. There are significant problems with both types of marine engines.
Inboard engines comprise all types of engine block configurations including V-Block and straight block or in-line engine blocks. Additionally, a small number of gasoline marine engines have been built using an engine block having horizontally opposed cylinders.
These gasoline marine engines are either designed specifically for marine usage or are of automobile origin and have undergone a significant conversion to make the engines appropriate for marine usage. For an engine to be appropriate for marine usage, the engine must satisfy the particular cooling requirements of mounting an engine within the hull of the boat. Specifically, a cooling system is required that will not use a radiator and fan for transferring the heat within the engine coolant to the atmosphere. Additionally, the cooling provided by air passing through the engine compartment of a car will not be present. Automobiles rely heavily on the radiator and fan and air cooling to keep the engine from overheating. Due to the constraints that are particular to mounting an engine within a hull of a small water craft, neither of these cooling modes are typically used on a boat engine.
Consequently, gasoline marine engines for small water craft must include greater engine cooling capabilities. Greater cooling capabilities are required of the water jackets that are cast into the cylinder blocks and cylinder heads. Additionally, cooling capabilities are also required of the exhaust system. Exhaust jackets are typically placed around the exhaust system manifold and pipes to cools these components with cooling water. Water jackets and exhaust jackets, both of which are specifically designed for the cooling requirements of the marine environment, are required in gasoline marine engines.
Coolant systems for marine use are typically of two types. A first system uses a heat transfer mechanism that uses raw water drawn from the water resource to cool the engine coolant used within the water jackets. Alternatively, raw water may in some cases be drawn from the water resource and then passed through the water jackets, and finally returned to the water resource. In each of these systems, raw water, as opposed to air, is used to cool the coolant fluid is used in the engine.
Because of space limitations marine engines are typically not used with a shiftable transmission. The propulsion system is typically driven directly by the flywheel of the engine.
In common jet propulsion systems, the jet impeller speed in RPM's is the same as the engine speed in RPM's. The impeller speeds that result are typically desirable for higher speed boat usage. Most boat engines are unable to run under 500 revolutions per minute, and therefore are driving the impellers at too high of a speed for low speed boating without the difficult use of the reverse bucket to slow the boat speed. These engines also do not allow for the desired level of speed modulation for the boat.
Propeller propulsion systems typically use a gear reduction system. In these systems, the propeller speed is a constant percentage of the engine RPM, as these systems also do not permit any change of the gearing while the boat is operating. These gear reduction systems seldom allow for low enough propeller speeds for low speed fishing which is commonly called trolling. This is because the systems are typically geared for higher speed use. For this reason, a propeller specifically designed for low speed operation must typically be used if low speed operation is desired. These low speed propellers drastically reduce the top end speed of the boat and are not considered desirable by most boat users.
For these reasons, those boat users that desire to operate their boats at trolling speeds are required to install a small trolling engine on their boats. The trolling engine capable of low speeds only becomes the second engine for the boat. These small trolling engines, which are typically outboard engines mounted on the transom of the boat, allow the user to have a high level of modulation control over the boat speed. The use of two engines on a boat is not without consequence, however. Two marine engines often means a doubling of the undesirable maintenance requirements of the boat. There are, of course, additional costs involved in the acquisition of a second engine for the boat. A second engine mounted on the transom also occupies one of the desirable fishing positions available within the hull of the boat.
The other option for low speed of an existing gasoline marine engine is to fit a trolling plate adjacent the propeller that can be pivoted behind the propeller to slow the propulsion of the boat. The use of these trolling plates is undesirable as little modulation of speed is possible. The operation of the trolling plates is also undesirably inconvenient. It is also likely that the use of a trolling plate generates a high level of underwater noise due to the constant striking of water on the plate. This likely would scare away fish from the vicinity of the boat.
Existing inboard gasoline marine engines, in the lower horse power classes, also lack the necessary torque at low speed to push the boat up on plane if the boat is carrying a heavy load of passengers and gear. For boat users that fish in large rivers and rivers with a strong current, there may be considerable frustration involved in getting the boat to move upstream if the boat cannot generate enough low speed torque. Several fishermen and their gear can add a significant load to a small water craft. It is not uncommon for existing gasoline marine engines for small water craft to be inadequate under these conditions.
Larger horsepower inboard gasoline marine engines have the necessary torque for most applications. However, these larger horsepower engines are quite massive, often weighing 900 pounds or more. Of course, the fuel consumption of these engines is also high. This reduces the operating range of the boat and increases the necessary fuel storage and therefore the weight of the fuel on the boat.
An additional problem associated with existing inboard gasoline marine engines of all horse power classes is the size, particularly the height, of the engine. The decks of small water craft have space for seating and gear storage. Unfortunately, the main inboard engine occupies a significant portion of this space at the rear of the boat in front of the transom. The engine typically includes a cover to separate the engine from the interior of the boat. The height of the cover which extends over the engine is typically too high for comfortable or safe seating. Additionally the engine cover restricts the ability of the number of people that can stand at the back of the boat and fish. This position at the back of the boat is typically the most desirable place from which to fish. Due to the shape of existing marine engines for small water craft, very few marine engines have been successful at minimizing the space requirements of an inboard engine.
Existing outboard marine engines also have had significant problems. Most existing outboard engines are two stroke engines that are know to be responsible for extremely high emissions of unburned hydrocarbons, as well as other atmospheric pollutants. Outboard engines also require higher levels of maintenance than inboard engines of comparable horsepower. Although outboard engines do minimize the deck space which the engine occupies, outboard engines do extend quite high above the transom and are an obstruction to using the back of the boat for fishing. The location of outboard engines also has a tendency to increase the noise level within the boat due to the engine.
For the previously mentioned reasons, there is a need for an inboard gasoline marine engine for small water craft that develops sufficient torque to function adequately at low speeds. There is a need that this engine weighs much less than existing engines which are able to produce a high torque at low speeds. This would provide adequate boat operation in river currents, and adequate operation of the boat if the boat is loaded down with people and gear.
There is a farther need for a single inboard gasoline marine engine for small water craft that will operate at very low speeds without stalling so that the single marine engine can be used for low speed trolling. There is a need that this engine also offers the boat operator a high level of speed modulation. There is a need that this engine also has performance characteristics suitable for higher speed boat use.
There is a need that this inboard gasoline marine engine for small water craft be of a minimal height so as to occupy a minimum of deck space in the boat. It would be advantageous that this marine engine would fit under a platform or seat located in front of the transom, or actually fit beneath the deck. This would ensure that a maximum of deck space is available to be fully used by the boat occupants.
There is a need that this inboard gasoline marine engine for small water craft operates with very low polluting exhaust emissions to ensure that minimal harm to water sources and the atmosphere results from using the boat. There is also a need that this engine operates with minimal noise levels. Finally there is a need that the engine operates in a reliable manner and requires a minimum of maintenance.
SUMMARY
The inboard gasoline marine engine for small water craft of the present invention comprises a two cylinder horizontally opposed four stroke engine. The engine includes a massive crank shaft rotationally mounted in the crank case of the engine. A small flywheel is connected to one end of the crank shaft. The flywheel additionally drives the propulsion system used along with the engine. The fly wheel is typically disposed at the back of the engine, although positioning the fly wheel in the front position would also be possible. Opposite the flywheel on the front of the engine is a main belt for operation of an alternator, and a cover for a timing belt or chain. Two cam shafts are driven by the crank shaft through the timing belt or chain. A cylinder block or jug is located on each end of the crank case. A large bore cylinder (4¼ in.) is disposed in each cylinder jug. Reciprocating in each cylinder is a large diameter piston that has a long stroke (5 in.). Each piston is connected to the crank shaft through a long connecting rod (10 in.). A cylinder head and valve cover are mounted at each end of the engine. Water jackets, that are designed for a marine engine that will not use a radiator and fan, surround the cylinder blocks. A fuel delivery system is used to provide fuel to each cylinder. Specifically, a carburetor is located adjacent to each cylinder head. The carburetors that are included in a gasoline fuel delivery system for the engine, could be replaced with fuel injectors. Air induction is also handled by the carburetors that are attached to each cylinder head. In a preferred version, on the top of the engine crank case is a fluid transfer manifold. The fluid transfer manifold distributes engine cooling fluid which has passed through a heat transfer mechanism. The heat transfer mechanism, in a preferred version, uses raw water to lower the temp of the engine cooling fluid. The bottom of the engine is defined by the oil pan An exhaust system comprising a water cooled exhaust pipe extends from each cylinder head. The water cooling for the exhaust pipes is accomplished by water jackets.
The inboard gasoline marine engine for small water craft of the present invention has been designed to solve the size problems that are associated with existing gasoline marine engines. The inboard gasoline marine engine further solves the previously mention problems of inadequate engine torque and insufficient low speed operation that are associated with existing gasoline marine engines for small water craft.
In particular, the inboard gasoline marine engine of the present invention has a length of approximately 41⅜ inches, as measured between the two valve covers, and a height of 17½ inches. This relationship of height to length corresponds perfectly to the mounting location of the engine in front of the transom, and beneath a platform at the back of the boat. Alternatively, the engine mounting location in some cases may actually be beneath the deck. Forward mounting locations, such as those used in competition water skiing water craft, are also possible, with similar benefits.
The height of the engine which of less than half of the length ensures that the engine can be mounted on the hull, while ensuring that adequate air space surrounds the engine. The height of the engine (17½ in.) between the front and rear of the engine is also less than 5 times the bore diameter (4¼ in.) of the cylinder bores. These ratios of engine length to engine height, and bore diameter to engine height have not been used in previously designed inboard gasoline marine engines.
The dimensions of the engine provide many benefits to boat users. Most boats that use an inboard engine have a substantial portion of the boat deck occupied by the engine and the cover which extends over the engine. Typically, only two small seats exist at the back of the boat due to the existence of the marine engine in this location. Current inboard marine engines also are a huge obstruction to the use of the back of the boat for fishing. The present engine allows a fill width seat or an unobstructed fishing platform to be used at the back of the boat. This may allow as many as four passengers to sit at the rear of the boat, or fish from this location. Alternatively, a substantial amount of gear could be stored at this location.
The inboard gasoline marine engine for small water craft of the present invention has been designed to provide high torque to the propulsion system powered by the engine when the engine is operating at low RPM's.
The high torque has been provided by the use of large bore cylinders of approximately 4¼ inches. Additionally, the piston stroke is approximately 5 inches. The large bore and large stroke along with a long connecting rod of 10 inches allow the engine to develop tremendous low-end speed torque. The large bore and large stroke create a large displaced cylinder volume for each of the two pistons used in the engine. The displacement is approximately 70 cubic inches us in each of the cylinders. This displacement per cylinder is higher than what has been previously used in inboard gasoline marine engines for small water craft. This displacement per cylinder is higher than 62.75 cubic inches per cylinder, which is used in a number of current V block automobile engines used for marine use.
The long connecting rod causes the piston to “dwell” longer in the vicinity of top dead center within the cylinder. This is import during the crossover from compression to the power stroke. If the piston dwells near top dead center and ignition is initiated properly, there will actually be a longer period of time for the pressure created during combustion to press against the top of the piston. In effect, increasing the piston dwell allows the pressure to build higher while the minimum cavity exists in the chamber, and this higher pressure level translates into more effort against the head of the piston during the early portion of the power stroke.
There is also a secondary mechanical advantage from a long connecting rod. Since pistons dwell longer near the top of the stroke, the crank arm swings over further before the combustion cavity begins to open. This allows the pressure of combustion to be more effectively transmitted to the crank arm during the period when the pressure is the highest. This increased leverage exists throughout the power phase, though it is most effective in the early portion of the stroke. The end result is a smoother engine that produces more effective work during the power stroke. In simple terms, this translates into more torque and more horsepower.
The high torque at low speeds provided by the inboard gasoline marine engine of the present invention ensures that a boat powered by the present engine will have sufficient torque to operate in river currents or operate when heavily loaded down with passengers and gear.
The inboard gasoline marine engine of the present invention is able to produce the high torque at low speeds only otherwise available by engines weighing as much as three times that of the present invention. The present invention weighs approximately 300 pounds and will produce 150 ft—lbs of torque. Accordingly, the engine has a torque to weight ratio of 1 pound of torque for only 2 pounds of weight.
The inboard gasoline marine engine for small water craft of the present invention has been designed to provide low speed operation to the boat in which the engine is used. Specifically, the engine includes a crank shaft having a large mass and large moment of inertia. The high mass crank of approximately 65 lbs, assists in the low RPM operation of the engine by having a large rotational inertia which is able to produce fill compression of the air and fuel within the cylinders at low RPM's without causing the engine to stall. The high mass crank also assists in the low RPM operation of the engine by mining torsional distortion cause by the opposing cylinders pushing on the crank. The minimizing of torsional distortion further minimizes vibrational shaking which can interfere with low RPM operation of an engine. The crank shaft also includes a close spacing of the journals and counterweights. Two cylinder horizontal opposed engines have had a tendency to rock forward and rearward which can interfere with operation of an engine. The high mass and close spacing of the crank both assist in minimizing the rocking.
The high mass crank, in providing a high rotating moment of inertia to the engine allows for the use of a low mass flywheel. The flywheel weighs only 5 pounds.
Also included in the design of the engine are long but light connecting rods, and light pistons. By minimizing the weight of these components, the engine is further able to minimize rocking and vibration by minimizing the pulling apart of the engine by the rotational mass of the reciprocating pistons and connecting rods.
The cam timing is also set to leave an adequate amount of residual exhaust remaining in the cylinder during the intake stroke to maintain the heat necessary for combustion. This also assists in low RPM operation of the engine as inadequate heat for combustion will cause stalling of an engine.
The low RPM operation of the engine is unique in inboard gasoline marine engines for small water craft. The present invention is able to run reliably with a base idle of substantially lower than 500 RPM. The present invention is able to run reliably at a base idle of 350 to 375 RPM. This contrasts with a base of 500 for the next lowest advertised base idle for existing inboard gasoline marine engines.
The low RPM operation allows for the use of a single engine in a water craft which is capable of significant low speed modulation and is thus suitable for providing desirable trolling speeds for fishing from the water craft. The low hull speeds which are provided by the engine obviate the need for a trolling engine or a trolling plate. The exclusion of a trolling engine further minimizes the space in the boat that is occupied by engines and is therefore unusable for fishing or is other recreational uses. The exclusion of a trolling engine also eliminates weight.
The inboard gasoline marine engine of the present invention runs cleanly and meets all emissions standards. The environmental benefits of the present invention over existing marine engines are significant. The clean, quiet operation of the engine results in minimal environmental impacts from the use of a water craft powered by the engine.
The inboard gasoline marine engine of the present invention is not of automobile origin, but is specifically designed as a marine engine for small water craft.
As has been described in this summary, the present invention is designed to provide the performance required by small water craft such as river boats, work boats, pontoon boats, water skiing boats, fishing boats, and deck boats.
These and other features and advantages of the present invention will be apparent upon inspection of the following drawings, description, and claims.
DRAWINGS
FIG. 1 is a front view of the horizontally opposed four cycle inboard gasoline marine engine for small water craft of the present invention.
FIG. 2 shows a rear view of the engine.
FIG. 3 shows a top view of the engine.
FIG. 4 shows a side view of the engine.
FIG. 5 shows a top view of the engine crank case shown in cross section.
FIG. 6 shows the engine front view of FIG. 1, in a partial cross section.
FIG. 7 is a front view of the crank case with the timing belt cover removed.
FIG. 8A shows the interior of the crank case.
FIG. 8B shows the inclusion of the marine engine of the present invention and a commercially available jet propulsion system into a small water craft.
FIG. 8C shows the inclusion of the marine engine of the present invention and a commercially available propeller propulsion system into a small water craft.
FIG. 8D shows the a top view into the hull of the small water craft.
FIG. 9 is a top view of the engine showing a preferred version of the cooling system which is used with the engine of the present invention.
FIG. 10 is a graph of the operating characteristics of the engine.
DESCRIPTION
FIG. 1 is a front view of the horizontally opposed four cycle inboard gasoline marine engine for small water craft of the present invention. This view shows a crank case comprising first and second crank case halves 10 and 12 . The crank case encloses the rotating crank shaft of the engine, as well as the connecting arms that attach pistons to the crank shaft. First and second cam shafts are also disposed in the crank case. These interior engine components will be shown and disclosed in later drawings and are not shown in FIG. 1 .
The crank case bottom includes an oil pan 14 and drain plug 15 . First and second horizontally disposed cylinder jugs 16 and 18 are secured to the opposite ends of the crank case at 180 degrees from each other. Within each cylinder jug is a cylinder bore and a piston which reciprocates within the cylinder bore. Capping each cylinder bore are first and second cylinder heads 20 and 22 . The inside of the cylinder heads define the top of the combustion chambers for both cylinders. The combustion ratio within the cylinders is approximately 9.
An induction port and an exhaust port are included in each cylinder head. A valve (not shown) is disposed within each of these ports. Attached to cylinder heads 20 and 22 are first and second small bore carburetors 24 and 26 . Carburetor 26 shows an air inlet 27 . Carburetors 24 and 26 produce the proper fuel and air mixtures that are introduced into the combustion chamber of each cylinder through the inlet port. A spark plug (not shown) is also disposed in each cylinder head.
First and second valve covers 28 and 30 enclose the overhead valves of each cylinder. The valve covers include a distal end. The engine includes a length defined by the distance between the distal ends of the two valve covers which is 41⅜ inches.
Also shown in FIG. 1 is a timing belt cover 32 which is attached to the front of the crank case and encloses the timing belt which is driven by the crank shaft and which rotates the two cam shafts at the proper speed. An engine drive belt 38 is shown which is rotated by a pulley wheel 40 . The pulley wheel 40 is rotated by the crank shaft. The belt 38 rotates pulley wheel 44 of a water pump 42 . The water pump is part if the engine cooling system. The water pump delivers coolant fluid to the water jackets disposed around the cylinder bores. The belt 38 also drives the pulley 46 of the alternator 47 . A starter motor 48 is also shown which engages the ring gear of the flywheel. The starter motor 48 is disposed near the bell housing top 50 .
FIG. 2 shows a rear view of the engine. In this view, the full bell housing 52 is shown, as is the center of the flywheel 56 . A starter housing 54 which receives the starter is also shown on the bell housing. FIG. 2 shows the height of the engine which is defined by the distance from the top 50 of the bell housing 52 to the bottom of the oil pan 14 . This height is 17¾ inches. The height is considerably smaller than other existing four cycle inboard gasoline engines for small water craft. It would be possible, although difficult, to decrease the height by decreasing the size of the flywheel and the bell housing. Such a modification is within the scope of the invention. Additionally, all engine components such as the starter motor, water pump and associated hoses and manifolds, and the alternator are mounted on the engine in such a manner as to not extend vertically above the top of the bell housing.
FIG. 3 shows a top view of the engine. In this view, both carburetors are shown, as are the spark plugs 21 and 23 and exhaust ports 29 and 31 . FIG. 3 also shows the cold water inlet hose 43 for the cooling system, and the water pump outlet 45 which feeds a coolant fluid to the water jackets of both cylinders through suitable inlets such as is shown at 60 and 61 . Suitable hoses, which are not shown in this figure, would be used for this purpose. Water jacket coolant outlets 62 and 63 would be connected by hoses to a heat transfer mechanism that uses raw water for cooling the coolant fluid. In a preferred version, the water pump 42 feeds coolant fluid to a fluid transfer manifold which then feeds a coolant fluid to the water jackets of both cylinders. The cooling system will be shown in greater detail in FIG. 9 .
FIG. 4 shows a side view of the engine. This view shows the front to back width of the engine to be only 19½ inches. Also shown is the path of an exhaust pipe 60 , which is shown extending from the engine at exhaust port in dashed lines. The exhaust pipe extends upward to form a water trap and the bends downwardly to a position where the exhaust pipe would exit the transom of the boat.
FIG. 5 shows a top view of a portion of the engine with the crank case halves 10 and 12 shown in cross section. This view shows the massive crank shaft used in the engine. The relative position of the first and second cam shafts 150 and 151 to the crank shaft are also shown in this figure.
The crank shaft includes three main bearings 102 , 104 and 106 , a first end 108 , which may be attached to a vibration damper, and a flywheel end 110 . A first cylinder journal bearing 112 which is intermediate counterweights 114 and 116 , and a second cylinder journal 118 which is intermediate the counterweights 120 and 122 are also shown. The journal offsets or throws from the main bearing axis of the crank shaft are 2½ inches creating a 5 inch stroke for both pistons. The counterweights and journals have been placed as close as possible to decrease the rocking due to the opposing cylinders. If more than two cylinders are used in the engine, which is possible, the rocking, which is characteristic of two cylinder horizontally opposed engines, would be less of a concern.
The crank shaft weighs 65 pounds which results in a rotating mass of 32.5 pounds of mass per cylinder due to the crank shaft alone. The moment of inertia of the crank shaft is approximately 480 pound * inch {circumflex over ( )}2. This high mass results in a high inertia that ensures that even at very low RPM's, full compression will achieved in the cylinders, and the engine will not stall. The high rotating mass per cylinder is disproportionate to that shown in prior art marine engines, and is primarily responsible for allowing the engine to operate at low RPM's below 400 RPM. The use of a high mass crank shaft, and the use three main bearings supporting the crank shaft, both contribute to minimizing the rocking of the crank shaft caused by the two opposing pistons pushing on the crank shaft This rocking is characteristic of two cylinder horizontally opposed engines. The use of a high mass of the crank shaft, and the use three main bearings supporting the crank shaft, both also contribute to reducing overall vibrations of the engine.
FIG. 6 shows the engine front view of FIG. 1, with a partial cross section showing the interior of the crank case halves 10 and 12 , cylinder jug 16 , cylinder head 20 and valve cover 28 . In this figure, the long length of the connecting rod 130 can be seen. Specifically, the connecting rod 130 measures 10 inches from the center of the journal bearing 112 to the center of the piston pin 134 . Attached to the connecting rod 130 is piston 13 which is disposed within the cylinder bore which measures 4¼ inches. Surrounding the cylinder bore 138 is a water jacket 140 which provides cooling fluid to cool the cylinder. The cam shaft 150 is shown with the lobe shown having rotated past the valve lifter 152 . Valve lifter 152 is attached to a push rod which engages rocker arm 156 , and thus actuates exhaust valve 158 . Spark plug location 160 is shown above the valve 158 .
FIG. 6 shows that the overall engine height, in relation to the throws of the crank shaft, is remarkably short. The overall height is less than twice the length of the connecting rods. The overall height is less than 5 times the bore. This compactness provides considerable benefits to the placement of the engine within the size constraints of a small water craft. The low overall height of the engine in relation to the large bores and large crank shaft throws is disproportionate to that shown in prior art marine engines.
The large bore and stroke of the engine are also disproportionate to that shown in prior art marine engines. The large bore and stroke result in a the engine producing high torques at low RPM's. The displaced volume per cylinder of the engine is at least 68 cubic inches. In marine engines, such a large displacement per cylinder is only available in large V block automobile engines which are converted for marine use. Such large V block engines, which do provide high torques at low speeds, do not have the size benefits of the present invention, nor are such engines capable of the low speed operation provided by the present invention.
FIG. 7 is a front view of the crank case with the timing belt cover removed. FIG. 7 shows the crank shaft end 108 which rotates the timing belt 160 through gear 166 . The timing belt 160 rotates the cam shaft gears 162 and 164 which both have twice the diameter of the gear 166 . The timing belt causes the short duration cam shafts 150 and 151 to rotate at half the speed of the crank shaft 108 . Also included in this figure is a belt tensioning bracket 168 which includes tension wheel 169 .
The cam timing is set to leave an adequate amount of residual exhaust remaining in the cylinder during the intake stroke to maintain the heat necessary for combustion. This also assists in low RPM operation of the engine as inadequate heat for combustion will cause stalling of an engine. The overlap period when the exhaust valve and intake valve are open simultaneously is approximately 30 to 35 degrees. The operable overlap period is between 10 and 40 degrees.
The low RPM operation of the engine is unique in inboard gasoline marine engines for small water crap. The present invention is able to run reliably with a base idle of substantially lower than 500 RPM. The present invention is able to run reliably at a base idle of less than 400 RPM, typically 350 to 375 RPM. This contrasts with the next lowest advertised base idle for existing inboard gasoline marine engines, which is 500 RPM.
Through the use of the large mass crank and the proper cam timing, the present invention teaches a new method of operating an engine for a small water craft at a low RPM. This method obviates the need for a second small trolling motor, which is currently required for low speed operation. Also contributing to the low RPM operation of the engine are engine components that increase the air speed during induction to ensure sufficient filling of the combustion chamber. These components include the large cylinder capacity (the larger the cylinder the greater the void which is need to be filled by the atmosphere when the valve opens, this raises air speed which aids in filling the cylinder at low RPM's), long connecting rods (the piston dwells longer at top dead center with a long rod, consequently, cylinder gas expansion pressures are increased), a short duration camshaft (the short periods of time that the valve is open result in greater air speeds as the atmospheric air tries to fill the void caused by the descending piston on the intake stroke), a small bore carburetor (the smaller the throttle bore, the more restrictive the throttling which causes increased atmospheric air speed which aids in cylinder filling at low RPM), a short intake pipe (a short pipe causes less elastic stretch of the air column, and results in a stronger pull on the throttle valve at intake opening), and unrestrictive intake and exhaust runners (high efficiency of the intake and exhaust system aids in cylinder filling at low RPM). Also assisting in the low RPM operation of the engine are delayed exhaust valve opening to extend the timing of the power phase to maize low speed torque, early intake valve closing (this increases low speed torque and reduces low RPM reverse pulsing), Additionally, the use of two cylinders in the engine contributes to low speed operation because of fewer power cycles occur per revolution of the crank shaft.
The present engine provides the benefits of low speed operation, but also allows high speed operation of the water craft. This is because low speeds can be attained through the low RPM operation of the boat, as opposed to the use of special low speed propellers.
FIG. 8A shows the interior of the crank case half 10 after removal of the other crank case half 12 . This figure shows the light weight flywheel 56 which is attached to the flywheel end 110 of the crank shaft. The flywheel weighs only approximately 5 pounds, and has a low moment of inertia of approximately 75 pound * inch {circumflex over ( )}2. A suitable coupling plate 57 attaches drive shaft 182 of a commercially available jet propulsion unit 180 to the flywheel. The flywheel is used in the engine both as means for attachment of a marine propulsion system and as a support for the ring gear used by the starter which is not clearly shown in this figure.
FIG. 8B shows the inclusion of the marine engine of the present invention and a commercially available jet propulsion system 180 into the small water craft 200 . In this figure, the low height of the engine as it is installed within the hull of the small water craft is shown. The platform 210 above the engine may be a seat, or a standing platform for fishing. Should the hull be deep enough, the platform may be the actual deck.
FIG. 8C shows a commercially available propeller propulsion I/O system powered by the engine of the present invention. As was mentioned earlier, a low speed propeller would not have to be used in the propeller propulsion system, as low speeds are provided by the low RPM operation of the engine. It is possible to achieve trolling speeds of less than 2 miles per hour while operating the engine at low RPM's which powers a propeller system fitted with a midrange or high speed propeller. Here again, the engine is positioned low in the hull and occupies a minimum of space within the small water craft.
FIG. 8D shows the a top view into the hull of the small water craft 200 showing the position of the platform 210 .
FIG. 9 is a top view showing a preferred version of the cooling system which is used with the engine of the present invention. The cooling system includes a heat transfer cylinder which includes an inlet hose 71 which connects the heat transfer cylinder to a raw water inlet and pump. The raw water inlet and pump are typically disposed on the bottom of the hull, and draw raw water from the water resource which will be used for the transfer of engine heat. A raw water return hose 72 returns the raw water, to which heat has been transferred, back to the water resource. The heat transfer cylinder, raw water inlet and pump and raw water return are all well known in the art.
A water pump inlet hose 74 attaches the water pump to the heat transfer cylinder 70 , and feeds cold cooling fluid to the water pump. A water pump outlet hose 75 feeds the cold cooling fluid exiting the water pump to a fluid transfer manifold 76 . Cold cooling fluid is transferred to the water jacket inlets of both cylinders 60 and 61 through hoses 77 and 78 , respectively. Heated cooling fluid is returned to the fluid transfer manifold 76 through return lines 79 and 80 . This heated cooling fluid is returned to the heat transfer cylinder 70 through hose 81 .
The heat transfer cylinder may be disposed in the position as shown, or could be mounted away from the engine, if desired. The heat transfer cylinder would typically not be taller than the engine. The fluid transfer manifold would be disposed as shown on the top of the crank case, and would not extend above the top of the flywheel bell housing. It is understood that other mounting positions could be available for the heat transfer manifold which would not be at the top of the crank case. Although not shown, exhaust water jacket hoses which attach a water jacket disposed around each exhaust pipe to the fluid transfer manifold, could be used for each exhaust pipe. Alternatively, the exhaust pipes water jacket hoses could be attached directly to the heat transfer cylinder.
FIG. 10 shows the operational characteristics of the engine and shows the high torques, which are above 120 ft—lb/sec, which are achieved at low RPM's.
Although a preferred version of the engine has been shown and described it is understood that various modifications to the engine are possible which remain within the spirit of the invention. Such modifications include the use of more than 2 cylinders, as a four cylinder, or possibly 6 or 8 cylinder engine could be built using the concepts taught by the invention. Also possible is the use of fuel injection in place of the carburetors. A engine block that included cylinders cast into the block as opposed to a crank case and attached cylinder jugs would be possible in the present invention. The large mass crank and large bore stroke relationship of the present invention could be used in a well know V block engine configuration. Two types of raw water cooling could be used in the invention. This would include: the described preferred version which is a closed system that uses cooling fluid cooled within a heat transfer mechanism through the use of raw water; or a second version using raw water entirely within the system and eliminating the heat transfer mechanism.
It is therefore understood that various other modifications and changes of form or detail could readily be made without departing from the spirit of the invention. It is intended that the invention be not limited to the exact form and detail herein shown and described, nor to anything less than the whole of the invention disclosed and hereinafter claimed.
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An inboard gasoline marine engine for small water craft comprises a two cylinder horizontally opposed four stroke engine. The engine includes a massive crank shaft rotationally mounted in the crank case of the engine. A small flywheel is connected to one end of the crank shaft. The flywheel additionally drives the propulsion system used along with the engine. The fly wheel is typically disposed at the back of the engine, although positioning the flywheel in the front position would also be possible. Opposite the flywheel on the front of the engine is a main belt for operation of an alternator, and a cover for a timing belt or chain. Two cam shafts are driven by the crank shaft through the timing belt or chain. A cylinder block or jug is located on each end of the crank case. A large bore cylinder (4¼ in.) is disposed in each cylinder jug. Reciprocating in each cylinder is a large diameter piston that has a long stroke (5 in.). Each piston is connected to the crank shaft through a long connecting rod (10 in.). A cylinder head and valve cover are mounted at each end of the engine. Water jackets, that are designed for a marine engine surround the cylinder blocks. A fuel delivery system is used to provide fuel to each cylinder. Specifically, a carburetor is located adjacent to each cylinder head. The engine is capable of operating at very low RPM's. The engine also produces high torques at low seeds. The engine is of a size that minimizes the space occupied by the engine within the small water craft.
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This is a division of application Ser. No. 686,702, filed Dec. 27, 1984, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to an improvement in a loom, and more particularly to a device for removing a picked weft yarn from the shed of warp yarns in order to facilitate re-starting of the loom in case of loom stopping due to mispick or failed weft insertion.
2. Description of the Prior Art
In connection with conventional looms, when mispick arises during its operation, a loom stop signal is produced upon detection of the mispick in order to switch off a main motor and apply a brake to a main shaft of the loom, thereby automatically stopping the loom. In this case, the stopping of the loom is usually completed at the beating-up step after the next weft picking is made, since a certain time period is required from the time point of braking the main shaft to the time point of actual loom stopping. Accordingly, in order to re-start the loom, it is necessary to remove a weft yarn picked after the mispick arising in addition to the mispicked weft yarn.
In this regard, a device for removing the weft yarn picked after mispick arising has been hitherto proposed, in which a guide or obstructing plate is projectable of a weft inserting nozzle to obstruct the weft picking by allowing the weft yarn to strike against the guide plate, thereafter the thus obstructed weft yarn is sucked into a suction nozzle to be removed. After loom stopping, a mispicked weft yarn is manually removed upon making a reverse revolution of the loom by an operation angle to enable removal of the mispicked weft yarn.
However, drawbacks have been encountered in such a conventional picked weft yarn removing device in which the weft yarn to be picked from the weft inserting nozzle is obstructed from its advance by the guide plate and then sucked into the suction nozzle. That is, the posture of the weft yarn after striking the guide plate is unsettled, so that there frequently occurs separation of the weft yarn from the suction nozzle thereby making uncertain the suction of the weft yarn into the suction nozzle. In this regard, it has been necessary to strictly set the operation timing of the suction nozzle and the like.
SUMMARY OF THE INVENTION
A loom of the present invention is provided with a member movable together with a reed and formed with a guide space through which a weft yarn projected from a weft inserting nozzle is picked into the shed of warp yarns. The guide space is locatable between the weft inserting nozzle and the warp yarns. An air flow passage is provided to merge in the guide space in such a manner that the weft yarn lying in the guide space is forced into the air flow passage to be removed under the influence of an air stream developed through the guide space. Accordingly, the weft yarn picked prior to loom stopping due to mispick can be surely removed from the warp shed, thereby facilitating re-starting of the loom.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the loom according to the present invention will be more clearly appreciated from the following description taken in conjunction with the accompanying drawings in which like reference numerals designate corresponding parts and elements, and in which:
FIG. 1 is a plan view of an embodiment of a loom of the present invention;
FIG. 2 is a fragmentary side elevation of an example of a picked weft yarn removing device in the loom of FIG. 1;
FIG. 3 is fragmentary plan view, partly in section, of the picked weft yarn removing device of FIG. 2;
FIG. 4 is a side view of a removing pipe of the picked weft yarn removing device of FIG. 2;
FIG. 5 is a sectional view taken in the direction of arrows substantially along the line V--V of FIG. 4;
FIG. 6 is a fragmentary side elevation of a modified example of the picked weft yarn removing device;
FIG. 7 is a longitudinal sectional view of an air tensor used in the loom of FIG. 1;
FIG. 8 is a side elevation of a drum type weft reservoir used in the loom of FIG. 1;
FIG. 9 is a plan view of the weft reservoir of FIG. 8;
FIG. 10 is a sectional view taken in the direction of arrows substantially along the line X--X of FIG. 8;
FIG. 11 is a view taken in the direction of an arrow XI of FIG. 10;
FIG. 12 is a sectional view taken in the direction of arrows substantially along the line XII--XII of FIG. 11;
FIG. 13 is a view taken in the direction of an arrow XIII of FIG. 10;
FIG. 14 is a circuit diagram of a control system including air flow and electric circuits, of the loom of FIG. 1;
FIG. 15 is a block diagram showing a hardware arrangement for the control system of FIG. 14;
FIGS. 16A, 16B and 17 are flow charts showing a software arrangement of the control system of FIG. 14;
FIG. 18 is a fragmentary perspective view of another example of the picked weft yarn removing device;
FIG. 19 is a side elevation of the picked weft yarn removing device of FIG. 18;
FIG. 20 is a circuit diagram similar to FIG. 14, but showing a control system of the loom using the picked weft yarn removing device of FIG. 18; and
FIG. 21 is a fragmentary perspective view similar to FIG. 18, but showing a further example of the picked weft yarn removing device.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is shown an embodiment of a loom in accordance with the present invention, which loom is of the air jet type. The loom consists of a loom frame 1 on which a back roller 3 is rotatably supported, and heads 4 and reed 5 are operatively supported. The reference numeral 2 denotes a plurality of warp yarns which extend through a cloth fell 6 to a woven fabric 7 which is passed on a breast beam 8. Yarn supplies or bobbins 9A, 9B are rotatably supported by a holder 11 attached to the loom frame 1. An air tensor 12 is supported by stays 13, 14 attached to the loom frame 1 and functions to provide tension to a weft yarn 10 supplied from the yarn suppliers 9A, 9B by applying an air stream in a direction opposite to the advancing direction of the weft yarn 10. A drum type weft reservoir or detaining device 15 is provided to measure and detain the weft yarn 10 drawn from the air tensor 12 through a guide pulley 16.
A weft inserting or main nozzle 17 is arranged to insert or pick the weft yarn 10 into the shed of the warp yarns 2 where the weft yarn has been drawn from the weft reservoir 15 through a guide 18. A picked weft yarn removing device 19 is disposed between the weft inserting nozzle 17 and the rows of the warp yarns 2 to remove the picked weft yarn 10 from the shed of the warp yarns 2. A weft end suction device for sucking in an end of the picked weft yarn 10 is disposed on a counter-weft picking side which is opposite to a weft picking side where weft picking is made by the weft inserting nozzle 17, relative to the rows of the warp yarns 2. Cutters 21, 22 are located opposite to each other relative to the rows of the warp yarns 2 to cut the opposite ends of the picked weft yarn 10.
The picked weft yarn removing device 19 will be discussed with reference to FIGS. 2 to 5. A reed holder 181 is fixed on a sley sword 180 at the top section, and formed with a longitudinal groove 182 in which a lower frame of a reed 5 is inserted together with a wedge 183. The wedge 183 is forced into the groove 182 between the wall of the groove 182 and the reed lower frame by screwing in the bolts 184, thereby securing the lower frame of the reed 5 in position. The reed 5 has a plurality of reed blades 185 each of which is formed with a groove or cutout 186 in such a manner that a row of aligned grooves 186 define a weft guide groove or channel 187 (in FIG. 14). The weft inserting nozzle 17 is fixedly mounted on the reed holder 181 at the end section on the weft picking side and directed to the weft guide groove 187. Additionally, a plurality of auxiliary nozzles 189 are installed through support blocks 188 to the reed holder 181 at suitable intervals along the direction of weft insertion. Each auxiliary nozzle 189 is located and adapted to eject an air jet diagonally relative to the weft guide groove 187.
The cutter 21 has a fixed blade 191 which is fixed to a cutter holder 190. A movable blade 192 of the cutter 21 is fixedly mounted on a spindle 193 which is rotataby supported on the cutter holder 190. A drive lever 194 is also fixedly mounted on the spindle 193 and adapted to be driven by a cam (not shown) which rotates in timed relation to a main shaft 252 (in FIG. 14) of the loom. The cutter 21 is disposed so as to be locatable in a space formed by removing reed blades 185 on the weft picking side at beating-up step of the reed, and adapted to execute a cutting action at the beating-up step, more specifically at the initial stage of the return stroke of the reed 5.
A pipe or guide member 196 forming part of the picked weft yarn removing device 19 is flattened at its central section having a cross-section as shown in FIG. 3. The flattened central section 196 has opposite parallel walls which are respectively formed at their center portion with two holes 197 whose axes are aligned with each other, the holes form part of a guide space through which the weft yarn 10 passes to be picked. The upper section of the pipe 196 tightly fits in a connecting member 199 which is fixed to the upper frame of the reed 5, thus securing the pipe 196 in position. The pipe 196 is located between the cutter 21 and the rows of the warp yarns 2, and so disposed that the axes of the guide holes 197 are aligned with the axes of the weft inserting nozzle 17 and the weft guide groove 187. The connecting member 199 is formed therein with a communication passage 200 to which a flexible pipe 201 is connected. A pipe 234 leading from a pressurized air supply source 210 is connected to the pipe 201 through a flow amount regulator 235 and a solenoid valve 236 as shown in FIG. 14. Additionally, a flexible pipe 202 is connected to the lower end section of the pipe 196 and connected to the suction port of a blower 246 through a filter 244 and a pipe 245 as shown in FIG. 14. It will be understood that a part of the pipe 196 lower than the guide holes 197 constitutes a downstream pipe section 196a (having an air flow passage therein) by which the picked weft yarn 10 is sucked to be removed under the influence of a suction air stream caused by the blower 246, while a part of the pipe 196 above the guide holes 197 constitutes a upstream pipe section 196b by which the picked weft yarn 10 extending through and lying in the guide hole 197 is forced into the inlet of the downstream pipe section 196a under the influence of the ejected air stream.
Otherwise, as shown in FIG. 6, the above-discussed picked weft yarn removing device 19 is applicable to an air jet loom provided with a weft guide device consisting of parallelly aligned air guide members each of which is formed with an air guide opening 205 and a weft yarn escape clearance 206, in which the guide hole 197 of the picked weft yarn removing pipe 196 faces the air guide opening 205.
The air tensor 12 will be discussed with reference to FIG. 7. The air tensor 12 consists of a transparent pipe 25 having opposite open ends. Air ejection nozzles 26, 27 are provided at the opposite ends of the transparent pipe 25 in such a manner that the tip section of each air ejection nozzle fits in the open end of the pipe 25 and is fastened in position by a band 28, 29. These air ejection nozzles 26, 27 are the same in construction, and accordingly an explanation is made only about the nozzle 27 for the purpose of simplicity of illustration. The nozzle 27 has an outer tube 30 which is constructed of a large diameter section 30a and a small diameter section 30b both fitting in the pipe 25. As seen in FIG. 7, the small diameter section 30b is located on the upstream side of the large diameter section 30a relative to the movement of the weft yarn 10 as indicated by an arrow. A yarn introduction pipe 32 is disposed within the outer tube 30 in such a manner that the tip end of the introduction pipe 32 is located within the small diameter section 30b of the outer tube 30. The yarn introduction pipe 32 is secured in position by fastening a base plate section (no numeral) of the pipe 32 onto the outer tube large diameter section 30a by means of small screws 33. Thus, an annular nozzle opening 34 is defined between the inner surface of the small diameter section 30b and the outer surface of the yarn introduction pipe 32. Additionally, the outer tube 30 is securely provided at its large diameter section 30a with a connector pipe 35 which opens to the inside of the large diameter section 30a.
The air ejection nozzle 26 is provided at the end of the pipe 25 on the inlet side and adapted to eject pressurized air drawn through a pressurized air supply pipe 211 in the same direction as the advancing direction of the weft yarn 10 thereby causing the weft yarn 10 to pass through the pipe 25 for the purpose of setting the weft yarn 10. The air ejection nozzle 27 is provided at the opposite end of the pipe 25 on the outlet side and adapted to always eject pressurized air introduced through a pressurized air supply pipe 214 in the opposite direction to the advancing direction of the weft yarn 10 to provide tension to the weft yarn 10.
The weft reservoir 15 will be discussed with reference to FIGS. 8 to 13. Referring to FIGS. 8 to 10, a gear box 42 of the weft reservoir 15 is attached by brackets 40, 41 to the loom frame 1. A rotatable shaft 44 is rotatably supported through a bearing 43 on the gear box 42. The rotatable shaft 44 is provided at its top end section with a stationary support member 46 which is supported through a bearing 45 on the rotatable shaft 44. A generally cylindrical drum 48 is secured to the stationary support member 46 in such a manner that the axis thereof is aligned with the axis of the rotatable shaft 44. A plurality of permanent magnets 49 are fixedly disposed on the stationary support member 46. Additionally, a plurality of permanent magnets 51 are fixedly disposed on a fixed support member 50 and located so as to face toward the permanent magnets 49 of the stationary support member 46, respectively. Each magnet 49 and each magnet 51 have different Poles from each other, so that the magnetic attraction developed therebetween keeps the support member 46 and accordingly the drum 48 stationary.
The rotatable shaft 44 is formed along its axis with an elongate weft introduction hole 52 which is opened at its front end (on a base section side) and closed at its rear end close to the drum 48. A hollow weft guide pipe 53 is fixed to the rotational shaft 44 in such a manner that the hollow thereof is in communication with the weft introduction hole 52 of the rotatable shaft 44. The weft guide pipe 53 is adapted to rotate around the axis of the rotational shaft 44. Upon rotation of the rotatable shaft 44, the weft guide pipe 53 rotatably passes through a space between the oppositely located permanent magnets 49 and 51. The tip end of the weft guide pipe 53 is bent toward the surface of the drum 48. Secured at the rear end section of the rotatable shaft 44 is a weft introduction pipe 55 whose axial opening 54 is in communication with the weft introduction hole 52 of the shaft 44. It is to be noted that the rear or tip end of the weft introduction pipe 55 is made slender to form a nozzle opening 56 between it and the wall surface of the weft introduction hole 52 through which nozzle opening pressurized air is ejected to cause the weft yarn 10 to pass into the weft introduction hole 52 for the purpose of setting the weft yarn 10. The nozzle opening 56 forms part of an annular space (no numeral) formed around the slender front end of the weft introduction pipe 55, which annular space communicates with an air chamber 58 through communication holes 57 formed radially in the rotatable shaft 44. The air chamber 58 is formed around the rotatable shaft 44 and supplied with pressurized air through a pressurized air supply pipe 217. A flow amount regulator valve 219 is disposed in the pipe 217 to regulate the flow amount of the pressurized air flowing through the pipe 217. A guide pulley 16 is located in the vicinity of the inlet side or front end of the weft introduction pipe 55 and rotatably supported by a stay 59 fixed to the gear box 42. Additionally, a ballooning cover 60 is disposed around the drum 48 to preventing excessive ballooning of the weft yarn 10 to be drawn out from the drum 48. The cover 60 is fixed through a stay 61 to the bracket 40.
A manually rotatable wheel 62 is fixedly mounted on the rotatable shaft 44 to manually cause the rotatable shaft 44 to rotate. In addition, a gear 64 is fixedly mounted on the rotatable shaft 44 by means of a key 63. Two gears 68, 69 are fixedly mounted on a shaft 66 by means of a common key 67 which shaft is rotatably supported through bearings 65 on the gear box 42. The gear 68 is in engagement with the gear 64 mounted on the rotatable shaft 44. The gear 69 is in engagement with a gear 73 which is fixedly mounted on a shaft 71 by means of a key 72. Shaft 71 is rotatably supported through bearings 70 on the gear box 42. Additionally, a gear 74 is fixed to an extended section of the gear 73 by means of bolts 75 and located spacedly parallel with the main body of the gear 73. The gear 74 is in engagement with a gear 79 which is fixedly mounted on a shaft 77 by means of a key 78 which shaft 77 is rotatably supported through bearings 76 on the gear box 42. A hollow shaft 80 is formed at a part thereof with a slit and is mounted on an end section of the shaft 77 and fixed in position by means of a fastening member 81 which is adapted to fasten the hollow shaft in an embracing manner. A ring 82 fits on the hollow shaft 80 and is secured in position by means of a bolt 83.
A drive shaft 84 is driven by the main shaft 252 (in FIG. 14). A toothed pulley 85 is fixedly mounted on the drive shaft 84. A cogged belt 89 is passed around the toothed pulley 85 and a toothed pulley 87 to drivingly connect them. The toothed pulley 88 is fixedly mounted on a shaft 86 by means of a key 87 which shaft 86 is rotatably supported by the loom frame 1. The shaft 86 is fixedly provided at its projected end section with a coupling 90 through which an end section of a shaft 92, provided at its central section with splines 91, is fixedly connected to the shaft 86. A connector 96 is rotatably mounted through a bearing 97 on the other end section of the shaft 92, and formed at one end thereof with a flange 93 and provided at the other end thereof with a one-side counterpart tooth (or a depression) 95, of a engaging clutch 94 which is adapted to be engaged only at a certain phase. The flange 93 is fixed to the ring 82 by bolts 98 as a single member. Fitted to the splines 91 at the central section of the shaft 92 is a change-over member 100 which is axially slidably movable and fixed to the shaft 92. The change-over member 100 serves as a single member in the rotational direction. The change-over member 100 is formed with an other-side counterpart tooth (or a projection) 99 of the engaging clutch 94 which tooth is engageable with the tooth 95. The change-over member 100 is biased leftward in FIG. 10 under the action of a compressed spring 102 interposed between it and the flange 101 of the coupling 102, thereby allowing the clutch 94 to engage.
A change-over lever 103 has at one end a bifurcated section provided with rollers 104, 105 which are inserted into a peripheral annular groove 106 of the change-over member 100. Referring to FIGS. 11 and 12, the change-over lever 103 is rotatably mounted on a spindle 108 of a bearing 107 fixed to the bracket 41. Change-over lever 103 is formed at the other end thereof with an elongated hole 109 in which a pin 111 formed with a receiver member 110 is fitted. The receiver member 110 is threadedly connected to the tip end of a piston rod 115 of an actuator 114 which is fixed to the bracket 41 though a bracket 112 and a stay 113, and fixed in position by means of a lock nut 116. The reference numeral 117 denotes a bolt which is threadedly connected to a stay 118 and fixed in position by means of a lock nut 119. Bolt 117 is adapted to be brought into contact with a projecting section 120 of the receiver member 110 to restrict the movement of the piston rod 115 during the projection of the piston rod 115 (when the engaging clutch 94 is disengaged).
On the shaft 71, a gear 122 is rotatably mounted and additionally an attraction plate 124 of an electromagnetic clutch 123 is loosely fitted. The gear 122 and the attraction plate 124 are always engaged with each other in the rotational direction by means of a pin 125. A friction plate 126 is fixedly mounted on the shaft 71 by means of a key 127 and is located facing the attraction plate 124. Additionally, an electromagnet 129 is rotatably mounted through a bearing 128 on the shaft 71. The electromagnet 129 is fixed through a stay 130 to the gear box 42 so as to prevent rotation of electromagnet 124, and is located opposite the attraction plate 124. The friction plate 126 is interposed between electromagnet 129 and attraction plate 124 as shown in FIG. 13. The gear 122 is in engagement with a gear 134 fixedly mounted on an output shaft 133 of a small-size motor 132 for weft winding which motor is fixed through a bracket 131 to the gear box 42 as shown in FIG. 13.
The gear 74 of the shaft 71 is in engagement with a gear 136 fixedly mounted on a shaft 135 which is rotatably supported by the gear box 42 as shown in FIG. 8, so that the shaft 135 is adapted to be drivable to rotate. Cams 137, 138 are fixedly mounted on the shaft 135. A bracket 138 fixed to the gear box 42 fixedly carries a fixed spindle 140 on which levers 141, 142 are rotatably mounted. Cam rollers 143, 144 are rotatably fixed to the levers 141, 142, respectively. The levers 141, 142 are biased counterclockwise in FIG. 8 under the action of tension springs 145, 146 which have one end connected to the levers 141, 142, thereby allowing the cam rollers 143, 144 to contact with the cams 137, 138, respectively. The other ends of the springs 145, 146 are connected to a stud 147 projecting from the bracket 139 which stud serves also as a stopper for release levers 162, 163 which will be discussed hereinafter.
The bracket 139 fixedly carries a holder 148 in which sliding rods 149, 150 are slidably disposed to be passed through the holder 148. The sliding rods 149, 150 are fixedly provided at their one end with drive frames 151, 152, respectively. Inserted into the drive frames 151, 152 are tip end portions of the levers 141, 142, which tip end portions are provided with rollers 153, 154, respectively, in contact with the inner surface of the drive frames 151, 152. Accordingly, the sliding rods 149, 152 are axially reciprocally movable at predetermined timings under the action of the cams 137, 138. Engaging pins 155, 156 are inserted into the tip end sections of the sliding members 149, 150, respectively, are fixed in position by means of lock nuts 157, 158. Thus, upon reciprocal movement of the sliding rods 149, 150, the engaging pin 155 can be inserted into or withdrawn from a hole 159 formed at the border section between a tapered or frustoconical section 48a and a straight or cylindrical section 48b of the drum 48, whereas the engaging pin 156 can be inserted into or withdrawn from a hole 161 formed in the straight section 48b of the drum 48, passing through a through-hole 160 formed in the ballooning cover 60.
The release levers 162, 163 are rotatably mounted on a shaft 164 fixed to the bracket 139 and have their tip end sections facing rollers 165, 166 which are movably fixed to the middle sections of the levers 141, 142, respectively. Accordingly, when the release levers 162, 163 are manually operated counterclockwise in FIG. 8, the left end section of lever 162(163) moves downward and pushes roller 165(166) down. This causes the levers 141, 142 to rotate clockwise thereby to withdraw the engaging pins 155, 156 from the holes 159, 161 of the drum 48. Consequently, rotation of the rotatable shaft 44 and the weft guide pipe 53, and operation of the engaging pins 155, 156 are usually effected by the drive shaft 84 via the engaging clutch 123; however, it is arranged that the same rotation and operation can be effected by operating the motor 132 for weft winding upon changing-over the engaging clutch 94 to a disengaged state and engaging the electromagnetic clutch 123. As shown in FIGS. 8 and 9, a proximity switch 167 is fixed through a bracket 168 to the gear box 42 and adapted to detect when the weft guide pipe 53 comes into a location immediately above the proximity switch 167.
As shown in FIGS. 10 and 11, an iron piece 169 is fastened to the hollow shaft 80 in such a manner to embrace the hollow shaft 80. A proximity switch 170 is disposed in the vicinity of the iron piece 169 and fixed to the bracket 41, and adapted to detect the approach of the iron piece 169 thereto. It is to be noted that the iron piece 169 and the proximity switch 170 are brought into close proximity to each other or face each other at 300 degrees in rotational angle of the main shaft 252 (in FIG. 14), the rotational angle being 0 degree at the beating-up stage. As shown in FIG. 11, limit switches 171, 172 are fixed to the bracket 41 through brackets 173, 174, respectively, and located on opposite sides of the change-over member 100. The limit switch 171 is adapted to be switched on only in a state in which the engaging clutch 94 is engaged, whereas the limit switch 172 is adapted to be switched on only in a state in which the engaging clutch 94 is disengaged.
An air supply system will be discussed mainly with reference to FIG. 14. The air ejection nozzle 26 for weft introduction purposes of the air tensor 12 is arranged to be supplied with pressurized air from the pressurized air source 210 through the pipe 211 via a solenoid valve 212 and a flow amount regulator valve 213. The air ejection nozzle 27 for tension providing purposes is arranged to be supplied with air from the pressurized air source 210 through the pipe 214 via a solenoid valve 215 and a flow amount regulator valve 216. It is to be noted that the valves 215, 216 are adjusted so that the amount of air flow to be supplied to the air ejection nozzle 26 is larger than that to the air ejection nozzle 27. The air chamber 58 (in FIG. 10) leading to the nozzle opening 56 (for weft introduction purposes) of the weft reservoir 15 is supplied with pressurized air from the pressurized air source 210 through a pipe 217 via a solenoid valve 218 and a flow amount regulator valve 219. The air actuator 94 for change-over of the engaging clutch 94 is supplied with pressurized air from the pressurized air supply source 210 through the pipe 220 via a solenoid valve 221. It is to be noted that the solenoid valve 221 is adapted to release air from the side of the actuator 114 to atmospheric air in its closed state.
Connected to the weft inserting nozzle 17 is a pipe 222 which leads from the pressurized air supply source 210 and is provided with a regulator 223, a solenoid valve 224 and a mechanical valve 225. The mechanical valve 225 is adapted to open at a predetermined rotational angle of the loom main shaft 252. Additionally, another pipe 226 leading from the pressurized air supply source 210 and provided with a solenoid valve 227, a flow amount regulator valve 228, and a check valve 229 are provided in parallel with a portion of the pipe provided with the regulator 223, the solenoid valve 224, and the mechanical valve 225 pipe 226 is connected to the pipe 222 upstream of the mechanical valve 225.
The auxiliary nozzles 189 are connected through a mechanical valve 233 to an air tank 231 (for the auxiliary nozzles 189) which is in turn connected through a solenoid valve 230 to the pressurized air supply source 210. The mechanical valve 233 is used for each auxiliary nozzle 189 or for a group of auxiliary nozzles 189, and adapted to open at a predetermined rotational angle of the loom main shaft 252.
To the pipe 201, connected through the connector 199 to the removing pipe 196 of the picked weft yarn removing device 19, the pipe 234 leading from the pressurized air supply source 210 and provided with the flow amount regulator valve 235 and the solenoid valve 236 is connected. Connected additionally to the pipe 201 is a pipe 240 which is provided with a check valve 241 and a flow amount regulator valve 242. Pipe 240 is branched off from an air supply line through which pressurized air is supplied to an air actuator 239 for providing tension to the warp yarns 2, the pressurized air being fed to the air supply line from the pressurized air supply source 210 through a pipe 237 via a solenoid valve 238. The lower end section of the removing pipe 196 and the weft end suction device 20 on the counter-weft picking side are connected respectively through the pipes 202, 243 to the suction port of the blower 246 through the filter 244 and the pipe 245.
A driving system of the loom will be discussed with reference to FIG. 14. The driving system consists of a main motor 250 which has an output shaft on which a pulley 251 is fixedly mounted. A belt 254 is passed around the pulley 251 and a pulley 253 fixedly mounted on the main shaft 252 to drivingly connect them, so that the main shaft 252 is driven by the main motor 250. An electromagnetic brake 255 is connected to the output shaft of the main motor 250 and adapted to brake the main shaft 252. A small-size motor 256 for inching purposes has an output shaft which is connected through an electromagnetic clutch 257 to the pulley 251 in order to drive the main shaft 252 at a low speed. A gear 258 is fixedly mounted on the main shaft 252 in engagement with a gear 259 fixedly mounted on the drive shaft 84 thereby to drive the drive shaft 84.
A controller 300 is comprised of a microcomputer and is electrically connected to the solenoid valves 212, 215, 218, 221, 224, 227, 230, 236, 238, the electromagnetic clutch 123, the weft winding motor 132, the blower 246, the main motor 250, the electromagnetic brake 255, the inching motor 256, the electromagnetic switch 257, the proximity switches 167, 170 and the limit switches 171, 172.
The controller 300 will be discussed with reference to FIG. 15. The controller 300 includes a CPU 301, a RAM 302, a ROM 303, a bus line 304, an interface 305 for input, and an interface 306 for output. The reference numeral 307 denotes a rotatable disc which is rotatable in timed relation to the loom main shaft 252 and formed at its periphery with projections 308 which are located at intervals of an angle of 1 degree. An angle sensor 309 is provided to output an angle signal representing the angle corresponding to the projection 308 upon facing to the projection 308. The angle signal from the angle sensor 309 is input through the input interface 305 into the controller 300. Additionally, also input through the input interface 305 are signals from a switch 310 for preparation of starting the loom, a switch 311 for operating the loom, a switch 312 for stopping the loom, a switch 313 for reverse rotation inching, a switch 314 for normal rotation inching, a switch 315 for reverse rotation inching by one cycle in loom operation, a starting position setting switch 316 for setting the phase or angular position of the loom main shaft 252 at a starting position, a manually operated weft winding switch 317 for accomplishing weft winding on the drum 48 to set the phase or angular position of an operative member of the weft reservor 15 at a starting position, a clutch disengaging switch 318 for disengaging the clutch 94 during the manual operation of the loom, a weft introduction switch 319 for introducing the weft yarn into the air sensor 12, the weft reservoir 15, and the weft inserting nozzle 17. It is to be noted that the weft introduction switch 319 is of the automatically restorable foot operated type whereas the other switches are of the automatically restorable push button type.
A weft feeler 320 is provided to detect mispick and failed weft picking. Additionally, a warp feeler 321 is provided to detect cutting of warp yarns. The signals from these feelers 320, 321 are also input through the input interface 305 to the controller 300. Presetters 322, 323, 324, 325, 326, 327 are provided to preset a variety of angles and times in loom operation, the signals from these presetters being input through the input interface 305 into the controller 300. It will be understood that the signals from the proximity switches 167, 170, and the limit switches 171, 172 are also input through the input interface 305 into the controller 300.
Drivers 328, 329, 330, 331, 332, 333, 334, 335, 336 are provided to drive solenoid valves 212, 215, 218, 221, 224, 227, 230, 236, 238, respectively. Additionally, drivers 337, 338, 339, 340, 341, 342, 343 are provided to drive the electromagnetic clutch 123, the weft winding motor 132, the blower 246, the main motor 250, the electromagnetic brake 255, the inching motor 256, and the electromagnetic clutch 257. These drivers 328-343 are electrically connected to the output interface 306.
In addition, a lamp 346 is provided to indicate the operation of the loom. The reference numeral 347 denotes a driver for driving the lamp 346, which driver is also electrically connected to the output interface 306. p The manner of operation of the above-described loom will be discussed hereinafter with reference to the flow charts of FIGS. 16A and 16B.
In starting the loom, when the loom is in condition for starting in which a predetermined length of the weft yarn 10 is wound on the drum 48, the starting preparation switch 310 is first closed. Then, the blower 246 is driven. Subsequently, the electromagnetic clutch 257 is switched off (or disengaged) to disconnect the output shaft of the main motor 250 and that of the inching motor 256. Next, the solenoid valve 224 disposed in the pipe 222 leading to the weft inserting nozzle 17, and the solenoid valve 230 disposed upstream of the tank 231 connected to the auxiliary nozzles 189 are opened.
Subsequently, the loom operating switch 311 is closed. Then, the electromagnetic brake 255 is switched off, and the main motor 250 is driven. Accordingly, the loom main shaft 252 is rotated through the pulley 251, the belt 254, and the pulley 253.
During operation of the loom, the drive shaft 84 is driven to rotate by the main shaft 252 through the gears 258 and 259. The rotation of drive shaft 84 causes the shaft 86 to rotate through the toothed pulley 85, the cogged belt 89, and the toothed pulley 88, and further causes the change-over member 100 to rotate through the coupling 90 and the shaft 92. The change-over member 100 drives the connector 96 to rotate through the engaging clutch 94, and further the shaft 77 to rotate through the bolt 98, the ring 82, the bolt 83, and the hollow shaft 80. The shaft 71 is rotated by the shaft 77 through the gears 79 and 74. Then, the shaft 71 rotates once per each rotation of the main shaft 252.
Upon rotation of the gear 74 fixedly mounted on the shaft 71, the shaft 135 is rotated through the gear 136 which is in engagement with the gear 74. Then, the shaft 135 also rotates once per each rotation of the main shaft 252. The rotated shaft 135 causes the cams 137, 138 fixedly mounted thereon, to rotate so that the sliding rods 149, 150 make their reciprocating movement at predetermined timings under the force transmission through the cam rollers 143, 144, the levers 141, 142, the rollers 153, 154, and the drive frames 151, 152. This causes the engaging pins 155, 156 to be inserted into or withdrawn from the holes 159, 161, respectively, at predetermined times. The rotation of the shaft 71 causes the gear 73 fixedly mounted on the shaft 71 to rotate, and accordingly the shaft 66 is rotated through the gear 69. The rotation of the shaft 66 causes the rotatable shaft 44 to rotate under the force transmission through the gears 68, 64. Then, the rotatable shaft 44 rotates four times per one rotation of the main shaft 252, so that the weft guide pipe 53 rotates around the drum 48 thereby to wind up the weft yarn 10 on the drum 48.
Thus, under rotation of the weft guide pipe 53, the weft yarn 10 of a predetermined length required for one weft picking is wound on the drum straight section 48b between the engaging pins 155 and 156 by a time point immediately before the weft picking. When the weft picking step has come, the mechanical valve 225 is first opened to eject pressurized air from the weft inserting nozzle 17. Immediately after this, the engaging pin 156 is withdrawn from the hole 161 to release the weft yarn 10, so that the weft yarn 10 is drawn or pulled by the air ejection from the weft inserting nozzle 17 and inserted through the guide opening 197 of the picked weft yarn removing pipe 196 into the weft guide groove 187. In timed relation to this, the mechanical valve 233 for the auxiliary nozzle 189 is opened slightly before the tip end section of the weft yarn 10 passes by the auxiliary nozzle 189, thereby ejecting pressurized air from the auxiliary nozzle 189. Thus, the tip end of the weft yarn 10 is successively blown away along the weft guide groove 187 under the influence of air jets which are successively ejected from the auxiliary nozzles 189 disposed along the weft guide groove 187. The mechanical valve 233 for the auxiliary nozzle 189, by which the tip end section of the weft yarn 10 has passed, is closed to stop air ejection from the auxiliary nozzle 189. The weft picking of the weft yarn 10 is completed when the weft yarn 10 is engaged with the engaging pin 156; immediately before this the mechanical valve 225 is closed to stop the air ejection from the weft inserting nozzle 17.
At the step of beating-up, after the engaging pin 156 is inserted into the hole 160, the engaging pin 155 is withdrawn from the hole 159, so that the weft yarn 10 (of the length required for one weft picking) wound on the drum tapered section 48a removes to the drum straight section 48b. Thereafter, the engaging pin 155 is again inserted into the hole 159 to engage with the continuously wound weft yarn 10. In this state, the weft reservoir 15 stands ready for the next weft picking. It is to be noted that the solenoid valve 215 is opened simultaneously with a main electric source being switched on, in which a weak air stream is always ejected from the nozzle opening 34 of the nozzle 27 to draw the weft yarn 10 in the direction opposite to the advancing direction of the weft yarn 10, i.e., in the direction from the side of the drum 48 to the side of the yarn supplier 9A, thereby providing tension to the weft yarn 10.
During loom operation, the controller watches for signals from the weft feeler 320, the warp feeler 321, and the loom stopping switch 312. For example, in case a mispick arises so that the weft feeler generates a stopping signal, a loom stopping angle is set at 180 degrees in an open shed state, and thereafter the solenoid valves 224, 230 are closed to prevent excessive air ejection while main motor 250 is switched off and the electromagnetic brake 255 is switched on. It is to be noted that in case a warp cutting arises so that a loom stopping signal is generated from the warp feeler 321 or in case the loom stopping switch 312 is closed, the loom is stopped in that the electromagnetic brake 255 is applied when the loom stopping angle is set at 300 degrees in a closed shed state which is suitable for restoring the warp yarn 2.
At this loom stopping step, the mispicked weft yarn 10 is cut by the cutter 21 upon being beaten-up by the reed 5, and then the next weft picking is made under the influence of the remaining air in the pipes downstream of the solenoid valves 224, 230. The loom stopping is made at approximately 200-300 degrees at the beating-up step, in which the last picked weft yarn 10 is being connected to the weft inserting nozzle 17, without being cut.
Next, discrimination is made by CPU 301 as to whether a pulse signal is input from the angle sensor 309 within a predetermined time period or not. A decision of loom stopping is made when there has been no input of the pulse signal. After making the decision of loom stopping, an actual or present rotational angle (loom stopping angle) read from the pulse signal of the angle sensor 309 is compared with a preset loom stopping angle. When the present loom stopping angle exceeds the preset loom stopping angle (this condition being nearly reached in case of loom stopping due to mispick or failed weft picking), the electromagnetic clutch 257 is switched on (engaged) to make connection of the inching motor 257 while the loom operation indicating lamp 346 is lighted, thereafter a clutch disengaging signal is generated to disengage the clutch 94.
Meanwhile, another or separate CPU 301' is operating in accordance with a flow chart as shown in FIG. 17. That is, as an interlock, a discrimination by CPU 301' is first made as to whether the main motor 250 is switched on or off. If switched off, i.e., in case of other than normal loom operation, watching is made as to whether a clutch disengaging signal (only a first time) is generated or not, and as to whether the manual clutch disengaging switch 318 is closed or not. When the first time clutch disengaging signal is generated, the solenoid valve 221 is opened to blow pressurized air into the actuator 114. Accordingly, the piston rod 115 is extended to allow the changeover lever 103 to rotate clockwise in FIG. 11 through the receiver 110 and the pin 111, thereby moving the change-over member 100 rightward through the rollers 104, 105 to put the engaging clutch 94 into a disengaged state. Then, if the limit switch 172 is recognized to be switched on, a clutch answer signal is changed to OFF and output, and the solenoid valve 236 and the blower 246 are switched on for a predetermined time period.
In the flow chart in FIG. 17, when the manual clutch disengaging switch 318 is closed, the valve 221 is opened to disengage the engaging clutch 94 while the clutch answer signal is changed to OFF and output after the limit switch 172 is confirmed to be switched on. After the above-mentioned operation takes place upon generation of the clutch disengaging signal or closure of the manual clutch disengaging switch 318, the controller checks whether the weft introduction switch 319 is closed or not or whether the weft winding switch 317 is closed or not.
Turning to the flow charts in FIGS. 16A and 16B, whei it is confirmed that the clutch answer signal from the other CPU 301' is OFF and the limit switch 172 is switched on, the inching motor 256 is switched on to make its reverse rotation, and the electromagnetic switch 255 is switched off, so that the main shaft 252 is reversely rotated through the electromagnetic clutch 257 by the inching motor 256. At this time, since the clutch 94 is in the disengaged state, the weft reservoir 15 is not operated while operating the side of a weaving section of the loom. When the angle signal from the angle sensor 309 reaches a valve of the preset loom stopping angle in the process of detecting the angle signals, the inching motor 256 is switched off, the electromagnetic brake 255 is switched on to effect a braking action, and the lamp 346 is put out. When the actual loom stopping angle does not exceed the preset loom stopping angle, discrimination is made by CPU 301' as to whether the actual loom stopping angle agrees with the preset loom stopping angle. If agreement is found, loom stopping is maintained as it is. If the agreement is not found, i.e., the actual loom stopping angle has not reached the preset loom stopping angle (this condition is reached in case of loom stopping due to warp yarn cutting), the electromagnetic clutch 257 is switched on (or engaged), and after the lamp 346 is lighted the inching motor 256 is switched on to normally rotate while the electromagnetic brake 255 is switched off thereby to drive the weaving section of the loom and weft reservoir 15 to normally revolve at a low speed. When the actual loom stopping angle has reached the preset loom stopping angle, the inching motor 256 is switched off, the electromagnetic brake is switched on to effect a braking action, and the lamp 346 is put out.
After the loom has been stopped at the preset loom stopping angle, in case of loom stopping due to mispick or failed weft picking, the blower 246 is operated simultaneously with the opening of solenoid valve 236. Upon opening of the solenoid valve 236, pressurized air is supplied through the pipe 210 and the connector 199 into the removing pipe 196, thereby generating a high speed air stream flowing from the upstream pipe section 196b to the downstream pipe section 196a traversing a guide space between the guide openings 197. Additionally, an air stream for sucking is generated within the downstream pipe section 196a upon operation of the blower 246. Thus, the weft yarn 10 inserted through the guide openings 197 is blown downward under the influence of the air stream directed downward traversing the guide space between the guide openings 197, and the thus blown weft yarn 10 is effectively sucked into the downstream pipe section 196a under the influence of the sucking air stream by the blower 246, thereby pulling out the lastly picked weft yarn 10. Such an operation is carried out for a time period preset in the presetter, and accordingly when a time lapse has occurred for the preset time period, the solenoid valve 236 is closed and the blower is switched off. While the air stream for removing the lastly picked weft yarn has been described as being generated after stopping loom operation in this instance, it will be understood that the air stream may be generated simultaneously with the operation of the electromagnetic brake 255 to also accomplish the weft yarn removing action in the loom stopping process.
After the lastly picked weft yarn is automatically removed upon loom stopping due to mispick, the one cycle reverse rotation inching switch 315 is closed by an operator. When the one cycle reverse rotation inching switch 315 is closed upon being pushed for a moment, the electromagnetic clutch 257 is switched on, the lamp 346 is switched on, and the clutch disengaging is generated. In case the clutch 94 has already been disengaged while the clutch answer signal has become OFF, the inching switch motor 256 is switched on and the electromagnetic brake is switched off after the limit switch 172 is confirmed to be switched on, thereby reversely rotating the main shaft 252 of the loom at a low speed. At this time, since the clutch 94 is in the disengaged state, measurement and detaining operation of the weft yarn cannot take place, thereby preventing the weft yarn 10 from wasting. Thereafter, when the reverse rotation of the loom has made one cycle in order to reach the preset loom stopping angle (180 degrees), the inching motor 256 is switched off, the electromagnetic brake 255 is switched on, and the lamp 346 is switched off, thereby stopping the loom. In this state, the mispicked weft yarn 10 is pulled out. During this loom stopping, if the reverse rotation inching switch 313 is closed, only the loom main shaft 252 can be intermittently reversely rotated at a low speed while the switch is pushed. If the normal rotation inching switch 314 is closed, the loom main shaft 252 (the main shaft 252 and the weft reservoir 15 in case the clutch 94 is engaged) can be intermittently normally rotated at a low speed while the switch is pushed.
In order to put the loom in starting condition for re-starting after pulling out the mispicked weft yarn, it is necessary to put the main shaft 252 and the weft reservoir 15 into a condition suitable for closed shed starting. For this purpose, the starting position setting switch 316 and the weft winding switch 317 are usually closed by the operator in the mentioned order.
When the starting position setting switch 316 is first closed, the electromagnetic clutch 257 is switched on and the lamp 346 is switched on while generating the clutch disengaging signal. If the clutch 94 is disengaged and the clutch answer signal becomes OFF, the inching motor 256 is switched on and electromagnetic brake 255 is switched off after the limit switch 172 is confirmed to be switched on, thereby reversely rotating the loom main shaft 252 at a low speed. When the loom reverse revolution has reached 300 degrees in closed shed starting, the inching motor 256 is switched off, the electromagnetic brake 255 is switched on, and the lamp 346 is switched off, thereby stopping the loom. Thus, the position setting for the main shaft 252 is completed.
Subsequently, when the weft winding switch 317 is closed, the solenoid valve 236 is opened and the blower 246 is operated as shown in the flow chart in FIG. 17, thus generating the ejection air stream in the removing pipe 196 upstream of the guide opening 197 and the suction air stream in the pipe 196 downstream of the guide opening 197. Immediately after generation of such air streams, the electromagnetic clutch 123 and the weft winding motor 132 are switched on for a predetermined time period. Due to this, the electromagnetic 129 of the electromagnetic clutch 123 attracts the attraction plate 124 to be pressed on the friction plate 126, while the rotation of the weft winding motor 132 causes the shaft 71 to rotate at a low speed through the gear 134, the gear 122, the pin 125, the attraction plate 124, the friction plate 126, and the key 127. Upon rotation of the shaft 71, the shaft 135 is rotated through the gears 74, 136, so that the cams 137, 138 are driven to allow the engaging pins 155, 156 to be inserted into or withdrawn from the holes 159, 160, respectively. In timed relation to the movement of the engagement pins 155, 156, the rotatable shaft 44 is rotated by the gears 73, 69, the shaft 66 and the gears 68, 64 due to the rotation of the shaft 71 in order to accomplish winding of the weft yarn 10 on the drum 48.
When the phase of the weft reservoir 15 becomes 300 degrees in angle, the iron piece 169 faces the proximity switch 170 to allow the switch 170 to be switched on, thereby closing the solenoid valve 221. Accordingly, the piston rod 15 is withdrawn under the action of a spring (not shown) disposed within the air actuator 114, and the change-over member 100 is moved leftward in FIG. 11, i.e., toward the side of the connector 96 under the biasing force of the spring 102, thereby allowing the tooth (projection) 95 at the end face of the change-over member 100 to contact the end face of the connector 96. It is to be noted that the clutch 94 is adapted to engage only at a certain phase (300 degrees). When, the phase of the weft reservoir 15 has already exceeds 300 degrees in angle, the limit switch 171 is still switched off while the limit switch 172 is still switched on. Thus, upon further rotation of the weft winding motor 132 with the teeth 95, 99 of the clutch 94 in condition to contact each other, the teeth 95, 99 are at last brought into mesh with each other when the weft reservoir phase next reaches 300 degrees. In this state, even if the weft winding motor 132 has been switched on, the weft winding motor 132 does not rotate under the action of load caused by the meshing of the teeth 95, 99 on the side of the main shaft 252, so that the weft reservoir 15 does not operate. Thereafter, upon lapse of a time, the electromagnetic clutch 123 is switched off and the weft winding motor 132 is switched off. At this stage, the change-over member 100 is fully moved leftward under the bias of the spring 102 upon disappearance of rotational torque, so that the teeth 95, 99 are fully brought into mesh with each other while the limit switch 171 is switched on and the limit switch 172 is switched off. At angular phases other than 300 degrees, the teeth 95, 99 of the clutch are not brought into complete mesh with each other, so that the change-over member 100 does not move as far leftwardly as is possible.
During this, discrimination is made by CPU 301 as to whether the limit switch 171 is switched on or not. If it is switched on, the solenoid valve 236 is closed while the blower 246 is switched off. This causes the weft guide pipe 53 to rotate four times from 300 degrees, which corresponds to one cycle in phase of the loom. During this time period, the weft yarn 10 is wound on the drum 48 by the weft guide pipe 53 while the engaging pins 155, 156 are inserted into or withdrawn from the holes 159, 161, respectively. Accordingly, when the engaging pin 156 is withdrawn from the hole 161, the weft yarn 10 is drawn out under the influence of suction air stream within the removing pipe 196, so that the weft yarn 10 between the drum 48 and the removing pipe 196 stands ready in a state of tension.
In the state where the clutch 94 has been automatically disengaged, the clutch 94 is again engaged so that it is preset in the state where the loom has been stopped because driving is stopped. When the abovementioned starting operation (without weft picking) is made in this state, the loom operation again starts. That is, upon closure of the starting preparation switch 310, the operation returns an earlier position in the flow chart in FIGS. 16A and 16B, so that the operation is again initiated upon closure of the loom operation switch 311.
In order to introduce the weft yarn 10 to pass through the air tensor 12, the rotatable shaft 44, the weft guide pipe 53 and the weft inserting nozzle, the weft introduction switch (foot switch) 319 is closed prior to closure of the weft winding switch 317. Then, discrimination is made by CPU 301 as to whether the proximity switch 167 is switched on or not, i.e., whether the weft guide member 53 is brought into an upper position (or a position for facilitating the operation) or not. If the weft guide member 53 is not brought into the upper position, the electromagnetic clutch 123 is switched on, and the weft winding motor 132 is driven.
Consequently, the shaft 71 is rotated at a low speed via the output shaft 133, the gear 134, the gear 122, the pin 125, the attraction plate 124, the friction plate 126, and the key 127. The rotation of the shaft 71 causes the shaft 135 to rotate through gears 74, 136, so that the cams 137, 138 are driven thereby to allow the engaging pins 155, 156 to be projected or withdrawn. In timed relation to this, i.e., upon rotation of the shaft 71, the rotatable shaft 44 is rotated through the gears 73, 69, the shaft 66, and the gears 68, 64, so that the weft yarn 10 is wound on the drum 48 by the weft winding pipe 53. When the weft guide pipe 53 faces the proximity switch 167, the electromagnetic clutch 123 and the weft winding motor 132 are switched off. This is made to locate the weft guide pipe 53 on the upper side in order to facilitate the operation.
Then, the solenoid valves 212, 218, 227 are opened, so that pressurized air is ejected from the weft introduction air nozzle opening 56 in the rotatable shaft 44 and from the weft inserting nozzle 17. Upon air ejection from the weft introduction nozzle 26, air fed into the pipe 25 under pressure is ejected through the weft introduction opening 31 of the nozzle 27 since the nozzle 26 is adapted to be larger in air flow amount than the nozzle 26 for tension providing purpose. Accordingly, when the weft yarn 10 is brought to the inlet section of the weft introduction opening 31 of the nozzle 26, the weft yarn 10 is drawn into the pipe 25 under the sucking action of the air stream generated there, and subsequently discharged from the weft introduction opening 31 of the nozzle 27. Thereafter, the tip end section of the weft yarn 10 is brought into the inlet section of the weft introduction opening 54 of the weft introduction pipe 55 of the rotatable shaft 44, and sucked into the weft introduction opening 54 under the influence of an air stream flowing from the nozzle opening 56 through the weft introduction hole 52 and discharged out of the tip end section of the weft guide pipe 53. Thus, the weft yarn 10 is discharged from the tip end section of the weft guide pipe 53 into between the ballooning cover 60 and the drum 48. Therefore, when the tip end section of the weft yarn 10 is brought to the inlet section of the weft inserting nozzle 17 upon passing through the guide 18, it is suched into the weft inserting nozzle 17 and discharged from its outlet section to be inserted into the guide opening 197 of the picked weft yarn removing pipe 196. Thus, the introduction operation of the weft yarn 10 into the various devices can be easily accomplished.
When the weft introduction operation has been completed, the weft introduction switch (foot operated switch) is released to be switched off. Accordingly, upon discrimination by CPU 301 of the weft introduction switch 319 being changed from the ON position to the OFF position, the solenoid valves 212, 218, 227 are closed to stop ejection of air for weft introduction. Then, the solenoid valve 236 is opened, for example for 5 seconds which is set by the presetter in order to generate a descending air stream in the picked weft yarn removing pipe 196, while the blower 202 is switched on for the same time period thereby to positively suck the descending air stream into the removing pipe 196 through the filter 244 and the pipe 202. Consequently the tip end section of the weft yarn 10 passing through the guide opening 197 of the removing pipe 196 is sucked into the removing pipe 196. Thereafter, the weft winding switch 317 is closed.
FIGS. 18 and 19 illustrate another example of the picked weft yarn removing device 19' which is similar in principle to the above-discussed corresponding device 19. As shown, the reed 5 is fixed in position in such a manner that its lower frame is inserted together with a wedge member 402 in a laterally extending groove 401 of a reed holder 400 which is swingingly movable forward and backward under the action of the sley sword 180 (shown in FIG. 2), the wedge member 402 being forced in by screwing in bolts 403. A plurality of reed blades 404 of the reed 5 are formed respectively with grooves 405 which are located on the side of the cloth fell. The aligned grooves 405 constitute a weft guide groove or channel 406. The weft inserting nozzle 17 is fixedly supported by a holder 410 which is fixed in position by a headed bolt 408 fitted in a laterally extending groove 407 and a nut 409. The groove 407 has a T-shaped cross-section and opens to the front side surface. The weft inserting nozzle 17 faces and is aligned with the weft guide groove 406. A plurality of auxiliary nozzles 189 are aligned along the weft guide groove 406 at predetermined intervals. Each auxiliary nozzle 189 is supported by a holder 413 which is fixed in position by a headed bolt 411 fitted in the groove 407 and a nut 412.
A parent reed blade or guide member 414 located on the weft picking side forms part of the picked weft yarn removing device 19'. The parent reed blade 414 is aligned with the reed blades 404 and fixedly disposed between the upper and lower frames of the reed 5, and is located on the side of the weft inserting nozzle 17 relative to the rows of the warp yarns 2. The parent reed blade 414 has the same cross-sectional shape as the reed blades 404 and therefore is formed with a groove 415 (or the guide space) whose cross-section is the same as that of the reed blades 404, so that the parent reed blade groove 415 is aligned with the reed blade groove 405.
As shown, the parent reed blade 414 is considerably wider than the reed blade 404, and therefore its groove 415 is wider than that of the reed blade 404. The groove 415 of the parent reed blade 414 is defined by upper and lower wall faces which are opposite each other, and a side wall face located generally perpendicular to the upper and lower wall faces, so that the groove 415 opens to the side of the cloth fell. The parent reed blade 414 is formed at the lower wall face with a suction opening 416 which opens to the groove 415. Additionally, an induction passage 417 (or air flow passage) in communication with the suction opening 416 is formed in the body of the parent reed blade 414. A connector pipe 418 is connected to the induction passage 417. The flexible pipe 202 is connected to the connector pipe 418 and leads to the suction port of the blower 246 via the filter 244 and the pipe 245 as shown in FIG. 20. Furthermore, the parent reed blade 414 is formed at the upper wall face with an ejection opening 419 which is in communication with an induction passage 420 formed in the body of the parent reed blade 414. A connector pipe 421 is connected to the induction passage 420. The flexible pipe 201 is connected to the connector pipe 421. This pipe 201 leads to the pipe 234 from the pressurized air supply source 210 via the flow amount regulating valve 235 and the solenoid valve 236. It will be understood that, in this instance, the parent reed blade 414 serves as a weft yarn restraining member for restraining the picked weft yarn 10 until beating-up by the reed 5.
With this configuration, during normal loom operation, the weft yarn 10 is picked through the parent reed blade groove 415 into the weft guide groove 406 constituted by the row of the aligned reed blade grooves 405 under the influence of an air jet ejected from the weft inserting nozzle 17, in which auxiliary air jet ejection is made from the respective auxiliary nozzles 189 with advance of the tip end section of the weft yarn 10 to successively blow away the weft yarn 10 along the weft guide groove 406, thus achieving a weft picking.
Now, if mispicking or failed weft picking arises during such a weft picking process, the loom is stopped at the next beating-up step in which the weft yarn 10 is being pushed deeply in the groove 415 of the parent reed blade 414 so that the weft yarn 10 certainly exists in the groove 415. Accordingly, when the solenoid valve 236 in FIG. 20 is opened and the blower 246 is operated, air is ejected from the ejection opening 419 to force the weft yarn 10 into the suction opening 416, and the weft yarn 10 is simultaneously sucked into the suction opening 416. The weft yarn 10 is then sucked into the pipe 202 through the induction passage 417 and the connector pipe 418, thus pulling out the last picked weft yarn 10 from the shed of the warp yarns 2. The weft yarn 10 is cut by the cutter 21 in the position between the weft inserting nozzle 17 and the parent reed blade 414 at re-starting of the loom.
FIG. 21 illustrates a further example of the picked weft yarn removing device 19" which is similar to the device 19' of FIGS. 18 and 19 with the exception that the weft yarn restraining member or guide member 414' is not formed integral with the reed 5 so that the parent reed blade does not serve as the weft yarn restraining member. In this example, the weft yarn restraining member 414' is shaped similar to the parent reed blade 414 of FIG. 18 and has a similar configuration, but is disposed separately and independently from the reed 5.
As will be appreciated from the above, the above-discussed loom is equipped with the picked weft yarn removing device which is arranged such that the weft yarn projected from the weft inserting nozzle and lying in a guide space can be forced into an air flow passage under the influence of an air stream developed through the guide space. Accordingly, the weft yarn to be removed certainly lies restrained in the guide space in the state to be passed therethrough at any time and therefore forcing the weft yarn into the air flow passage can be surely effected, thereby facilitating re-starting the loom.
Additionally, the above-discussed loom is equipped with a loom starting device by which preparation of starting the weft reservoir can be made only upon operating the manual switch for weft winding after the phase of the loom main shaft is set for starting, thereby greatly facilitating preparation of the loom for starting. Particularly, the starting phase of the main shaft is obtained after at least one weft yarn winding is made on the drum of the weft reservoir, regardless of weft reservoir condition as to whether no weft yarn or some weft yarn has been wound on the drum of the weft reservoir, thereby making the loom very practical.
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A loom having a drum type weft reservoir including a drum on which a predetermined length of a weft yarn is wound to be measured and reserved prior to weft picking. The weft reservoir is automatically prepared for loom starting by merely operating a manual switch. The local includes a clutch which is engaged at a predetermined operational phase of the loom to drive the weft reservoir. If the manual switch is actuated when the clutch is disengaged, then the clutch is engaged at a second time substantially later than the first time at which the predetermined operational phase is reached. Any cut, broken or unnecessary weft yarn remaining wound on the drum when the switch is actuated is removed during the interval between the first and second times, e.g. by pulling the weft yarn from the side of a weft inserting nozzle. The weft yarn is pulled from the weft inserting nozzle side by a device such as a picked weft yarn removing device adapted to pull the weft yarn wound on the weft reservoir drum in the direction of the weft inserting nozzle. When the second time comes, the weft reservoir is driven and a new weft yarn is wound on the weft reservoir drum for use as the weft yarn when the loom starts. The loom thus is prepared for starting merely by actuating the manual switch, regardless of the number of turns of weft yarn wound on the drum before the switch is actuated.
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FIELD OF INVENTION
The present invention is for novel Kluyveromyces marxianus yeast strains that produce ethanol. More specifically, the mutagenized yeast strains are able to grow aerobically on glucose at 47° C., and anaerobically at 46° C. on glucose, galactose, galacturonic acid, and pectin. Of particular interest, yeast strain NRRL Y-50798 was able to grow anaerobically on xylose at 46° C.
BACKGROUND OF INVENTION
The United States Environmental Protection Agency has issued a rule to increases the volume requirements for total renewable fuel to 20.5 billion gallons and for cellulosic biofuel to 3.0 billion gallons by 2015. To meet these mandates, it will be necessary to use cellulosic biomass, an abundant and renewable carbon source, as a feedstock.
Currently, S. cerevisiae is frequently used to ferment biomass sources to produce fuel ethanol. One of the drawbacks in using conventional S. cerevisiae strains is that S. cerevisiae strains typically optimally operate between 25° C. and 30° C. to produce ethanol in industrial fermentation systems. The produced heat from the fermentation system generally requires some means of cooling the system to the optimal temperature range. In the absence of cooling, heat stress on the yeast strain reduces the production yield. Additionally, a yeast strain that optimally ferments at higher temperatures would improve the efficiency of simultaneous saccharification and fermentation, and allow for the continuous ethanol removal by evaporation under reduced pressure. As such, there is a need to develop a heat tolerant yeast strain to take advantage of producing fuel ethanol at higher temperatures.
The yeast strain, Kluyveromyces marxianus , has an advantage over typical Saccharomyces cerevisiae with respect to higher operating temperature ranges in that Kluyveromyces marxianus has been reported to grow at 47° C. and above (Nonklang, S. et al., Appl. Environ. Microbiol. 2008, 74(24), 7514-7521) and produce ethanol at temperatures above 40° C. (Fonseca, G. G., et al., Appl. Microbiol. Biotechnol. 2008, 79, 339-354).
Additionally, K. marxianus offers other benefits compared to typical S. cerevisiae strains. Other benefits include the ability to grow on a wide variety of substrates not utilized by S. cerevisiae such as xylose, xylitol, cellobiose, lactose, arabinose, and glycerol (Nonklang, S.; Abdel-Banat, B. M. A.; Cha-aim, K.; Moonjai, N.; Hoshida, H.; Limtong, S.; Yamada, M.; Akada, R. High-temperature ethanol fermentation and transformation with linear DNA in the thermotolerant yeast Kluyveromyces marxianus DMKU3-1042 Appl. Environ. Microbiol. 2008, 74(24), 7514-7521 and Rodrussamee, N.; Lertwattanasakul, N.; Hirata, K.; Suprayogi; Limtong, S.; Kosaka, T.; Yamada, M. Growth and ethanol fermentation ability on hexose and pentose sugars and glucose effect under various conditions in thermotolerant yeast Kluyveromyces marxianus. Appl. Microbiol. Biotechnol. 2011, 90, 1573-1586). K. marxianus also grows on sucrose, raffinose, and inulin at 45° C. under a static condition even when glucose is present unlike S. cerevisiae . Given the benefits offered by K. marxianus , further evaluation of various strains is warranted.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention together with the above and other objects and advantages may best be understood from the following detailed description of the embodiment of the invention illustrated in the drawings, wherein:
FIG. 1 is a graph depicting cell kill curves for Kluyveromyces marxianus NRRL Y-1109 wild-type (WT) strain irradiated at 14 cm for 9 h with UV-C 234 nm.
FIG. 2 is a depiction of Kluyveromyces marxianus mutant strains NRRL Y-50798 and Y-50799 grown on glucose medium at 30° C. and 47° C. for 5 days under aerobic conditions compared to K. marxianus NRRL Y-1109 wild-type (WT).
FIG. 3 is a graph depicting ethanol production (g/L) and cell growth (absorbance at 660 nm) for wild-type (WT) Kluyveromyces marxianus NRRL Y-1109, K. marxianus mutant strains NRRL Y-50798 and Y-50799, and Saccharomyces cerevisiae NRRL Y-2043 for 30 hours at 46° C. in 1 liter YM medium (10 g/L glucose) under microaerophilic conditions in a 2-L Fernbach flask.
FIG. 4 depicts scanning electron micrographs of Kluyveromyces marxianus mutant strains Y-50798 and Y-50799 compared to K. marxianus NRRL Y-1109 wild-type (WT).
FIG. 5 depicts VNTR fingerprints of genomic DNA of Kluyveromyces marxianus mutant strains Y-50798 and Y-50799 compared to K. marxianus NRRL Y-1109 wild-type (WT).
FIG. 6 is a depiction of anaerobic and aerobic growth on selected substrates at 46° C. for 7 days of mutant strains Y-50799 (top position on plate) and Y-50798 (right) compared to wild-type Kluyveromyces marxianus NRRL Y-1109 (bottom) and Saccharomyces cerevisiae NRRL Y-2043 (left).
FIG. 7 is a depiction of anaerobic and aerobic growth on additional substrates at 46° C. for 7 days of Saccharomyces cerevisiae NRRL Y-2043 (top right position on plate), wild-type Kluyveromyces marxianus NRRL Y-1109 (bottom right), and mutant strains Y-50798 (bottom left) and Y-50799 (top left).
DEPOSIT OF BIOLOGICAL MATERIAL
Strains Y-50798 and Y-50799 are identified as variants of Kluyveromyces marxianus based on variable nucleotide tandem repeat (VNTR) analysis. Both NRRL Y-50798 and NRRL Y-50799 were deposited on Jan. 15, 2013, under the provisions of the Budapest Treaty in the Agricultural Research Culture Collection (NRRL) in Peoria, Ill., and have been assigned Accession Nos. NRRL Y-50798 and NRRL Y-50799.
The subject cultures have been deposited under conditions that assure that access to the cultures will be available during the pendency of this patent application to one determined by the Commissioner of Patents and Trademarks to be entitled thereto under 37 CFR §1.14 and 35 USC §122. The deposits are available as required by foreign patent laws in countries wherein counterparts of the subject application, or its progeny, are filed. However, it should be understood that the availability of the deposits does not constitute a license to practice the subject invention in derogation of patent rights granted by governmental action.
Further, the subject culture deposits will be stored and made available to the public in accord with the provisions of the Budapest Treaty for the Deposit of Microorganisms, i.e., they will be stored with all the care necessary to keep them viable and uncontaminated for a period of at least five years after the most recent request for the furnishing of a sample of the deposits, and in any case, for a period of at least 30 (thirty) years after the date of deposit or for the enforceable life of any patent which may issue disclosing the cultures. The depositor acknowledges the duty to replace the deposits should the depository be unable to furnish a sample when requested, due to the condition of the deposits. All restrictions on the availability to the public of the subject culture deposits will be irrevocably removed upon the granting of a patent disclosing them.
As described herein, Kluyveromyces marxianus strain NRRL Y-50798 is also referred to as strain 7-1. Kluyveromyces marxianus strain NRRL Y-50799 is also referred to as strain 8-1.
BRIEF DESCRIPTION OF THE SEQUENCES
The invention can be more fully understood from the following detailed description and the accompanying sequence descriptions, which form a part of this application.
SEQ. ID. NO. 1: CAGCAGCAGCAGCAG is a PCR primer.
DETAILED DESCRIPTION OF THE INVENTION
Disclosed herein is an isolated Kluyveromyces marxianus having been deposited with the United States Department of Agriculture, Agricultural Research Patent Culture Collection as Accession Deposit Number NRRL Y-50798. Also disclosed is an isolated Kluyveromyces marxianus having been deposited with the United States Department of Agriculture, Agricultural Research Patent Culture Collection as Accession Deposit Number NRRL Y-50799.
Disclosed is an isolated Kluyveromyces marxianus having been deposited with the United States Department of Agriculture, Agricultural Research Patent Culture Collection as Accession Deposit Number NRRL Y-50798.
Also disclosed is an isolated Kluyveromyces marxianus having been deposited with the United States Department of Agriculture, Agricultural Research Patent Culture Collection as Accession Deposit Number NRRL Y-50799.
Also disclosed is a method of producing ethanol comprising culturing yeast strain NRRL Y-50798 or NRRL Y-50799 under suitable conditions for a period of time sufficient to allow fermentation of at least a portion of feedstock to ethanol. In one embodiment of the method, the conditions include hexose sugars. In another embodiment of the method, the conditions include pentose sugars. In yet another embodiment of the method, the yeast strains ferment glucose and xylose at aerobic conditions. In yet another embodiment of the method, the feedstock contains galacturonic acid. In another embodiment of the method, the strain NRRL Y-50798 or Y-50799 grow on a substrate consisting essentially of galacturonic acid, pectin, glucose, arabinose, xylose, and galactose under aerobic conditions. In another embodiment of the method, the strain NRRL Y-50798 or Y-50799 grow on a substrate comprising of guar.
Generation of Isolates 7-1 and 8-1 (NRRL Y-50798 and Y-50799)
Duplicate 2-L Fernbach flasks were prepared by adding 1 L of YM medium [0.3% yeast extract, 0.3% malt extract, 0.5% peptone (Becton, Dickinson and Company, Franklin Lakes, N.J., USA), and 1.0% dextrose (Sigma Aldrich, St. Louis, Mo., USA)] to each flask and inoculating with 20 mL of a culture of wild-type K. marxianus NRRL Y-1109 (USDA, ARS Culture Collection) grown on YM medium in a 100-mL flask at 28° C. for 2 days. The Fernbach flasks were incubated at 28° C. for 2 days at 100 rpm. The culture from each flask was divided into two Beckman 500-mL spin bottles and pelleted in a Beckman Avanti J20 centrifuge (Beckman Coulter, Inc., Indianapolis, Ind., USA) at 20° C. for 20 minutes at 2056×g. Cell pellets were washed and resuspended in 50 mL of sterile water. A 25-mL aliquot was taken from each resuspension and placed into a Marsh RR-0014 deep trough plate with baffled bottom (Marsh Biomedical Products, Inc., Rochester, N.Y., USA). Before irradiation, a 10-μL sample was taken from the resuspension in the trough plates, diluted to 10 −5 , and evaluated using a Reichert Neubauer/Bright-Line® Hemacytometer (American Optical Corp., Buffalo, N.Y., USA) to obtain an estimate of cell density. The cells were irradiated for 9 hours with 234 nm UV-C radiation [UVP, LLC Light Table (inverted); Upland, Calif., USA] at a distance of 14 cm above the plates. Samples (100 μL) were taken every hour during irradiation, diluted to 10 −4 , plated, and the surviving colonies counted to determine the kill curve. The progress of the irradiation was monitored by taking samples every hour during irradiation, diluting and plating them, and counting the surviving colonies to determine the kill curve. The results show that 80% mortality is obtained after 9 hours of irradiation ( FIG. 1 ). Strains Y-50798 and Y-50799 were derived from the 82% kill plate, WT plate 1 of FIG. 1 .
An automated protocol on a robotic workcell (as described in Hughes, S. R., et al., J. Assoc. Lab. Autom. 2011, 16, 292-307 and incorporated herein by reference) was used after irradiation to spread 600-μL aliquots from each trough plate onto 128×96 mm Omni Tray plates (Thermo Fisher Scientific, Waltham, Mass., USA) containing YM medium [0.3% yeast extract, 0.3% malt extract, 0.5% peptone, 2% Bacto™ Agar (Becton, Dickinson and Company, Franklin Lakes, N.J., USA), and 1.0% dextrose] or 2% xylose complete minimal medium plus all amino acids [1.4 g yeast synthetic drop-out medium supplement, 0.06 g L-leucine, 0.04 g L-tryptophan, 0.02 g L-histidine, 0.02 g L-uracil; 20 g D-xylose (Sigma Aldrich, St. Louis, Mo., USA), 20 g Bacto Agar; and 6.7 g yeast nitrogen base without amino acids (Sigma Aldrich, St. Louis, Mo., USA) per liter]. The plates from several passive and active stackers were moved to the liquid handler in a scheduled fashion where they were spotted with medium and then with irradiated culture from the Marsh deep trough plates on the deck. The spread plates (a total of 192 plates, 96 from each trough plate) were wrapped and placed into Mitsubishi anaerobic chambers (Mitsubishi Gas Chemical America, Inc., New York, N.Y., USA) containing an AnaeroPack dry chemical system (Sigma Fluka, Buchs, Switzerland) at 46° C. for 5 months.
Two YM plates each contained one growing colony when the spread plates were unwrapped. Duplicate samples were picked manually from these colonies, designated strains Y-50798 and Y-50799, respectively, and spread onto plates containing YM or YPD [1.0% yeast extract, 2.0% Bacto Peptone, 2.0% Bacto Agar, and 2.0% D-glucose (Sigma Aldrich, St. Louis, Mo., USA)] medium or 2% xylose complete minimal medium plus all amino acids, and the plates were incubated at 46° C. for 2 weeks anaerobically to isolate individual colonies. Four colonies were picked manually from each of the re-spread anaerobic plates onto plates containing YM, YPD, or xylose complete minimal medium plus all amino acids (one sample per plate, 4 samples per medium) and incubated aerobically at 28° C. for 3 days to confirm that strains Y-50798 and Y-50799 were still capable of aerobic growth.
Samples were also taken and plated on YPD medium for evaluation of growth at 30° C. and 47° C. to compare thermotolerance of mutant strains to that of wild-type K. marxianus NRRL Y-1109. The mutant strains were further evaluated for growth on various substrates aerobically and anaerobically at 46° C. in comparison to wild-type K. marxianus NRRL Y-1109 and to S. cerevisiae NRRL Y-2043 in the following examples.
Example 1
Fermentation in 2-L Fernbach Flask
Fermentation experiments using wild-type K. marxianus NRRL Y-1109, mutant strains Y-50798 and Y-50799, and S. cerevisiae NRRL Y-2043 were performed in 2-L Fernbach flasks containing YM liquid medium maintained at 46° C. A liquid preculture was grown in a 100-mL flask on YM medium for 2 days at 28° C. The density of the preculture was adjusted to an absorbance equivalent to 1.0 at 660 nm (Beckman DU 800; Beckman Coulter, Inc., Indianapolis, Ind., USA) and 20 mL were added to 1 liter of YM medium in the Fernbach flask. The fermentation was carried out at 46° C. at 100 rpm for 30 hours. The absorbance at 660 nm and ethanol production were measured at approximately 10-hour intervals.
Ethanol production (g/L) and cell growth (absorbance at 660 nm) were monitored during a 30-hour fermentation experiment in a 2-L Fernbach flask in YM medium (10 g/L glucose) at 46° C. for wild-type K. marxianus NRRL Y-1109, mutant strains Y-50798 and Y-50799, and S. cerevisiae NRRL Y-2043 ( FIG. 3 ). S. cerevisiae NRRL Y-2043 did not grow at 46° C. and therefore no ethanol was produced. Cell growth for wild-type K. marxianus NRRL Y-1109 and mutant strain Y-50799 rose from initial OD660 values of about 0.16 up to 0.55 at 5 hours then to 1.57 at 15 hours and remained essentially at that level for the remainder of the 30-hour experiment. Cell growth for mutant strain Y-50798 showed a delayed entry into log phase with the OD 660 value remaining at 0.18 until 5 hours, then rising to 1.22 at 15 hours showing a growth rate (based on slope) similar to that of wild-type Y-1109 and Y-50799. Growth was still increasing at 15 hours and the OD660 value reached 1.51 at 26 hours, similar to wild-type Y-1109 and Y-50799. For all three strains, ethanol production started at 5 hours. The ethanol level for wild-type K. marxianus NRRL Y-1109 reached a maximum of 4.7 g/L at 15 hours, after which it decreased steadily to 3.1 g/L at 30 hours. The ethanol level for mutant strain Y-50799 rose more slowly than for the wild-type strain, reaching a maximum of 3.9 g/L at 25 hours, after which it decreased steadily to 2.9 g/L at 30 hours. Ethanol production for mutant strain Y-50798 increased more slowly than mutant strain Y-50799 but was still rising at the end of the experiment (30 hours) where it was 3.4 g/L.
Example 2
Scanning Electron Images of NRRL Y-1109 and Mutant Strains Y-50798 and Y-50799
NRRL Y-1109, Mutant Strains Y-50798 and Y-50799 cells from YPD [1.0% yeast extract, 2.0% Bacto Peptone, and 2.0% D-glucose (Sigma Aldrich, St. Louis, Mo., USA)], 2% xylose [1.4 g yeast synthetic drop-out medium supplement, 0.06 g L-leucine, 0.04 g L-tryptophan, 0.02 g L-histidine, 0.02 g uracil, 20 g D-xylose, and 6.7 g yeast nitrogen base without amino acids (Sigma Aldrich, St. Louis, Mo., USA) per liter] or YPGA [1.0% yeast extract, 2.0% Bacto Peptone, and 2.0% galacturonic acid (Sigma Aldrich, St. Louis, Mo., USA)] liquid medium incubated aerobically at 46° C. for 12 hours were suspended in saline (0.85% NaCl) and centrifuged to remove residual medium. Following a modified procedure of Bang and Pazirandeh (Bang, S. S., et al., J. Microencapsul. 1999, 16(4), 489-499 and incorporated herein by reference), the cell pellet was suspended and fixed in 2.5% glutaraldehyde prepared in 100 mM cacodylate buffer, pH 7.2, for one hour on ice. To remove remaining glutaraldehyde, the cells were rinsed with the buffer twice and then with distilled water once, allowing several minutes for each step. The cells were dehydrated, respectively, in solutions containing 50%, 70%, 80%, and 100% ethanol successively for 15 minutes for each treatment. Cells were mounted on an aluminum stub and placed in a desiccator to dry overnight or until needed. The samples were subjected to scanning electron microscopy and analysis (Zeiss Supra 40 VP).
Cells from cultures of K. marxianus wild-type and mutant strains grown using glucose, xylose, or galacturonic acid as substrates were examined using scanning electron microscopy ( FIG. 4 ). The scanning electron micrographs of the wild-type K. marxianus NRRL Y-1109 and mutant strains grown on glucose show that the cells were generally similar in size, shape, and surface features. On the other hand, the micrographs of cells from these strains grown on xylose show that the cells of mutant strain Y-50798 are larger than those of the wild-type strain and that more of the Y-50798 cells have cratered surfaces compared to the wild-type cells. The cells of mutant strain Y-50799 grown on xylose are smaller than those of mutant strain Y-50798, however the surfaces are not only cratered but also wrinkled, and the shapes of the cells are flattened and distorted compared to the shapes of wild-type and Y-50798 cells. The micrographs of cells from strains grown on galacturonic acid, show that most of the cells of the wild-type strain have a relatively smooth, non-cratered surface and are urn-shaped with bud-like projections at the tops. In contrast, the cells of mutant strains Y-50798 and Y-50799 are larger and their surfaces are more cratered than those of the wild-type strain. The shapes of most of the cells of strain Y-50799 grown on galacturonic acid are round with dimples, which are notably different from the urn-shaped cells with bud-like projections observed in the micrograph for the wild-type strain.
Example 3
DNA Fingerprinting
Variable nucleotide tandem repeat (VNTR) PCR analysis was performed to detect differences in genomic DNA sequences using as PCR primer the 15-base pair (bp) 5×CAG repeat sequence. Genomic DNA from wild-type K. marxianus NRRL Y-1109 and mutant strains Y-50798 or Y-50799 was isolated from a 1-mL sample of a 2-day 37° C. culture in YPD liquid medium in a 1.5-mL polypropylene tube. The samples were vortexed for 30 seconds and then centrifuged at 15,800×g for 2 minutes (Thermo Micromax Microcentrifuge; Thermo Fisher Scientific, Waltham, Mass., USA). The supernatant was decanted and an additional 1 mL of the culture was added to the tubes. The tubes were vortexed for 30 seconds and then centrifuged at 15,800×g for 2 minutes. The supernatant was decanted and 400 μL of water were added. The mixture was boiled for 10 minutes followed by addition of 400 μL of phenol solution (saturated, pH 6.6; AMRESCO LLC, Solon, Ohio, USA). The tubes were vortexed for 30 seconds and then centrifuged at 15,800×g for 2 minutes. The aqueous phase was transferred by pipet to new 1.5-mL tubes and 400 μL of phenol:chloroform:isoamyl alcohol (25:24:1; tris buffer to pH 8.05; AMRESCO, LLC; Solon, Ohio, USA) were added. The tubes were vortexed for 30 seconds and then centrifuged at 15,800×g for 2 minutes. The aqueous phase was transferred by pipet to new 1.5-mL tubes and 400 μL of ethyl ether (water-saturated; Avantor Performance Materials, formerly J.T. Baker, Phillipsburg, N.J., USA) were added. The tubes were vortexed for 30 seconds and then centrifuged at 15,800×g for 2 minutes. The organic phase was removed by pipet and discarded, and 40 μL of 3 M sodium acetate, pH 5.2 (Sigma Aldrich, St. Louis, Mo., USA) were added to the remaining solution. The tubes were vortexed for 90 seconds and 1.5 mL of cold 100% ethanol was added. The tubes were placed into a −80° C. freezer overnight. After removal from the freezer, the tubes were centrifuged for 10 minutes at 15,800×g, and the liquid decanted. One mL of cold 70% aqueous ethanol solution was added and the tubes centrifuged for 10 minutes at 15,800×g. The liquid was removed with a pipet leaving the clear pellet on the bottom. The material was dried in a Savant SPD 2010 SpeedVac System (Thermo Fisher Scientific, Waltham, Mass., USA) for 5 minutes at 45° C. and 8 psi. The tubes were removed from the dryer, 70 μL of water were added, and the tubes were allowed to stand for 10 minutes. The concentration of genomic DNA obtained was determined by densitometry using an AlphaImager™ 3400 (Alpha Innotech Corporation, San Diego, Calif., USA).
The PCR mixture contained 2 μL genomic DNA (0.5 mg/mL), 32.5 μL water, 10 μL 5× Phusion HF Buffer with MgCl 2 , 1 μL 10 mM dNTPs, 4 μL (0.1 mg/mL) VNTR oligonucleotide primer (5′CAGCAGCAGCAGCAG3′) (SEQ. ID. NO. 1) and 0.5 μL Phusion Enzyme (Finnzymes Phusion High-Fidelity PCR kit; New England Biolabs, Ipswich, Mass., USA). The PCR reaction was prepared in a Phenix MPC-3420 96-well PCR plate (Phenix Research Products, Candler, N.C., USA) on ice and was carried out in a PTC-225 Tetrad Thermal Cycler (Bio-Rad Laboratories, Hercules, Calif., USA) using the following conditions: hold at 95° C. for 5 minutes, cycle at 95° C. for 1 minute, 42° C. for 1 minute, 72° C. for 1 minute, repeated for 30 times, followed by 72° C. for 5 minutes and a 4° C. hold. The procedure amplified the genomic sequence between two VNTR sequences to determine alterations in the microsatellite or minisatellite regions in the genome. The amplified DNA was analyzed by gel electrophoresis on 1% (w/v) agarose gels stained with ethidium bromide.
The PCR products amplified from the genomic DNA of K. marxianus NRRL Y-1109 wild-type strain and mutant strains Y-50798 and Y-50799 using a variable nucleotide tandem repeat (VNTR) primer produced different banding patterns (fingerprints) when analyzed on an agarose gel ( FIG. 5 ). The arrow on the left at approximately 275 bp points out a band that is present in the fingerprint of the wild-type strain but not detectable in the fingerprints of the mutant strains Y-50798 and Y-50799. The arrow on the right at approximately 750 bp points to a band present in mutant strain Y-50798 but not detectable in the wild-type strain or mutant strain Y-50799. The PCR products from the genomes of the mutant strains are different from each other and from the products from the genome of the wild-type strain.
The differences observed in the PCR products amplified from the genomic DNA of K. marxianus NRRL Y-1109 wild-type strain and mutant strains Y-50798 and Y-50799 using the VNTR sequence as PCR primer demonstrate that the mutant strains are different from each other and from the wild-type strain. VNTR analysis of wild-type and mutant strains Y-50798 and Y-50799 indicated mutations had occurred in the wild-type strain to produce strains Y-50798 and Y-50799.
Example 4
Growth of Strain Y-50798 on Various Substrates at 46° C.
Test tubes containing a mini magnetic stirrer were added 1 mL water, 0.005 g peptone, 0.0025 mg yeast extract, and 0.005 g agar. To tubes 1, 2, 3, and 4 were added, respectively, 0.005 g pectin, 0.005 g D-galacturonic acid, 0.005 g di-galacturonic acid, and 0.005 g tri-galacturonic acid (Sigma Aldrich, St. Louis, Mo., USA). The mixtures were stirred until the solids were dissolved and the solutions were autoclaved for 10 minutes. Tubes were slanted while cooling. A sample comprised of 9 loops of a culture of K. marxianus mutant strain Y-50798 was added to 4 mL of sterile-filtered water, and mixed. After mixing, 0.5 mL of the solution was added to each of the four slant media tubes and the tubes were placed inside an Innova 4230 Incubator Shaker (New Brunswick Scientific, Enfield, Conn., USA) at 47° C. (highest temperature at which this strain still grew well) for 15 days at 100 rpm. Images of the samples were captured using the AlphaImager 3400 system and analyzed using AlphaEase FC software (Alpha Innotech Corporation, San Diego, Calif., USA).
TABLE 1 Growth of mutant strain Y-50798 in a slant-tube assay using pectin as substrate compared to mono-, di-, and tri-D-galacturonic acids as substrates at 47° C. for 15 days at 100 rpm. % Adjusted Integrated % Density of color density density value pectin standard (relative to 20 g/mL Sample (IDV)* (based on IDV) pectin standard) Blank (no strain 11424 0.3 — added) Pectin 1109448 100.0 29.2 Mono- 853944 76.9 22.4 galacturonic acid Di-galacturonic 940680 84.7 24.7 acid Tri-galacturonic 846940 76.3 22.2 acid *Images were captured using the AlphaImager 3400 system and analyzed using AlphaEase FC software.
Comparison of Growth of K. marxianus NRRL Y-1109 Wild-Type Strain and Mutant Strains Y-50798 and Y-50799 at 30° C. and 47° C.
Growth levels of K. marxianus NRRL Y-1109 wild-type strain and mutant strains Y-50798 and Y-50799 were compared at 30° C. and 47° C. to examine thermotolerance of these strains. The results after the strains were spread on YPD plates and incubated for 5 days at 30° C. and 47° C. are shown in FIG. 2 . All strains grew well at 30° C., but only the mutant strains Y-50798 and Y-50799 grew at 47° C. Irradiation of the wild-type strain and selection at elevated temperature produced mutant K. marxianus strains with increased thermotolerance.
Anaerobic and Aerobic Growth on Various Substrates at 46° C. of Mutant Strains Y-50798 and Y-50799 Compared to Wild-Type K. marxianus NRRL Y-1109 and S. cerevisiae NRRL Y-2043
The aerobic and anaerobic growth of mutant strains Y-50798 and Y-50799 compared to wild-type K. marxianus NRRL Y-1109 and S. cerevisiae NRRL Y-2043 was examined on various substrates of industrial interest, including galacturonic acid, pectin, glucose, arabinose, xylose ( FIG. 6 ), cellulose, starch, guar, and galactose, ( FIG. 7 ). S. cerevisiae NRRL Y-2043 did not grow at 46° C. on any of these substrates. None of the strains tested grew on untreated cellulose or starch. Wild-type K. marxianus NRRL Y-1109 and mutant strain Y-50799 grew on all other substrates tested except essentially no growth was detected anaerobically on arabinose, xylose, or guar. Mutant strain Y-50798 showed essentially the same results except that it also grew to a detectable extent anaerobically on xylose and guar. Growth on hexose substrates was better than on pentose substrates. The results of the tube assay (Table 1) demonstrate that mutant strain Y-50798 has the ability to grow on pectin and to utilize the resulting mono-, di-, and tri-galacturonic acids to the same extent as the individual acids tested separately.
Example 5
Fermentation of Strains Y-50798, Y-50799 in Braun Reactor
Fermentations with wild-type K. marxianus NRRL Y-1109 and mutant strains Y-50798 and Y-50799 were performed in a B. Braun—Sartorius Biostat B reactor (B. Braun Biotech International GmbH (now Sartorius BBI Systems GmbH), Melsungen, Germany). Liquid precultures in YPD medium were incubated at 30° C. for 2 days at 100 rpm. The density of the preculture was adjusted to an absorbance equivalent to 1.0 at 660 nm (Beckman DU 800; Beckman, Indianapolis, Ind., USA), and 20 mL were added to 1 liter of medium in a 1.5-L culture vessel.
In the first stage of the fermentation, ethanol production was measured from YPD medium. The reactor was maintained at 46° C. with stirring (100 rpm) for 3 days with 1 mL/min sparge of filtered nitrogen (dissolved oxygen reading was 0) at a constant pH of 5.5. Samples were collected for ethanol, glucose, melanin, and 2,3-butanediol analysis and the cells were allowed to settle. Spent YPD medium was removed and YPGA medium was added. In the second stage of the fermentation, ethanol production was measured from YPGA medium. The reactor was maintained at 46° C. with stirring (100 rpm) for 7 days with 1 mL/min sparge of filtered nitrogen (dissolved oxygen reading was 0) at a constant pH of 5.5. After the second stage, samples were collected for ethanol, galacturonic acid, melanin, and 2,3-butanediol analysis.
The results presented in Table 2 show that with glucose as the carbon source, the ethanol yield after 3 days at 46° C. was 19% higher for mutant strain Y-50799 than for wild-type K. marxianus NRRL Y-1109 (0.51 and 0.43 g ethanol/g glucose, respectively). Cell growth of mutant strain Y-50799 on glucose as measured by OD660 was 2.7 times greater than that of wild-type strain. The cell growth and ethanol yield on glucose were the same for mutant strain Y-50798 and wild type. With galacturonic acid as the carbon source, the ethanol yield after 7 days at 46° C. was 41% higher for mutant strain Y-50798 than for wild-type K. marxianus NRRL Y-1109 (0.48 and 0.34 g ethanol/g galacturonic acid, respectively). Cell growth of mutant strain Y-50798 on galacturonic acid as measured by OD660 was 1.3 times greater than that of wild-type strain. The cell growth and ethanol yield on galacturonic acid were the similar for mutant strain Y-50799 and wild type. Both Y-50798 and Y-50799 produced almost a 3-fold increase in melanin production on galacturonic acid over wild type (Y-1109). However, Y-50798 appeared to redirect carbon from 2,3-butanediol production to increase melanin and increase ethanol production unlike Y-50799.
TABLE 2
Cell growth, substrate consumption, and production of ethanol, 2,3-butanediol, and
melanin using mutant strains Y-50798 and Y-50799 compared to wild-type Kluyveromyces
marxianus NRRL Y-1109 (WT) in a Braun-Sartorius Biostat B fermentor at 46° C. under
microaerophilic conditions.
Sugar
Ethanol
2,3-
remaining
Sugar
produced
Yield
Butanediol
Melanin
(g/L)
consumed*
(g/L)
(g ethanol/
(g/L)
(μg/L)
Sample
OD600
n = 3
(g/L)
n = 3
g sugar)
n = 3
n = 2
Glu
0.029
44.0 ± 0.1
0.0
0.0 ± 0.0
0.00 ± 0.00
0.54 ± 0.04
control
Glu WT
0.069
3.4 ± 0.1
40.6
17.5 ± 1.5 a
0.43
1.93 ± 0.02
0.67 ± 0.14
Glu 7-1
0.067
0.0 ± 0.0
44.0
20.0 ± 7.7
0.45
1.25 ± 0.04
1.04 ± 0.48
Glu 8-1
0.190
0.0 ± 0.0
44.0
22.5 ± 1.3 a
0.51
1.95 ± 0.06
0.84 ± 0.38
GA
0.089
42.2 ± 0.02
0.0
0.0 ± 0.0
0.00 ± 0.00
0.54 ± 0.07
control
GA WT
0.407
1.5 ± 0.01
40.7
13.9 ± 0.2 b
0.34
1.56 ± 0.03
0.64 ± 0.07
GA 7-1
0.523
0.0 ± 0.0
42.2
20.5 ± 0.2 b
0.48
1.11 ± 0.06
1.67 ± 0.28
GA 8-1
0.351
0.0 ± 0.0
42.2
14.8 ± 0.2
0.35
1.49 ± 0.11
1.78 ± 0.67
*Fermentation proceeded for 3 days using glucose (Glu) as carbon source. Spent medium was removed, galacturonic acid (GA) medium was added, and fermentation was continued for 7 days using GA as carbon source
a For difference between WT and 8-1, P = 0.014 (calculated using 2-tailed type 2 t-test).
b For difference between WT and 7-1, P < 0.00001 (calculated using 2-tailed type 2 t-test).
To the extent that the term “includes” or “including” is employed in the detailed description or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed in the detailed description or claims (e.g., A or B) it is intended to mean “A or B or both”. When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into” are used in the specification or the claims, it is intended to additionally mean “on” or “onto.” Furthermore, to the extent the term “connect” is used in the specification or claims, it is intended to mean not only “directly connected to,” but also “indirectly connected to” such as connected through another component or components.
While the invention has been described with reference to details of the illustrated embodiment, these details are not intended to limit the scope of the invention as defined in the appended claims. All cited references and published patent applications cited in this application are incorporated herein by reference. The embodiment of the invention in which exclusive property or privilege is claimed is defined as follows:
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Described are novel Kluyveromyces marxianus strains NRRL Y-50798 and Y-50799, that were obtained by UV-C irradiation of wild-type K. marxianus NRRL Y-1109 cultures. The UV-C-mutagenized strains were incubated under anaerobic conditions on xylose or glucose medium for a period of 5 months at 46° C. before being selected. These mutagenized strains have potential application in large-scale industrial conversion of lignocellulosic sugars to fuel ethanol given their ability to ferment at temperatures at 46° C. and above.
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FIELD OF THE INVENTION
This invention relates to a method for cementing a well and to apparatus useful in well cementing operations.
BACKGROUND OF THE INVENTION
In the conventional drilling of a well, such as an oil well, a series of casings and/or liners are commonly installed sequentially in the wellbore or borehole. In standard practice, each succeeding liner placed in the wellbore has an outside diameter significantly reduced in size when compared to the casing or liner previously installed. Commonly, after the installation of each casing or liner, cement slurry is pumped downhole and back up into the space or annulus between the casing or liner and the wall of the wellbore, in an amount sufficient to fill the space. The cement slurry, upon setting, stabilizes the casing or liner in the wellbore, prevents fluid exchange between or among formation layers through which the wellbore passes, and prevents gas from rising up the wellbore.
The use of a series of liners which have sequentially reduced diameters is derived from long experience and is aimed at avoiding problems at the time of insertion of casing or liner installation in the wellbore. The number of liners or casings required to reach a given target location is determined principally by the properties of the formations penetrated and by the pressures of the fluids contained in the formations. If the driller encounters an extended series of high pressure/low pressure configurations, the number of liners required under such circumstances may be such that the well cannot usefully be completed because of the continued reduction of the liner diameters required. Again, a further problem of the standard well liner configuration is that large volumes of cuttings are produced initially, and heavy logistics are required during early phases of drilling.
While several approaches to the resolution of these problems have been attempted, none have proven totally satisfactory. Accordingly, there has existed a need for a well lining and cementing technique or procedure, and means to carry it out, which would eliminate or significantly reduce the degree of diameter reduction required when a series of well liners must be inserted. The invention addresses this need.
SUMMARY OF THE INVENTION
There is thus provided, in one embodiment, a method or process, useful in cementing a well, especially a hydrocarbon well, which is characterized by the use of increased external and internal diameter liners, i.e., by a reduction in the degree of diameter reduction of the liners required, and which does not require excessively large initial conductor casing or surface pipe. Accordingly, in this embodiment, the invention relates to a method of cementing a wellbore in which a casing or first liner is provided in a wellbore. (As utilized herein, the terms “first” and “second”, etc., in relation to the casing or liners mentioned, are relative, it being understood that, after the initial “second” casing or liner is cemented, it may become a “first” liner for the next cementing operation as such operations proceed down the wellbore.)
Further drilling operations are then conducted to provide an enlarged wellbore. As used herein, the term “enlarged wellbore” refers to a wellbore or borehole having a diameter greater than that of the internal diameter of the casing or preceding liner, preferably greater than the external diameter of the casing or preceding liner, such a wellbore being provided or drilled in a manner known to those skilled in the art, as described more fully hereinafter. At a desired depth, or when it is otherwise decided to line and cement the enlarged wellbore, a second liner, whose greatest external (outside) diameter approximates, i.e., is only slightly smaller than the internal diameter of the casing or first liner provided, is then provided in the enlarged wellbore through the casing or first liner. The second liner comprises a minor section or segment of significantly or further reduced external and internal diameter (in relation to the remaining or remainder segment of the second liner) and is composed, at least in said minor section, of a deformable liner material. According to the invention, the second liner is positioned in relation to the enlarged wellbore so that the section of reduced external diameter is located or positioned in the lower portion of the casing or first liner and the remainder segment below the lower portion, in such manner that fluid may circulate freely, i.e., without substantial or significant impediment, in the annuli formed by the second liner and the enlarged wellbore and the internal wall of the casing or first liner.
Inside the bore of the larger remaining or remainder segment of the second liner there is disposed or provided, as more fully described hereinafter, a movable, fluid tight die member of appropriate dimensions, preferably positioned in the second liner distant from the bottom of the remainder segment and proximate the minor section of reduced external and internal diameter, and which, after initial positioning or installation in the enlarged wellbore, is fixed in relation to said wellbore. As utilized herein, the phrase “fluid tight”, in reference to the die member, is understood to indicate that the die member is appropriately sized and shaped and contains appropriate sealing means to prevent significant passage of fluid, even under substantial pressure, as described hereinafter, past its periphery or circumference which is contiguous to the interior wall or bore of the remainder segment of the second liner. The fluid tight die member, including the sealing means, is further a component or element of the novel die-expansion assembly of the invention which comprises means for transmitting a fluid to the bore of a liner, and means for connecting the die member to a drillstring. The latter means are important in positioning the novel liner-die assembly in the enlarged wellbore initially, as described more fully hereinafter, and in responding to applied fluid pressure. As utilized herein, the term “drillstring” is understood to include tool members or collars, etc., normally utilized in wellbore operations. In the specific context of the invention, the die-expansion assembly comprises means for transmitting a fluid to the bore of the remainder segment of the second liner, to the end that a fluid under significant pressure may be applied to the bore of the remainder segment of the second liner, and further comprises means for connecting the die member to a drillstring.
According to the method of the invention, upon proper positioning of the liner-die assembly of the invention in the wellbore, cement slurry is then pumped down the drillstring through the casing or first liner and the second liner (via the means for transmitting a fluid) and into the enlarged wellbore annulus in an amount sufficient to cement the wellbore annulus. After the cement is in place, the bottom or bottom end of the second liner is sealed, by standard techniques known to those skilled in the art, to prevent egress of fluid from the liner. As utilized herein, reference to the “bottom” or “bottom end” of the liner is to be construed as referring to a site downhole on or in the liner rather than as a precise location of the liner body. The sealing of the bottom end of the liner, coupled with the seal provided by the fluid tight die member, provides or constitutes, assuming a location of the die member removed or distant from the bottom of the liner, and, with the exception of communication with the aforementioned means for transmitting a fluid, a sealed compartment or recess in the bore of the remainder segment of the second liner. Substantial fluid pressure is then applied to the interior of this sealed remainder segment recess by pumping a fluid, e.g., a wellbore fluid such as a drilling fluid or a spacer fluid, through said means for transmitting a fluid which communicates with the compartment or recess. As fluid under pressure is introduced into the otherwise sealed recess, the increasing pressure therein tends to force the fluid tight die member up the second liner bore. According to the invention, as fluid pressure is increased in the sealed recess, the position of the die-expansion assembly, including the die member, is mechanically adjusted or allowed to adjust by translation upward in the liner (and the wellbore). The rate of upward adjustment or movement of the die-expansion assembly by upward movement of the running string and the application of pressure to the second liner bore recess are correlated so as to produce movement of the die member up through the section of reduced diameter with concurrent gradual deformation and expansion of the section of reduced diameter, providing an expanded section or segment having an external diameter equal to or approximating, preferably slightly greater or larger than that of the remainder segment of the second liner, as described more fully hereinafter. The expansion of the section provides an external diameter for the section which more closely approximates the internal diameter of the casing or first liner, while providing a larger flow passage internally for production fluids. Continued application of fluid pressure and correlated upward translation or adjustment of the position of the die-expansion assembly frees the die member from the second liner, the second liner then being positioned or allowed to remain with a substantial minor portion of the newly expanded segment in the casing or first liner. The cement slurry in the wellbore annulus is then allowed to set.
In yet further embodiments, the invention relates to a novel liner, which may additionally include expansion means therein; to an apparatus or tool for expansion of a liner having a reduced diameter section; and to a novel liner-die assembly or combination which is useful in cementing operations. More particularly, the liner of the invention comprises a wellbore liner having a minor section of reduced external and internal diameter composed of a deformable material and a larger remainder section of increased external and internal diameter. The expansion device or apparatus of the invention comprises unique fluid tight die means adapted for expansion of a liner section of reduced internal and external diameter, and preferably comprises a means for transmitting a fluid, e.g., a pipe; a die member adapted for expanding, at least substantially uniformly, the bore of a liner, on the periphery of said pipe; and sealing means positioned on the periphery of the die member adapted to provide a fluid tight seal between the bore of a liner and said die member. In the preferred arrangement, the pipe is provided at one end thereof with means for connecting the pipe to, or for suspending the pipe from, a drillstring, and is further preferably provided at the opposite end thereof with means for suspending a tool, preferably components used in cementing operations, and, especially, in one aspect of the invention, means to assist in sealing the end of the liner distant from said opposite end of the pipe.
The invention further relates to a novel liner-die assembly. In this aspect, the invention comprises the novel wellbore liner in which there is disposed the die-expansion assembly of the invention, as described, the assembly being disposed in said liner with the longitudinal axis of the means for transmitting fluid, or pipe, coincident with the axis of the liner and the fluid tight die member positioned in the remainder segment of the liner.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates schematically the prior art practice of telescoping liner sections.
FIG. 2 illustrates schematically a liner and liner assembly according to the invention.
FIGS. 3 and 4 illustrate sectional views of liner expansion tools according to the invention.
FIGS. 5 through 7 illustrate schematically the pipe expansion method or process of the invention.
DETAILED DESCRIPTION OF THE INVENTION
For a fuller understanding of the invention, reference is made to the drawing. Accordingly, in FIG. 1 there is shown a well string 1 extending to the earth surface 2 and to conductor pipe or casing 3 . Conductor pipe 3 is positioned in the portion 4 a of wellbore 4 , while pipe 5 is in reduced diameter section 4 b of the same wellbore. The wellbore forms segmented annulus 6 with pipes 3 and 5 , the width of the annulus segments being the same or approximately the same. A further reduced diameter section 9 is illustrated. As indicated, standard cementing operations provide a cemented annulus which stabilizes the wellbore, but the effective diameter of the conducting passage is progressively and substantially reduced as the well is deepened.
FIG. 2 illustrates an important aspect of the invention. Accordingly, in FIG. 2 there is shown a liner-die assembly designated generally as 10 . The assembly includes the liner component 11 which, as shown, comprises a liner head section 12 which includes a section of reduced external and internal diameter coupled to a main body portion or remainder segment 13 . In a practical case, the external diameter of the section of reduced external and internal diameter may be reduced from that of the remainder segment on the order of two inches or so, with a corresponding decrease in the internal diameter of the reduced diameter section. As will be understood by those skilled in the art, a “liner” or “casing” will be composed of segments or sections assembled and coupled by suitable means, such as by threading. In the present invention, the section of reduced external and internal diameter 12 may be formed in one or composed of more than one section of liner, it being recognized that the remainder section or segment will normally comprise many sections (30 ft.) to the end or bottom end thereof. Head section 12 , which comprises a deformable material, preferably is connected to the main segment of the liner 13 by appropriate threading of the two segments. Alternately, not shown, the head section and a portion of the remainder or main body segment may be of integral construction. An elastic or compressible sleeve (e.g., rubber) or sleeves 12 a may be provided on head section 12 or stability and sealing. A preferred fluid tight die assembly, indicated generally as 14 , and described more fully hereinafter, is provided. The preferred assembly 14 includes suitable mounting means or connecting means, such as a threaded connection 15 , for connecting to a running string or other tool, and may be provided with threads or other suitable connecting means to connect to other tools, e.g., cementing operation components, indicated generally at 16 , such as wiper plug launching apparatus, as described, for example, in U.S. Ser. No. 08/805,782, filed Feb. 25, 1997, by Gilbert Lavaure, Jason Jonas, and Bernard Piot, incorporated herein by reference. Liner segment 13 is provided with suitable partial sealing means 17 , such as a differential fill-up collar, at or near the end of the liner opposite the suspending or connecting means, to allow ingress of fluid into the liner during insertion thereof in the enlarged wellbore, seal the liner from ingress of fluid from the wellbore after its insertion, and prevent egress of fluid from the bore of segment 13 (as described more fully hereinafter). As will be evident to those skilled in the art, a portion of the liner containing the die assembly may suitably be lowered into a wellbore as a unit, to the purpose that, upon completion of the cementing and deforming technique described more fully hereinafter, a suitable cemented liner combination of genuine advantage is provided.
FIG. 3 illustrates the simplest form of the die member assembly. Accordingly, there is shown a die member 20 of suitable shape and composition, such as hardened steel, and adapted or sized and shaped to expand a liner section of reduced diameter. Other suitable die forming materials are well known, and the particular die member material utilized is a matter of choice. In the illustration, the die member 20 comprises enlarged sections of variable diameter and is of generally frustoconical shape provided with suitable beveling in the segment of the die member where shaping of the liner section will be initiated, although other deforming shapes of the die member may be provided. In each application of the invention, the die member will be shaped or designed to provide an at least substantially uniform expanded or deformed liner segment of circular or approximately circular periphery, the die structure being selected to provide a periphery of the deformed and expanded segment equal to or approximating (slightly larger or less than) the periphery of the remainder segment of the liner. As will be recognized by those skilled in the art, die structures are known, for example, which will deform the reduced diameter segment to provide an expanded internal periphery slightly larger than that of the die. This aspect of the invention is preferred, since there is the possibility of a virtual force fit of the expanded section in the casing or upper liner.
In this illustration, the die member 20 further comprises a fluid tight seal 21 , as previously described, such as a polymer cupseal, for sealing the die in a liner and allowing sufficient fluid pressure, as described hereinafter, to produce movement of the die member. The particular sealing material may be selected by those skilled in the art, a wide variety of sealing materials being suitable. For example, rubber or neoprene may also be utilized. The die member is provided with a bore or means 22 for transmitting a fluid in its center, and the bore terminates at both ends thereof with or in connecting means. Thus, threads are provided at 23 and 24 for connecting the die member to a running string or a tool, and suspending and/or positioning components, respectively.
A preferred embodiment of the die assembly is illustrated in greater detail in FIG. 4 . The die assembly shown comprises a pipe or generally tubular body 25 having threaded connecting means or segments 26 and 27 (box and pin) for connecting to a running string and suspending a tool or suitable cementing components in a liner, respectively. A die member 28 is provided on pipe 25 and is preferably of integral construction therewith, being of suitable shape and composition, as described with respect to FIG. 3, and adapted or sized and shaped in a similar manner to expand a liner section such as liner section 12 . The connecting means, in whatever form employed, e.g., as also shown in FIG. 3, thus enables the positioning or adjustment of the position of the die member in a liner by movement, for example, of a drillstring attached thereto. If not of integral construction, die member 28 may be mounted on pipe 25 by suitable mounting means (not shown). In a manner similar to the embodiment of FIG. 3, the die member 28 comprises enlarged sections of variable diameter and is of generally frustoconical shape provided with suitable beveling in the segment of the die member where shaping of the liner section 12 will be initiated, although other deforming shapes of the die member may be provided. The die member 28 further comprises a fluid tight seal 29 , as previously described.
The procedure of the invention and operation of the liner 10 assembly and die assembly 14 are understood more fully by reference to schematic FIGS. 5 through 7. Elements previously described with respect to FIGS. 1 through 4 are referred to by identical numbers. Accordingly, in FIG. 5 the liner assembly is provided in a wellbore 30 , such as an oil or gas well bore, and positioned in relation to cemented casing 31 , as shown. Wellbore 30 has a diameter greater than the external diameter of casing 31 , such wellbores being obtainable by use of a bi-center bit, under-reamer bit, or similar tool known to those skilled in the art. The external diameter of liner segment 13 is preferably slightly smaller than the internal diameter of casing 31 , being just sufficiently smaller to allow lowering thereof through casing 31 . The liner assembly is positioned in the enlarged wellbore, as shown, so that fluids, e.g., drilling mud or cement slurry, may be passed down the string 1 and via the pipe or bore 25 into the liner segment 13 or suitable tools or structure therein, described more fully hereinafter, out of the liner segment 13 , and into the wellbore annulus 32 , and through the annulus segment 33 , which is formed by the external wall of section 12 and the lower portion of casing 31 . Liner section 12 is formed, as mentioned, of a deformable liner material, such as a metal, e.g., steel or other alloy, which is suitable for liner duty. As used herein, the term “deformable” is understood in its common sense as indicating a capacity for shaping or expansion by suitable application of mechanical pressure. The fluid tight die assembly is positioned or disposed in the liner so that the longitudinal axes of the pipe and the liner are coincident. Pipe 25 may be of variable length and may or may not extend from liner 11 . As will be evident to those skilled in the art, the invention is particularly adapted to use of liners of decreased wall thickness.
As previously mentioned, liner segment 13 is provided with suitable structure 17 , at or near the end of the remainder segment of the liner, disposed from the die assembly, to allow ingress of fluid from the wellbore, such as a displacement fluid, during insertion of the liner, and sealing of the liner from ingress of cement slurry after cementing. In the usual case, a differential fill-up collar will be employed at or near the bottom of the liner to prevent wellbore fluids from entering the liner, and any suitable such collar or similar device may be employed. A variety of such devices are described in Well Cementing, edited by E. I. Nelson, Schlumberger Educational Services (1990), and the selection of a particular device is well within the ambit of those skilled in the art. Additionally, in order to seal the bottom of the liner after the cement has been placed in the wellbore annulus, as more fully described hereinafter, suitable sealing means, known to those skilled in the art, may be provided to prevent egress of fluid from the liner. Preferably, the wiper plug system described in the aforementioned Ser. No. 08/805,782 may be employed, to the effect that a fluid tight seal is formed at the end of the liner distant from the assembly, or the bottom of the liner.
In the position shown in FIG. 5, the liner assembly is especially adapted to a cementing operation, and hanger elements are not required since the liner assembly may be supported by the string 1 . More particularly, following standard cementing procedures, cement slurry may be pumped downhole through the string 1 and through liner 11 via pipe 25 in the die assembly, through flow distributor 16 , which may be that of the aforementioned wiper plug launching system, and out the bottom of the liner through open sealing means 17 . The cement slurry displaces drilling fluid and/or a suitable spacer fluid between the cement slurry and the drilling fluid in the wellbore annulus, the drilling fluid and/or spacer fluid passing from annulus 32 into annulus 33 in casing 31 without substantial impediment. The advantage of the reduced cross section of segment 12 , which permits flow of fluids out of the wellbore, is demonstrated at this juncture. Without such feature, the ultimate goal of a wider cross section for production fluids cannot be achieved because of the requirement for removal of fluids from the borehole annulus. Sufficient cement slurry is employed to fill the annulus 32 . The invention now provides for expansion of section 12 to provide for a larger diameter cross section corresponding to that of section 13 .
As shown in FIG. 6, sealing means 17 (schematically shown) at the bottom of liner section 13 is sealed to the ingress and egress of fluid. In the normal case, a wiper plug, which is solid, is sent downhole, after sufficient cement slurry has been sent into annulus 32 , to seal, with the differential fillup collar, the bottom of liner to egress of fluid. As mentioned, the technique of the aforementioned Ser. No. 08/805,782 is preferred. Fluid pressure is then applied to the bore of the liner segment 13 by pumping a fluid through the pipe 25 into the bore of liner 13 . Any suitable wellbore fluid or liquid available may be used, e.g., a displacement fluid, a completion fluid, water, or sea water. The fluid is pumped at sufficient pressure, e.g., 3000 psig, through pipe 25 to provide upward movement of die member 28 if the member is freed for movement. To this end, the position of the die assembly (including die member 28 ) is adjusted or allowed to adjust upward by gradual upward movement of the running string 1 . Adjustment of the drillstring length is made at a rate sufficient to move the die member upward or allow upward movement thereof, caused by the pressure on the die, at a controlled rate, in response to such continued sufficient application of fluid pressure, the continued application of sufficient pressure being indicated by change in drillstring weight. As continuing sufficient fluid pressure moves die member 28 upward, its movement causes the die member 28 to expand and shape the deformable liner section 12 so that the section diameter and radial cross section thereof equals or approximates the diameter and radial cross section of the lower section 13 . Further application of fluid pressure in the bore of liner 11 with continued adjustment of the position of die member 28 will free the die 28 from the liner 11 , as shown in FIG. 7 . The result of the deformation operation is the provision of an upper segment 12 of the liner 11 which now corresponds in size to that of lower segment 13 . The cement is then allowed to set, producing a stabilized wellbore with increased flow capability over conventional liner sequence technique.
While the invention has been described with reference to specific embodiments, it is understood that various modifications and embodiments will be suggested to those skilled in the art upon reading and understanding this disclosure. Accordingly, it is intended that all such modifications and embodiments be included within the invention and that the scope of the invention be limited only by the appended claims.
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A method of cementing a well permitting a reduction in the degree of diameter reduction of casing or liners required, and not requiring excessively large initial conductor casing, is described. The method is characterized by provision of an enlarged wellbore and a novel liner structure which is adapted for expansion of a reduced diameter section thereof downhole, providing, before expansion of the section, unimpeded flow of fluid from the enlarged wellbore during cementing and close fit of the expanded section with the casing or preceding liner, after cementing is completed and expansion of the section. A novel well liner structure and novel well liner expansion means are disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of multi-story parking garage structures and, more particularly, to an energy efficient garage structure.
[0003] 2. Discussion of the Background
[0004] Multi-story self park garages generally are constructed in urban areas, often near or adjacent to office towers, residential buildings or other commercial structures or stadiums. More recently these structures are provided with facades that are more esthetically appealing to better fit the surrounding environment and to complement adjacent structures. Also, for convenience of nearby residents and office workers, in recent years the first or ground floor of these structures has been used for retail space, such as for example drug stores. For those garages that are completely enclosed, an expensive heavily mechanized ventilation system is required to eliminate the vehicle exhaust gases that otherwise might accumulate. Most major cities have specific building codes that control the ventilation requirements. For those garages that use an open air approach (thus vastly eliminating the bulk of the mechanical ventilations system), there generally also is a requirement that at least 20% of the facade be open to permit adequate ambient ventilation allowing noxious fumes to escape. This has resulted in a variety of facades, none of which are esthetically pleasing and generally do not complement the nearby environment.
[0005] Multi-story garages also generally require at least two elevators; extensive lighting on each floor and use a multitude of other energy drawing equipment during their daily operation. Most such garages have a typical floor plan (for vehicle traffic) that tends to be of a spiral nature with up/down ramps. This leaves an unused area of the floor plan in at least one corner on each floor. To economically use this space, the elevators frequently are located in the corners. However it would be economically wasteful to build elevators in all four corners, as not that many are required.
[0006] It is a primary purpose of the present invention to provide both an air efficient ventilation system that has a unique and esthetically pleasing façade, and an energy producing system employed to take advantage of wind turbines for generating some of the power requirements of the facility. Preferably these turbines will be stacked and disposed at a corner of the garage to therefore make more efficient use of the dead space created by traditional vehicle flow patterns.
DESCRIPTION OF THE PRIOR ART
[0007] The present garage structure makes use of various commercial components, but to applicant's knowledge they have not been combined in the manner claimed herein. The façade structure in part consists of a unique arrangement of arrays of energy efficient translucent linear channel glass, of the type known as Pilkiington Profilit glass channels. They are described in greater detail at www.tgpamerica.com/structural-glass/pilkington-profilit. The preferred wind turbines of the present invention are know as Aerotecture International wind turbines, and are generally described at: www.aerotecture.com. Several different arrays are disclosed, including an independent structure of stacked arrays.
SUMMARY OF THE INVENTION
[0008] In view of the foregoing esthetic and energy deficient disadvantages inherent in known multi-story parking garages, the present invention provides an energy efficient garage which uses both natural ventilation in an esthetically pleasing arrangement, combined with wind turbines uniquely located for energy generation and placed for efficient use of structural space in the garage facility.
[0009] To attain these advantages, the present invention, in its preferred embodiment, generally comprises a multistory garage structure having a series of vertically stacked wind turbines for energy generation preferably disposed and integrated into the building structure in a manner that allows air flow against the turbines in an least two directions.
[0010] In a preferred embodiment, the wind turbines are located at what would be an interior corner of the garage facility thereby to efficiently take advantage of what would be unused space in the garage floor plan, while efficiently permitting multi-directional exposure of the turbines thru an open corner vertical facade without requiring an outbuilding area of the structure.
[0011] Yet another object is provide a glass façade for the structure which permits natural ventilation of the facility with an esthetic facade arrangement that has vertical openings arranged in a plurality of arrays, thereby seemingly providing a particular pattern of glass which enhances the building structure while effectively minimizing the visual effects of the openings.
[0012] A preferred objective is to provide a pattern of glass channels in which some overlap while others are spaced and which are arranged in a progression across a façade providing the structure with a dynamic quality for viewers while the spacing between the glass is calibrated to balance the garage natural air flow distribution and day-light distribution.
[0013] The vertical spacing of the glass channels and the use of the stacked wind turbines also cooperate to enhance air flow through the garage structure, integrating the benefits of both structures.
[0014] These and other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the appended claims forming a part of the disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
[0016] FIG. 1 is a perspective view of a new energy efficient garage structure according to the present invention;
[0017] FIG. 2 is an enlarged elevation view of one exterior wall of the novel garage structure;
[0018] FIG. 3 is an enlarged elevation view of an adjacent wall of the garage structure, and also depicting the wind turbine structure in a corner thereof;
[0019] FIG. 4 is a typical floor plan view as would exist in the garage of FIG. 1 ;
[0020] FIGS. 5A and 5B schematically depict elevation and plan views of a first pattern of the glass channel arrays used in the garage façade;
[0021] FIGS. 6A and 6B depict a second pattern of the glass channel arrays of the façade;
[0022] FIGS. 7A and 7B depict a third pattern of the glass channel arrays of the façade;
[0023] FIGS. 8A and 8B depict a fourth pattern of the glass channel arrays;
[0024] FIGS. 9A and 9B depict a fifth pattern of the glass channel arrays used in the façade;
[0025] FIG. 10 is an enlarged elevational view of an exemplar array of glass channels as may be used in the invention, and showing one form of mounting the channels;
[0026] FIG. 11 is a sectional view of the array of FIG. 10 , taken along the section lines A-A in FIG. 10 ;
[0027] FIG. 12 is a sectional plan view of the array of FIG. 10 , taken along the section lines B-B on FIG. 10 ;
[0028] FIG. 13 is a sectional plan view of the array of FIG. 10 , taken along the sectional lines C-C in FIG. 10 ;
[0029] FIG. 14 is a sectional view of the array of FIG. 10 , taken along the sectional lines D-D thereof;
[0030] FIG. 15 is a schematic perspective view of a single wind turbine of the type stacked for use in the garage of FIG. 1 ;
[0031] FIG. 16 is a plan view of the wind turbine of FIG. 15 ;
[0032] FIG. 17 is an elevational view of the wind turbine of FIG. 15 ;
[0033] FIG. 18 is an exemplar plan view of one floor showing the position of the wind turbine structure in the corner of the garage facility; and
[0034] FIG. 19 is an elevational view of the corner of the garage wall and structure of FIG. 18 , without the wind turbine in place.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] One example of a preferred form of garage structure incorporating the various inventions is depicted as 20 in FIG. 1 in perspective form. In this embodiment, the garage 20 is shown as a free standing structure to be located at the corner of a city block. While only two side walls are illustrated, the opposite sides may be mirror images (if for example the garage is located near a sports facility) or the opposing walls may be designed with less elegant facades if the garage will abut adjacent buildings where the facades will be partially or fully hidden from view.
[0036] In this instance, the garage 20 may consist of a ground or base line level 21 of retail space and employ internal ramps of various kinds (not shown, but different routing being well known to those in the art) permitting, in this case, effective spiral movement of vehicles from bottom to top and reverse for exiting. This particular version has roughly ten floors available for parking above the retail level, generally designated as 22 - 31 in FIG. 1 .
[0037] The garage 20 has roof line 32 that may or not be decorated and may or not provide for additional parking at the roof top level. In the preferred embodiment the garage roof is provided with plantings to provide an esthetic and air friendly environment. The planted roof will provide both visual and recreational amenity as well as localized climatic cooling of roof and garage summer heat gain.
[0038] Each of the two sides walls or facades depicted in FIGS. 2 and 3 has a particular arrangement of vertical glass channels spaced in a variety of arrays for both esthetic purposes and to facilitate the required air flow to evacuate noxious exhaust fumes from the vehicles within the garage. These will be explained in greater detail hereinafter.
[0039] FIG. 4 depicts a typical floor plan for this particular garage. It will be understood that the parking slots in this version consists instead of ramps 98 and 99 going up or down and with horizontal sections 97 at the ends of each 5 ramp and in the corners. In this particular embodiment, two sets of elevators 96 (and stairwells 97 ) are depicted in opposite corners.
[0040] As is apparent from the lines 92 and 93 which delineate parking lanes for vehicles, certain corners become “dead” space where no vehicle can be parked because of the interference with an adjacent vehicle. Thus at the lower left hand corner of FIG. 4 , designated as 99 on the drawing, it is clear that the angled lines 92 on the ramp 98 and the horizontal lines 93 on the end section 97 that no vehicle could be parked in the corner.
[0041] To make efficient use of that “dead” or otherwise unusable space, the wind turbine schematically illustrated as 100 in FIG. 4 is disposed in that corner is 99.
[0042] Before describing the facade and wind turbines in detail, it should also be understood that sometimes parking structures are not located at corners of a block but are disposed between adjacent buildings, and therefore would have no “free” corner. While the wind turbines still could be used at a corner and integrated into the building structure, this may inhibit sufficient air flow to adequately power the turbines to make them cost effective. In such case, a supported overhead parallel to the top 21 A of the retail space may be provided, and the wind turbines mounted exteriorly of the building to allow for air flow.
[0043] Turning now to FIG. 2 , it will be seen that the facade appears to have at least five different arrangements of arrays of glass channels designated as Patterns 1 through 5 and generally referred to as sections 40 through 80 . In the preferred embodiment, the glass channels may be of the type known as a Pilkington Profilit translucent linear channel glass which are supported by extruded metal tubes. This provides a facade wall that partially obscures vision but allows light to be both partially reflected and to pass thru to provide interior lighting during daylight hours. The glass may be selected for various tint and degree of translucency.
[0044] In the preferred embodiment, slightly green-tinted glass formed into a 10″ wide C-shaped vertical channel or plank, and arranged in various arrays, are supported at the top and bottom by an aluminum tube. As can be seen in FIG. 2 , the garage typically has concrete horizontally disposed beams at the perimeter which, when coupled with appropriate internal columns, permits adequate support of the internal ramps and landings. In the depicted embodiment, the angled ramps 98 are at the perimeter; in some structures the inclined ramps are centrally located while the horizontal landings extend around the entire inner perimeter.
[0045] As will be seen in FIG. 2 , the concrete floors 38 at the exterior perimeter are clad in well known fashion with some type of complementary metal casing which also provides the structure for holding the glass channels, as described hereinafter.
[0046] Five arrays or patterns are provided on each side will, and are created with the glass channels by varying the spacing and orientation of the channels. The densest pattern overlaps the channels by ⅔ of their width, while the most open spacing has a 10″ gap between channels. These arrays are best depicted in FIGS. 5-9 . The variable glass channel spacing is carefully calibrated against opposite walls to balance the garage's natural air flow distribution and meet local building requirements which may, for example, require 20% open wall space.
[0047] As illustrated in both FIGS. 2 and 3 , each of the side walls uses five different patterns of channels which are arranged in a progression across the facades, transitioning from the densest spacing to the more open. This subtle effect will lend the structure a dynamic quality as people walk and drive by, while the glass itself and spacing shields views into the garage. During the day, the channel glass will catch and reflect sunlight. At night exterior, projecting up-lights above the ground floor retail spaces will wash the façade with light, providing an enhanced appearance, much like an office building. It will be understood that by appropriate calibration other arrays and spacing may be provided both for esthetic reasons or to satisfy air flow requirements.
[0048] As seen in FIGS. 5-9 there are schematically illustrated the five different array patterns of the type distributed across the building facades. Pattern 1 ( 40 ) is depicted in FIGS. 5A and 5B . Upper and lower aluminum tubes 111 and 112 hold the glass channels 113 in position. In this array, referenced as a 3/3 spacing, each of the channels 113 are spaced 10″ apart, edge to edge providing an open gap as at 114 . As each channel is 10″ wide, the pattern is thus 3/3 and repeats for 60″ (3-10″ channels and 3 ten inch spaces).
[0049] Pattern 2 ( 50 ) is depicted in FIGS. 6A and 6B . This is referenced as ⅔ spacing. The gap distance 114 between each ten inch channel 113 is 6.75″.
[0050] Pattern 3 ( 60 ) is depicted in FIGS. 7A and 7B . This is ⅓ spacing, where the gap distance 114 between adjacent channels 113 is about 3.25″.
[0051] Pattern 4 ( 70 ) is depicted in FIGS. 8A and 8B . This is referenced as ⅓ overlap, wherein two adjacent channels 113 overlap by about ⅓, or 3.25 inches; and there is a gap 114 between adjacent overlapping pairs of channels of about 3.25″.
[0052] Pattern 5 ( 80 ) is depicted in FIGS. 9A and 9B . This is referenced as ⅔ overlap, where two adjacent channels 113 overlap by two thirds of their width and there is a gap 114 between adjacent pairs of channels of about 3.25″.
[0053] Where the channels 113 overlap, one will be reversed so that the appropriate spacing in the aluminum mounting tubes 111 and 112 can be provided. It will be apparent to one skilled in the art that numerous spacing patterns may be provided, in part depending upon the visual effect desired and the required spacing for ventilation purposes.
[0054] Schematically illustrated in FIGS. 10-14 are exemplary mounting structures. These illustrations are taken from the Pilkington web site and are simply demonstrative as to how the glass channels or planks 113 may be held in place. Upper and lower tubular channels similar to 111 and 112 are provided to essentially anchor the upper and lower ends of each channel 113 . To keep the channels mounted to the building and from moving laterally, and thereby preserve the necessary patterns, angled blocks, such as 115 and 116 in FIG. 11 are fixed at appropriate positions in the upper and lower tubes 111 and 112 . FIGS. 12 and 13 demonstratively illustrate overlapping channels with no gaps between adjacent pairs but depict the general concept. Where partial overlapping and gaps between adjacent pairs of channels is desired the angled blocks such as 115 and 116 in the upper and lower tubes 111 and 112 will be fixedly positioned. A screw/nut arrangement (not shown) will permit easy lateral adjustment of the blocks 115 and 116 in each tube 111 and 112 .
[0055] As an additional advantage of the energy efficient garage 20 , the present invention includes six vertically stacked low-speed and schematically illustrated Aerotecture wind turbines 100 positioned in the “dead” corner 99 of the garage. As illustrated, they extend from the base line 21 A above the first floor to slightly above the roof line 32 but may be positioned at different vertical spacing in this area.
[0056] These turbines are ideal for use with an annual on-site average wind speed in excess of 10 mph. These highly efficient turbines will work at low wind speeds from about 1-2 mph and higher and are expected to generate 10-15,000 Kilowatt-hours of power per year of electricity. This is enough power to light the exterior garage glass channel facades. All energy generated is fed directly into a 2-way meter so that it contributes directly to the grid and will result in direct energy savings and reduced grid demand. Moreover, in addition to efficiently utilizing what would be dead space in the building, it adds a unique and distinctive architectural feature to the structure. In this instance, the wind turbines are those produced by Aerotecture International as their model 610V. A schematic version, from that company's web site is attached and depicted in FIGS. 15-17 . Essentially each turbine 120 includes an outer support cage 121 , capable of being vertically stacked; the vanes 122 positioned for rotation within the cage, and appropriate electrical connection facility 123 at the lower end of the vanes. In the illustrated embodiment, six turbines 120 are stacked vertically in the “dead” corner 99 of the garage structure (see FIG. 18 ).
[0057] As seen in FIGS. 18 and 19 , there are numerous horizontal concrete beams 125 disposed angularly across the corner 99 of the garage. These beams provide several functions; they allow for anchoring of the cages along a vertical spine 126 running the full height of the corner and they also preclude vehicles from inadvertently running out of the garage!
[0058] To complete the esthetics and to facilitate air flow out of the garage, there are provided a series of vertically extending colored translucent glass panels 130 disposed behind the turbines 100 and extending vertically the height of the garage. The areas designate 8 128 are open areas permitting air flow and exhaustion of fumes from the garage. One form of glass panel may be that known as Vanceva which is also tempered so that if there is some impact of stones or the like they will not shatter. The glass panels 130 will provide a finished appearance consistent with the façade
[0059] The foregoing is considered as illustrative only of the principles of the invention. Since numerous modifications and changes will readily occur to those skilled in the art, the invention is not limited to the preferred embodiment and all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A multi-storied garage having an energy efficient ventilation system that incorporates a unique window array and vertically mounted energy producing wind turbines located in a corner of the garage structure that would otherwise be unusable for vehicle parking.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to apparatus and methods for constructing composite members.
[0003] 2. Description of Related Art
[0004] Composite items are typically constructed from layers of material that are laminated together. Some categories of materials used to fabricate composite items include fiber, fabric, tape, film and foil, and each of these categories includes a multitude of diverse materials. For example, typical fibers include glass, carbon, aramid, and quartz. When these fibers are arranged as woven sheets and unidirectional ribbons, they are referred to as fabric and tape, respectively.
[0005] Material placement is a process used to construct or fabricate composite items. These composite items include relatively simple planar sheets or panels to relatively large complex structures. Many composite items are built up from multiple layers or plies of composite materials. Some composite materials may be pre-impregnated with uncured resin (“prepreg”) or another binding agent.
[0006] In some applications an end effector of a machine for fabricating composite members arrays a group of prepreg tows into a continuous band and then presses them against the surface of a workpiece. Generally a compaction roller performs the task of pressing the tows against the workpiece. To accommodate misalignments between the end effector and the workpiece and elevation variations on the surface of the workpiece, the compaction roller is generally movable toward and away from the end effector. Unfortunately, movement of the compaction roller tends to reduce tension in the tows, which can cause rewinding of the spools that supply the tow, can degrade the quality of the lay-up and can contribute to despooling problems.
SUMMARY
[0007] The preferred embodiments of the present end effector and methods for constructing composite members have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of this end effector and these methods as expressed by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description of the Preferred Embodiments”, one will understand how the features of the preferred embodiments provide advantages, which include decreased complexity and cost as compared to prior art end effectors.
[0008] One embodiment of the present end effector for constructing composite members comprises an end effector that is configured to apply tow to a composite workpiece. The end effector comprises at least one tow supply spool for supplying tow; at least one redirect roller for changing a direction of travel of the tow; and at least one compaction roller configured to press the tow against the workpiece. The redirect roller and the compaction roller are configured to translate together along a compaction axis of the end effector, and are constrained from translating relative to one another. A direction of travel of the tow toward the redirect roller lies at substantially a right angle to the compaction axis.
[0009] One embodiment of the present methods for constructing composite members comprises the steps of: applying tow to a composite workpiece using an end effector; compacting the tow against the workpiece using a compaction roller; redirecting the tow toward the compaction roller using a redirect roller; translating the compaction roller and the redirect roller together along a compaction axis of the end effector; and feeding the tow toward the redirect roller at substantially a right angle to the compaction axis. The redirect roller and the compaction roller are constrained from translating relative to one another.
[0010] Another embodiment of the present end effector for constructing composite members comprises a method of manufacturing an aircraft, the method including at least a pre-production phase and a production phase. The method comprises the steps of: designing the aircraft, including subassemblies, and components therefor; specifying and procuring materials; fabricating the components from the materials; assembling the subassemblies by combining subsets of the components; and assembling the aircraft by combining subsets of the subassemblies. The step of assembling the subassemblies includes the step of fabricating a composite workpiece according to the method described in the paragraph above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The preferred embodiments of the present end effector and methods for constructing composite members will now be discussed in detail with an emphasis on highlighting the advantageous features. These embodiments depict the novel and non-obvious end effector and methods shown in the accompanying drawings. which are for illustrative purposes only. These drawings include the following figures, in which like numerals indicate like parts:
[0012] FIG. 1 is a flowchart illustrating steps in an integrated aircraft production process;
[0013] FIG. 2 is a front perspective view of one embodiment of the present end effector and positioning apparatus for the end effector, illustrating the end effector applying course material to a workpiece;
[0014] FIG. 3 is a front perspective view of one embodiment of the present end effector;
[0015] FIG. 4 is a detail front perspective view of the end effector of FIG. 3 ;
[0016] FIG. 5 is a schematic representation of relative locations and movement capabilities of the spools and rollers of one embodiment of the present end effector;
[0017] FIG. 6 is a schematic representation of relative locations and movement capabilities of the spools and rollers of another embodiment of the present end effector; and
[0018] FIG. 7 is a flowchart illustrating one embodiment of the present methods for constructing a composite member.
DETAILED DESCRIPTION
[0019] FIG. 1 illustrates an integrated aircraft production process 100 , in accordance with embodiments of the present disclosure. As used herein, the integrated aircraft production process 100 also may include manufacturing. support. or both. Typically, the process 100 includes a pre-production phase S 102 , a production phase S 104 , and a post-production phase S 106 . The pre-production phase S 102 may include aircraft design S 110 , including design of subassemblies and components, and material specification and procurement S 120 . Material specification and procurement S 120 may include selection and procurement of components fabricated, or subassemblies manufactured, by third parties. Examples of such third parties include, without limitation, vendors, subcontractors, and suppliers. The production phase S 104 may include component fabrication and/or subassembly manufacturing S 130 , and aircraft assembly S 140 . The pre-production phase S 102 and production phase S 104 can be elements of an integrated manufacturing process S 105 , including one or more of aircraft and component design, development, and simulation processes; material, component, and sub-assembly specification and procurement processes; automated production planning processes; fabrication and assembly processes; and quality control processes.
[0020] Frequently, aspects of a modern aircraft production process, such as the integrated process 100 , do not end with final assembly, but may extend over the service life of an aircraft. These aspects may involve iterative and interactive collaborations between manufacturer, governmental authorities, customers and aircraft operators. Accordingly, the integrated production process 100 can include a post-production phase S 106 . The post-production phase S 106 may include aircraft delivery and qualification S 150 , and/or aircraft maintenance and service S 160 . The aircraft delivery and qualification S 150 may include providing an aircraft to customer specifications, which may have changed from the time the aircraft was assembled. Thus, delivery and qualification can include repair, modification, and/or revision of one or more elements of the aircraft after delivery to a customer or operator. Also, it may be desirable to perform a modification, maintenance, a repair, and/or an upgrade to an aircraft in the service interval between aircraft delivery and retirement. Therefore, aircraft maintenance and service S 160 can include repair, maintenance, modification, and/or upgrade of a portion of an airframe, including an airframe manufactured or assembled using traditional, pre-existing materials, components, and/or subassemblies.
[0021] FIGS. 2-4 illustrate one embodiment of the present end effector 10 for constructing a composite member 12 , and positioning apparatus 14 for the end effector 10 . With reference to FIG. 2 , the positioning apparatus 14 is configured to position and/or control the movement of the end effector 10 with respect to a composite workpiece 16 . In the illustrated embodiment, the positioning apparatus 14 is a robotic armature or gantry-type positioning apparatus that is movable along a track 18 . The positioning apparatus 14 may be configured to provide the end effector 10 with three to ten or more degrees of freedom. However, those of ordinary skill in the art will appreciate that the positioning apparatus 14 may embody virtually any configuration, and may provide the end effector 10 with any number of degrees of freedom. In fact, in some embodiments the end effector 10 may be stationary. The configuration of the positioning apparatus 14 , and in fact the provision of positioning apparatus 14 , is not critical to the present embodiments.
[0022] The end effector 10 is configured to fabricate a composite member 12 by applying course material 20 to a composite workpiece 16 . The course material 20 may comprise, for example, tow, prepreg tow, slit tape, slit tape tow, tape, fibers, fiber tows, films, foils. etc. Particular examples of fibers include glass, aramid, carbon, and various other fibers. The tow may include individual fibers, bundles, cords, plaits, ribbons in the form of unidirectional “tape”, woven fabric, biaxial cloth, etc. The material may be dry or wet or preimpregnated with resin or another binding substance. The tow may also include a backing or separator film that substantially prevents the tow from adhering to itself while it is on the spool or in roll form. Those of ordinary skill in the art will appreciate that in certain embodiments the tow may not include a backing. For simplicity, the description of the present embodiments will use the term “tow” to describe the material applied to the workpiece 16 . However, as used herein, including in the claims below, the term “tow” shall be understood to be synonymous with “course material”. Those of ordinary skill in the art will appreciate that the material used is not critical to the present embodiments.
[0023] Depending upon the material characteristics of the tow 20 , it may be advantageous to control environmental variables such as, for example, temperature and humidity. In addition, based on manufacturer's specifications and/or empirically derived data, the storage and/or application conditions for the tow 20 may differ from one application to another. Therefore, in some embodiments the end effector 10 may include a housing (not shown) that encloses the tow 20 . The end effector 10 may also include environmental control assemblies (not shown) such as a heater and/or chiller.
[0024] Typically, the composite member 12 is fabricated from multiple plies or layers of tow 20 , as illustrated in FIG. 2 . Thus, the workpiece 16 includes the workpiece surface itself and/or any previously applied layers of tow 20 . As shown in FIGS. 3 and 4 , the end effector 10 includes a cylindrical compaction roller 22 that presses the tow 20 against the workpiece 16 . The workpiece 16 is configured to provide a suitably stable and finished surface for ply placement. Characteristics of the workpiece 16 , such as size, shape, contour, and the like, are based upon design parameters of the composite member 12 to be fabricated.
[0025] As shown in FIG. 2 , the workpiece 16 may be controlled to rotate about an axis C, and in such embodiments the workpiece 16 is typically referred to as a mandrel. In other embodiments, the workpiece 16 may be stationary or controlled to move along and/or about various axes. For example, the workpiece 16 may be secured to a sliding table, or X-Y table (not shown). The movement of the workpiece 16 and/or the positioning apparatus 14 acts to position the end effector 10 with respect to the workpiece 16 . Furthermore, the movement of the workpiece 16 and the positioning apparatus 14 may be coordinated to such a degree that the devices operate much like a single unit. However, those of ordinary skill in the art will appreciate that movement of the workpiece 16 is not critical to the present embodiments.
[0026] FIGS. 3 and 4 provide front perspective views of one embodiment of the present end effector 10 . With reference to FIG. 3 , in the illustrated embodiment the end effector 10 comprises a support structure 24 including a substantially flat support panel 26 . A plurality of tow supply spools 28 are arranged radially about the support panel 26 . Although twelve tow supply spools 28 are shown, those of ordinary skill in the art will appreciate that fewer or more may be provided. In the illustrated embodiment, six tow supply spools 28 are provided in an upper portion 30 of the end effector 10 and six tow supply spools 28 are provided in a lower portion 32 of the end effector 10 . For simplicity, the discussion herein will focus on the six upper tow supply spools 28 . Those of ordinary skill in the art will appreciate, however, that characteristics of the upper tow supply spools described herein may also apply to the six lower tow supply spools.
[0027] Each cylindrical tow supply spool 28 is mounted to a spindle 34 and includes a helically wound supply of tow 20 . As tow 20 is drawn off each spool 28 to be supplied to the workpiece 16 , the tow supply spool 28 rotates about its spindle 34 . Each spindle 34 may include a tensioner (not shown), such as a brake, that assists in maintaining a desired tension in the tow 20 . For example, a suitable tensioning device may include a belt (not shown) that wraps around a portion of the circumference of the spindle 34 and generates friction that retards the rotation of the spindle 34 . The friction may be modulated by a solenoid or a servo acting upon the belt. Advantageously, the spindles 34 do not require bi-directional movement or complicated rewind apparatus in order to maintain tension, as explained in detail below.
[0028] With reference to FIG. 3 , in the illustrated embodiment the end effector 10 further comprises a plurality of backing take-up spools 36 , a plurality of dancer rollers 38 and a plurality of redirect rollers 40 . Each of the backing take-up spools 36 , dancer rollers 38 and redirect rollers 40 spins freely on an axle or spindle (not shown). One backing take-up spool 36 , one dancer roller 38 and one redirect roller 40 is provided for each tow supply spool 28 . However, in FIGS. 3 and 4 the lower redirect rollers 40 and associated support structures have been omitted for clarity. The backing take-up spools 36 and dancer rollers 38 are located closely adjacent their respective tow supply spools 28 and the redirect rollers 40 are located in a cluster near a center of the support panel 26 . Each length of tow 20 follows a set path about the spools and rollers as follows. Each path of tow travel begins as the tow 20 leaves its respective supply spool 28 , continues around its respective backing take-up spool 36 , then around its respective dancer roller 38 and then to its respective redirect roller 40 .
[0029] As each tow 20 travels around its respective backing take-up spool 36 the backing (not shown) separates from the tow 20 and winds onto the take-up spool 36 . As explained above, in certain embodiments the tow 20 may not include a backing. In such embodiments the backing take-up spools 36 may not be present, or they may be present but unused. Those of ordinary skill in the art will appreciate that alternative apparatus may be provided for separating the tow 20 from its backing. For example, one such apparatus includes a vacuum nozzle (not shown) in fluid communication with a vacuum source and configured to generate sufficient suction to draw off the tow backing. Such apparatus is disclosed in U.S. Patent Application Publication No 2006/0180264 entitled “Modular Head Lamination Device and Method”, the entire contents of which are hereby incorporated by reference.
[0030] After the tow 20 and backing are separated, the tow 20 continues around its respective dancer roller 38 . The dancer roller 38 advantageously dampens any rapid changes in the feed rate of the tow 20 . The dancer roller 38 also facilitates a smooth removal of the tow 20 from the spool 28 , and directs the path of tow travel toward its respective redirect roller 40 . The tow 20 travels around its respective redirect roller 40 and toward the compaction roller 22 . The path of tow travel from the redirect rollers 40 to the compaction roller 22 extends along an axis X′, known as a compaction axis or compliance axis ( FIGS. 4 and 5 ). Along this axis the tow 20 may be directed past one or more optional components such as, for example, combs, cutting assemblies, clamps, dancers, idlers, etc.
[0031] With reference to FIGS. 3 and 4 , the configuration of the end effector 10 , with the tow supply spools 28 arranged radially around the redirect rollers 40 , feeds each tow 20 to its respective redirect roller 40 at substantially a right angle to the compaction axis X′. Thus, one step in one embodiment of the present methods comprises feeding the tow 20 to the redirect roller(s) 40 at substantially a right angle to the compaction axis X′, as illustrated in step S 700 of FIG. 7 . The right angle feed, which is illustrated schematically in FIG. 5 , advantageously contributes to a substantially constant tension in each tow 20 , as described in detail below. The redirect roller(s) 40 redirect the tow 20 toward the compaction roller 22 , as illustrated in step S 702 of FIG. 7 .
[0032] As tow 20 is dispensed from the end effector 10 and applied to the workpiece 16 , as illustrated in step S 704 of FIG. 7 , the compaction roller 22 presses the tow 20 against the workpiece 16 , as illustrated in step S 706 . From time to time the workpiece 16 and the end effector 10 may become misaligned and/or the surface of the workpiece 16 may become uneven, such as through unanticipated tow buildup. In order to accommodate these misalignments and uneven surfaces, the compaction roller 22 is configured to be translatable along the compaction axis X′ ( FIG. 4 ) relative to the end effector 10 . For example, the compaction roller 22 may be translatable plus or minus 1 to 20 mm along the compaction axis X′, as indicated by the double-headed arrow in FIG. 5 . Thus, as the compaction roller 22 travels over the surface of the workpiece 16 it may translate back and forth along the compaction axis X′ in response to misalignments and uneven surfaces. To accommodate this translation. the compaction roller 22 is mounted on a compaction roller subassembly 42 ( FIGS. 3-5 ) that is slidably secured to a pair of brackets 44 that are in turn secured to the support structure 24 . Only one of the brackets 44 is visible in FIGS. 3 and 4 , and for clarity the structure that secures the brackets 44 to the support structure 24 has been omitted. The brackets 44 may be stationary with respect to the support structure 24 , or they may be capable of relative movement. The compaction roller subassembly 42 is urged toward the workpiece 16 by, for example, one or more pneumatic cylinders (not shown). Those of ordinary skill in the art will appreciate that alternative apparatus may be used to urge the compaction roller subassembly 42 toward the workpiece 16 .
[0033] As illustrated in FIG. 4 , in the present embodiments the redirect rollers 40 are advantageously mounted to the compaction roller subassembly 42 . This configuration is also shown schematically in FIG. 5 . In FIG. 5 only one redirect roller 40 is shown, and represents the multiple redirect rollers shown in FIG. 4 . As shown, the redirect rollers 40 are mounted at an upstream end of the compaction roller subassembly 42 and the compaction roller 22 is mounted at a downstream end of the subassembly 42 . Because the redirect rollers 40 and the compaction roller 22 are both mounted to the compaction roller subassembly 42 , they are constrained from moving relative to one another. They translate as a unit in both directions along the compaction axis X′, as illustrated by the double-headed arrow in FIG. 5 . Thus, as the compaction roller 22 travels over the surface of the workpiece 16 and translates back and forth along the compaction axis X′ as described above, the redirect rollers 40 translate along the compaction axis X′ in sync with the compaction roller 22 , as illustrated in step S 708 of FIG. 7 . This simultaneous movement of the compaction roller 22 and the redirect rollers 40 , coupled with the substantially ninety-degree feed angle of the tow 20 to the redirect rollers 40 , advantageously maintains a nearly constant tension within the tow 20 .
[0034] In prior art apparatus for constructing composite members, movement of the compaction roller along the compaction axis disadvantageously lowers tension in each tow. The present embodiments reduce or eliminate such tension losses by feeding the tow 20 to the redirect rollers 40 at a substantially ninety-degree feed angle to the compaction axis, coupled with synchronous movement of the compaction roller 22 and the redirect rollers 40 along the compaction axis X′. As the compaction roller 22 moves relative to the end effector 10 , the redirect rollers 40 move along with it. Thus, tension in the region of the tow path between the redirect rollers 40 and the compaction roller 22 remains substantially constant. And because the tow 20 is fed to the redirect rollers 40 at a substantially ninety-degree angle to the compaction axis, movement of the redirect rollers 40 with respect to the tow supply spools 28 does not generate any significant variations in tension in the region of the tow path between the tow supply spools 28 and the redirect rollers 40 . The reduction or elimination of these variations in tow tension enable the present embodiments to produce high-quality composite members 12 without the need for complex and expensive bi-directional tow supply spools and rewind apparatus. The overall cost and complexity of the end effector 10 are thus reduced.
[0035] Those of ordinary skill in the art will appreciate that the present embodiments are susceptible to many variations that are nevertheless within the scope of the claims below. For example, additional rollers may be added to the end effector 10 to suit particular applications. FIG. 6 illustrates, schematically, one such alternative embodiment including a second redirect roller 46 . While only one second redirect roller 46 is shown in FIG. 6 , those of ordinary skill in the art will appreciate that a plurality of second redirect rollers 46 may be provided. The second redirect roller 46 is located between the tow supply spool 28 and the first redirect roller 40 . Tow 20 is fed from the tow supply spool 28 around the second redirect roller 46 to the first redirect roller 40 . Advantageously, the configuration of FIG. 6 maintains the substantially ninety-degree tow feed angle to the first redirect roller 40 and the synchronous movement of the first redirect roller 40 with the compaction roller 22 .
[0036] The above description presents the best mode contemplated for carrying out the present end effector for constructing composite members, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this end effector. This end effector is, however, susceptible to modifications and alternate constructions from that discussed above that are fully equivalent. Consequently, this end effector is not limited to the particular embodiments disclosed. On the contrary, this end effector covers all modifications and alternate constructions coming within the spirit and scope of the end effector as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the end effector.
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An end effector, and methods for constructing composite members, in which a compaction roller and redirect rollers translate synchronously along the compaction axis. Additionally, the end effector includes an advantageous arrangement of spools and rollers that directs tow to the redirect rollers at substantially a right angle. Movement of the compaction roller along the compaction axis induces little, if any, changes in tow tension. The substantially constant tow tension advantageously reduces rewinding of the tow supply spools. which can degrade the quality of the lay up and contribute to despooling problems.
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BACKGROUND OF THE INVENTION
The present invention relates to novel 1-methyl-3,4-dihalo-5-alkylthiopyrazole derivatives and their use as fungicides.
The 1-methyl-3,4,5-trihalopyrazole intermediate used in the preparation of this compound, as well as processes for preparing it, is disclosed in my commonly-assigned pending U.S. patent application "Intermediates for 1-Methyl-3,4-Dihalo-5-Substituted-Thio-, Sulfinyl- or Sulfonyl-Pyrazole Fungicides", Ser. No. 393,214, filed June 28, 1982.
Fungicidal 1-methyl-3,4-dihalo-5-substituted thio-, sulfinyl- or sulfonyl-pyrazoles which have a ##STR2## group attached to the 5-sulfur wherein R' and R" are independently hydrogen, alkyl, cycloalkyl, alkenyl of 2 or more carbon atoms, alkylene carbalkoxy or aryl or aralkyl optionally substituted with 1 or 2 substituents each independently selected from halogen, nitro, cyano, lower alkyl, lower alkoxy, trihalosubstituted methyl and phenoxy are disclosed in my commonly assigned pending U.S. patent application "Fungicidal and Algicidal 1-Methyl-3,4-Dihalo-5-Substituted Thio-, Sulfoxyl- or Sulfonyl-Pyrazoles", Ser. No. 393,213, filed June 28, 1982.
Other fungicidal pyrazole derivatives are disclosed in my commonly assigned U.S. patent application "Fungicidal 1-Methyl-3,4-Dihalo-5-Substituted-Sulfonylpyrazoles", Ser. No. 499,570, filed June 31, 1983.
SUMMARY OF THE INVENTION
The 1-methyl-3,4-dihalo-5-alkylthiopyrazole compounds of this invention are represented by the general formula: ##STR3## wherein R 1 is alkyl having 3 to 6 carbon atoms or benzyl where the phenyl ring is optionally substituted with 1 to 2 substituents independently selected from halogen, cyano, nitro, trihalomethyl and lower alkyl; and Y is chloro or bromo.
Among other factors, the present invention is based upon my finding that the 1-methyl-3,4-dihalo-5-alkylthiopyrazole compounds of my invention are surprisingly effective as fungicides. In particular, these compounds are effective in combatting and preventing certain plant fungal infections.
The trihalo intermediates used in the synthesis of the compounds of this invention are disclosed in my commonly-assigned and co-pending U.S. patent application "Intermediates for 1-Methyl-3,4-Dihalo-5-Substituted Thio-, Sulfinyl- and Sulfonyl-Pyrazole Fungicides", Ser. No. 393,214, filed June 28, 1982.
Representative R 1 groups include n-propyl, isopropyl, n-butyl, isobutyl, n-pentyl, n-hexyl, benzyl and 4-chlorobenzyl. Preferred R 1 groups include n-propyl, n-butyl and isobutyl.
DEFINITIONS
As used herein, the following terms have the following meanings, unless expressly stated to the contrary.
The term "alkyl" refers to both straight- and branched-chain alkyl groups. The term "lower alkyl" refers to both straight- and branched-chain alkyl groups having a total of from 1 to 6 carbon atoms and includes primary, secondary and tertiary alkyl groups. Typical lower alkyls include, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, n-pentyl, n-hexyl, and the like.
The term "pyrazole" refers to the ##STR4## group. The conventional numbering system for this group is shown below: ##STR5##
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention may be prepared according to the following reaction sequences: ##STR6## wherein Y and R 1 are as defined in conjunction with formula I and b 1 and b 2 are bases.
Reaction (1) is carried out by reacting (II) and (III) in the presence of base (IV). Suitable bases, b 1 , include organic or inorganic bases, such as K 2 CO 3 , Na 2 CO 3 , triethylamine and the like. It is preferred to add an excess of (III) and (IV) per equivalent of (II) for ease of workup. It is especially preferred to add at least 3 and more preferably 5 equivalents of (IV) per equivalent of (II). Reaction (1) may be carried out by adding (IV) with stirring to a solution of (II) and solvent, followed by the slow addition of (III). For convenience, the reaction is carried out at ambient pressure. Suitable solvents include inert organic solvents such as toluene, benzene, dimethoxyethane, tetrahydrofuran and the like. The product (V), a low-melting white solid, is isolated by conventional procedures such as extraction, chromatography, and recrystallization.
Reaction (2) is conducted by adding V to a stirred mixture of VI and VII in solvent. It is preferred to heat the VI-VII mixture for a short period of time, on the order of about 15 to about 30 minutes, prior to adding V. The reaction is conducted at a temperature of about 50° to about 180° C., preferably from about 80° to about 140° C., and is generally complete within about 4 to about 24 hours. Although approximately equimolar amounts of V, VI and VII may be used, it is preferred to use about a 20 percent excess of VI relative to V. Suitable solvents include dimethyl sulfoxide (DMSO), dimethylformamide, dimethoxyethane, and the like. Suitable bases, b 2 , include strong inorganic bases such as potassium hydroxide, sodium hydroxide, and the like. The product, I, is isolated by conventional procedures such as extraction, washing, stripping, distilling, hard topping, chromatography, and the like.
When used as fungicides, the compounds of this invention are applied in fungicidally effective amounts to fungi and/or their habitats, such as vegetative hosts and non-vegetative hosts, e.g., animal products. The amount used will, of course, depend on several factors such as the host, the type of fungus and the particular compound of the invention. As with most pesticidal compounds, the fungicides of the invention are not usually applied full strength, but are generally incorporated with conventional, biologically inert extenders or carriers normally employed for facilitating dispersion of active fungicidal compounds, recognizing that the formulation and mode of application may affect the activity of the fungicide. Thus, the fungicides of the invention may be formulated and applied as granules, as powdery dusts, as wettable powders, as emulsifiable concentrates, as solutions, or as any of several other known types of formulations, depending on the desired mode of application.
Wettable powders are in the form of finely divided particles which disperse readily in water or other dispersant. These compositions normally contain from about 5% to 80% fungicide, and the rest inert material, which includes dispersing agents, emulsifying agents and wetting agents. The powder may be applied to the soil as a dry dust, or preferably as a suspension in water. Typical carriers include fuller's earth, kaolin clays, silicas, and other highly absorbent, readily wettable, inorganic diluents. Typical wetting, dispersing or emulsifying agents include, for example: the aryl and alkylaryl sulfonates and their sodium salts; alkylamide sulfonates, including fatty methyl taurides; alkylaryl polyether alcohols, sulfated higher alcohols, and polyvinyl alcohols; polyethylene oxides, sulfonated animal and vegetable oils; sulfonated petroleum oils, fatty acid esters of polyhydric alcohols and the ethylene oxide addition products of such esters; and the addition products of long-chain mercaptans and ethylene oxide. Many other types of useful surface-active agents are available in commerce. The surface-active agent, when used, normally comprises from 1% to 15% by weight of the fungicidal composition.
Dusts are freely flowing admixtures of the active fungicide with finely divided solids such as talc, natural clays, kieselguhr, pyrophyllite, chalk, diatomaceous earths, calcium phosphates, calcium and magnesium carbonates, sulfur, lime, flours, and other organic and inorganic solids which act as dispersants and carriers for the toxicant. These finely divided solids have an average particle size of less than about 50 microns. A typical dust formulation useful herein contains 75% silica and 25% of the toxicant.
Useful liquid concentrates include the emulsifiable concentrates, which are homogeneous liquid or paste compositions which are readily dispersed in water or other dispersant, and may consist entirely of the fungicide with a liquid or solid emulsifying agent, or may also contain a liquid carrier such as xylene, heavy aromatic naphthas, isophorone, and other nonvolatile organic solvents. For application, these concentrates are dispersed in water or other liquid carriers, and are normally applied as a spray to the area to be treated.
Other useful formulations for fungicidal applications include simple solutions of the active fungicide in a dispersant in which it is completely soluble at the desired concentration, such as acetone, alkylated naphthalenes, xylene, or other organic solvents. Granular formulations, wherein the fungicide is carried on relatively coarse particles, are of particular utility for aerial distribution or for penetration of cover-crop canopy. Pressurized sprays, typically aerosols wherein the active ingredient is dispersed in finely divided form as a result of vaporization of a low-boiling dispersant solvent carrier, such as the Freons, may also be used. All of those techniques for formulating and applying fungicides are well known in the art.
The percentages by weight of the fungicide may vary according to the manner in which the composition is to be applied and the particular type of formulation, but in general comprise 0.5% to 95% of the toxicant by weight of the fungicidal composition.
The fungicidal compositions may be formulated and applied with other active ingredients, including other fungicides, insecticides, nematocides, bactericides, plant-growth regulators, fertilizers, etc.
Many of the compounds of the invention are also useful for controlling microbiological organisms such as algae, bacteria, molds and occasionally aquatic weeds which foul aqueous industrial effluents and cooling streams, such as those occurring in the paper and food processing industries. They may also be used to control such organisms in other aqueous bodies such as lakes, streams, canals, pools, and the like. When so used, a biocidal quantity of one or more of the compounds of this invention is added to the aqueous growth environment of the organisms. Usually, this dosage will range between about 0.1 to 50 ppm. In any given instance, the optimum dosage will depend upon the particular organism and aqueous body involved. For instance, when used to control algae, these compounds will usually be employed at concentrations of about 0.1 to 10 ppm. In terms of pounds of compound per acre of water one foot deep, 0.1 to 10 ppm is equal to about 0.3 to 30 pounds per acre of water one foot deep. These compounds may be applied to the aqueous growth environments of such organisms as dispersible powders or in solution with water-miscible solvents.
In addition, some of the compounds of the present invention exhibit herbicidal activity, generally in post-emergent applications. For post-emergent applications, the herbicidal compounds will be applied directly to the foliage and other plant parts. Generally, those compounds exhibiting herbicidal activity are effective against weed grasses as well as broad-leaved weeds. Some compounds may be selective with respect to the type of application and/or type of weed.
A further understanding of my invention may be had from the following non-limiting examples.
EXAMPLES
Example 1
Preparation of 1-methyl-3,4,5-trichloropyrazole
To a rapidly stirred mixture of 11.4 g (0.046 mole) hexachloropropene and 16.6 g (0.12 mole) potassium carbonate in 100 ml toluene, 1.85 g (0.04 mole) methyl hydrazine was added slowly. The addition was slightly exothermic and the color of the reaction mixture turned to light orange-brown. The reaction mixture was then stirred overnight at ambient temperature. The reaction mixture was then heated to about 80° C. for about three hours and then cooled. A powdery solid appeared in the mixture. The mixture was filtered and the solids washed with ethyl ether.
The ethyl ether washings and reaction mixture filtrate were combined and stripped under reduced pressure and heat to give a black oil. The oil was chromatographed on a silica column, eluting first with hexane (which elutes unreacted starting materials) and then with methylene chloride. The methylene chloride eluate was stripped to give a pale yellow oil which solidified upon standing. Recrystallization from hexane gave 2.5 g of the product, a white solid with a melting point of 33°-35° C.
Elemental analysis for C 4 H 3 Cl 3 N 2 showed: calculated %C 25.90, %H 1.63, and %N 15.11; found %C 23.67, %H 1.65, and %N 13.8.
By following the above procedure, but starting with 114 g (0.4 mole) of hexachloropropene and the corresponding proportions of the other reactants, 32.9 g of the product was prepared, a 34% yield (of theoretical).
Example 1A
Preparation of 1-methyl-3,4,5-trichloropyrazole
To a stirring solution of 250 g (1 mole) of hexachloropropene in 250 ml toluene, there was added 94.4 g (2.05 moles) of methyl hydrazine dropwise. The temperature of the reaction mixture was maintained in the range of about 50° to about 60° C. by the use of external cooling. When the addition of methyl hydrazine was complete, the reaction mixture was cooled to room temperature and 276 g (2 moles) of potassium carbonate was added. The resulting mixture was carefully heated first to about 60° C., then gradually to about 85° to 90° C. Heating was carefully monitored to control occasional exotherm and degassing. After about three hours, the heat source was removed and the reaction mixture was allowed to cool to room temperature. The reaction mixture was diluted with about 500 ml ice water and extracted with methylene chloride. The organic layer (containing the product) was washed twice with water, dried over magnesium sulfate and concentrated on a rotovac to give a red oil (about 275 ml). The red oil was dissolved in hexane and filtered through a short silica column twice to give 133 g of a yellow oil which solidified. Spectra of the solid were identical to those of the product of Example 1.
Example 2
Preparation of ##STR7##
1-methyl-3,4-dichloro-5-(n-propylthio)pyrazole
A stirred mixture of 4.9 g (0.064 moles) propanthiol and 3 g (0.054 moles) potassium hydroxide in 50 ml dimethylsulfoxide was heated (at about 120° C.) for thirty minutes. Then 10 g (0.054 moles) 1-methyl-3,4,5-trichloropyrazole was added in one portion. Heating (at about 120° C.) of the stirred reaction mixture was continued for about 6 hours. The reaction mixture was allowed to cool. The reaction mixture was added to water (about 50 ml); the resulting mixture was extracted with ether. The etheral phase was separated, washed with water twice, and dried over magnesium sulfate. The solvent was then stripped. The product was distilled out at 124° C. under high vacuum and heat.
Elemental analysis for C 7 H 10 Cl 2 N 2 S showed: calculated %C 37.34, %H 4.48, and %N 12.44; found %C 37.06, %H 4.56, and %N 12.28.
Example 3
Preparation of ##STR8##
1-Methyl-3,4-dichloro-5-(4-chlorobenzylthio)pyrazole
A stirred mixture of 10.3 g (0.065 moles) 4-chlorobenzyl mercaptan and 3.0 g (0.054 moles) potassium hydroxide in 50 ml dimethylsulfoxide was heated (at about 120° C.) for about 20 minutes. Then 10 g (0.054 moles) 1-methyl-3,4,5-trichloropyrazole were added. Heating (at about 120° C.) of the stirred reaction mixture was continued for about 4 hours. The reaction mixture was allowed to cool. The reaction mixture was added to water (about 50 ml); the resulting mixture was extracted with ether. The etheral phase was separated and dried over magnesium sulfate. The solvent was stripped and the residue was hard-topped. The product was purified by high pressure liquid chromatography to give 6 g.
Elemental analysis for C 11 H 9 Cl 3 N 2 S showed: calculated %C 42.94, %H 2.95, and %N 9.11; found %C 43.2, %H 3.1, and %N 9.22.
Example A
Bean Powdery Mildew
The compounds of the invention were tested for the control of the Bean Powdery Mildew organism Erysiphe polygoni. Seedling bean plants were sprayed with a 250-ppm solution of the test compound in acetone, water and a nonionic emulsifier. The sprayed plants were then inoculated 1 day later with the organism. The plants were maintained for 10 days at temperatures of 68° F. at night with daytime temperatures of 72° F. to 80° F.; relative humidity was maintained at 40% to 60%. The percent disease control provided by a given test compound was based on the percent disease reduction relative to the untreated check plants. The results are tabulated in Table II.
Example B
Tomato Late Blight
Compounds of the invention were tested for the preventative control of the Tomato Late Blight organism Phytophthora infestans. Five- to six-week-old tomato (cultivar Bonny Best) seedlings were used. The tomato plants were sprayed with a 250-ppm suspension of the test compound in acetone, water and a nonionic emulsifier. The sprayed plants were then inoculated 1 day later with the organism, placed in an environmental chamber and incubated at 66° F. to 68° F. and 100% relative humidity for at least 16 hours. Following the incubation, the plants were maintained in a greenhouse for approximately 7 days. The percent disease control provided by a given test compound was based on the percent disease reduction relative to untreated check plants. The results are tabulated in Table II.
Example C
Celery Late Blight
The Celery Late Blight tests were conducted using celery (Utah) plants 11 weeks old. The Celery Late Blight organism was Septoria apii. The celery plants were sprayed with 250-ppm solutions of the candidate toxicant mixed with acetone, water and a nonionic emulsifier. The plants were then inoculated with the organism and placed in an environmental chamber and incubated at 66° F. to 68° F. in 100% relative humidity for an extended period of time (approximately 48 hours). Following the incubation, the plants were allowed to dry and then were maintained in a greenhouse for approximately 14 days. The percent disease control provided by a given candidate toxicant is based on the percent disease reduction relative to untreated check plants. The results are reported in Table II.
Example D
Tomato Early Blight
Compounds of the invention were tested for the control of the Tomato Early Blight organism Alternaria solani conidia. Tomato (variety Bonny Best) seedlings of 6- to 7-weeks old were used. The tomato plants were sprayed with a 250-ppm solution of the test compound in an acetone-and-water solution containing a small amount of a nonionic emulsifier. The sprayed plants were inoculated 1 day later with the organism, placed in the environmental chamber and incubated at 66° F. to 68° F. and 100% relative humidity for 24 hours. Following the incubation, the plants were maintained in a greenhouse for about 12 days. Percent disease control was based on the percent disease development on untreated check plants. The compounds tested and the results are tabulated in Table II.
Example E
Grape Downy Mildew
The compounds of this invention were tested for the control of the Grape Downy Mildew organism, Plasmopara viticola. Seedlings of Vitis vinifera var. Emperor (7+ weeks old) were used as hosts. The plants were sprayed with a 250 ppm solution of the test compound in an acetone and water solution containing a small amount of non-ionic emulsifier. The treated plants were inoculated one day later by spraying them with a spore suspension of the organism. The treated plants were then held in a greenhouse at a temperature of about 68° F. to about 72° F. (relative humidity varied between about 30 and about 99%) for 4 days. The plants were then placed in an environmental chamber at 100% relative humidity to induce sporulation. On removal from the chamber and after drying, the plants were evaluated for disease development. The percent disease control provided by a given test compound was based on the percent disease reduction relative to untreated check plants. The results are reported in Table II.
Example F
Bean Rust
The compounds of this invention were evaluated for their ability to eradicate Bean Rust caused by Uromyces phaseoli tipica on pinto beans.
Pinto bean plants, variety Idaho 1-11, 16 (summer) or 19 (winter) days old were inoculated with a 50-ppm suspension of uredospores in water containing a small amount of non-ionic surfactant. The inoculated plants were placed in an environmental chamber immediately after inoculation and incubated 20 hours. Following the incubation period, the plants were removed from the chamber and placed in a greenhouse maintained at 66°-68° F. and 60-80% relative humidity. Two days after inoculation, the plants were treated by spraying with a 250-ppm solution of test compound in an acetone and water carrier formulation containing a small amount of non-ionic surfactant. One or two replicate pots (each containing two plants) were used for each compound. In addition, one or two replicate pots were sprayed with the same carrier formulation (without a test compound) as a control (hereinafter "untreated Checks"). The plants were kept in the greenhouse until evaluated. The plants were evaluated for disease control when disease symptoms were well developed on the untreated Checks, normally about 14 days after treatment. The percentage disease control (or eradication) provided by a test compound was based on the percent disease reduction relative to the untreated Checks. The results are reported in Table II.
Example G
Mycelial Inhibition
A number of the compounds of the present invention were evaluated for in vitro fungicidal effectiveness by means of a mycelial inhibition test. This test is designed to measure the fungitoxic activity of fungicidal chemicals in terms of their degree of inhibition of mycelium growth. Fungi used were Phythium ultimum, Rhizoctonia solani, Fusarium monilofroma, Botrytis cinerea and Aspargillos niger. Each compound to be tested was dissolved in acetone to 500 ppm concentration. Paper strips were infused with the particular mycelium growth by covering the paper with a potato dextrose broth culture of mycelial suspension. The papers were then placed on potato dextrose agar plates and sprayed by means of a microsprayer with the fungicidal solution. The treated paper strips were incubated at 25° C. and the data is taken after 24 hours. Fungicidal activities are measured by a zone of inhibited mycelial growth from the center of the paper strip in terms of mg/cm 2 needed for 99% control of the fungus (ED 99 ). The effectiveness of the compounds tested for fungicidal activity is reported in Table II in terms of the percent of the ED 99 of the test compound of the ED 99 of the standard Difolatan®.
Example H
Algae and Aquatic Weeds Control
Representative compounds of the invention were tested as aquatic herbicides and algicides by the following method. The weed test species were Lemna minor and Elodea canadensis and the algae used was Spirulina maxima.
An acetone solution of the test compound and a small amount of an alkylarylpolyoxyethylene glycol-containing surfactant was prepared. This solution was mixed with a nutrient solution in quantity sufficient to give a concentration of 2 ppm. Eight oz. plastic cups were filled with 150 ml of this solution. A sample of the test, Lemna and Elodea, was added together to each cup. Forty ml of Spirulina culture with the 2 ppm treatment was placed in 11/2 oz. plastic cups or #4 glass vials. The containers were then placed in an illuminated environment and maintained at a temperature of about 20° C. for incubation. The containers were observed periodically for growth (as compared with an untreated check). The effectiveness of the test compound was determined based on a final observation of growth after 7 to 10 days. The results of the test on a 0-to-100 basis--0indicating no effectiveness and 100 indicating complete effectiveness--are reported in Table III.
TABLE I__________________________________________________________________________Compounds of the formula ##STR9## Elemental Analysis % C % H % NCompound Y R.sup.1 Physical State Calc. Found Calc. Found Calc. Found__________________________________________________________________________1 33503 Cl CH.sub.2 CH.sub.2 CH.sub.3 clear off-white 37.34 37.06 4.48 4.56 12.44 12.28 oil2 33149 Cl CH(CH.sub.3).sub.2 brown oil 37.34 35.85 4.48 4.42 12.44 12.413 33502 Cl CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3 clear oil 28.0* 29.7* 14.6** 13.4**4 33426 Cl CH.sub.2 CH(CH.sub.3).sub.2 clear oil 40.17 38.78 5.06 5.69 11.71 11.065 33425 Cl (CH.sub.2).sub.5 CH.sub.3 clear oil 44.94 44.58 6.04 6.89 10.48 9.1 6 33552 Cl ##STR10## yellow oil 42.94 43.2 2.95 3.1 9.11 9.22__________________________________________________________________________ *% Cl **% S
TABLE II__________________________________________________________________________Myceliar InhibitionCompound Phy. Rhiz. Fus. Botr. Asper. GDM TLB CLB TEB BR BPM__________________________________________________________________________1 33503 0 0 0 0 0 0 0 23 96 0 02 33149 0 0 0 0 0 14 0 -- 27 6 03 33502 0 0 0 0 0 0 29 0 71 0 04 33426 0 0 0 0 0 18 0 80 11 0 05 33425 0 0 0 0 0 8 0 27 23 0 06 33552 0 0 0 0 0 0 0 0 56 0 0__________________________________________________________________________ GDM -- Grape Downy Mildew (Plasmopara viticola) TLB -- Tomato Late Blight (Phytophthora infestans) CLB -- Celery Late Blight (Septoria apii) TEB -- Tomato Early Blight (Alternaria solani conidia) BR -- Bean Rust (Uromyces phaseoli tipica) BPM -- Bean Powdery Mildew (Erysiphe polygoni)
TABLE III______________________________________Compound Lemna Elodea Spirulina______________________________________1 33503 0 0 02 33149 0 0 03 33502 55 0 04 33426 0 0 05 33425 50 0 06 33552 63 0 33______________________________________
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Compounds of the formula: ##STR1## wherein R 1 is alkyl having 3 to 6 carbon atoms or benzyl where the phenyl ring is optionally substituted with 1 to 2 substituents each independently selected from halogen, cyano, nitro, trihalomethyl and lower alkyl; and Y is chloro or bromo, are fungicidal.
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FIELD OF THE INVENTION
The present invention relates to the field of physical exercise equipment and, more particularly, to an improved weight lifting exercise bench.
BACKGROUND
Weight lifting exercise benches have been known in the art for a number of years. More recently, as physical fitness has gained greater public interest and awareness, a number of developments have occurred in the design and use of exercise benches.
The original exercise bench, which is still in use, comprises a flat raised horizontal platform supported by a frame upon which a user lies while performing various arm exercises, such as bench presses and pullovers (which develop the triceps and chest muscle groups.)
The use of this original bench has limitations, in that an assistant was generally required to hand the weights to and take the weights from the bench user. Moreover, a bench user, who performed exercises thereon without assistance, could be injured if he became exhausted and was unable to escape from under the weights.
To improve the above-described original bench design, vertical support members at one end of the bench were extended above the level of the platform and "J"-shaped hook members were added to the upper portions of the extended vertical support members, thereby allowing the barbell weights to be supported above the users head and shoulders. This improved exercise bench was therefore, more convenient and safer in that a user could install a barbell on the "J"-shaped hook without assistance, and could place the barbell thereon after completion of his exercise so that he could escape from under said barbell.
Thereafter, exercise benches were provided with a platform having means for slanting the head end thereof upward relative to the horizontal portion of the end of the platform supporting a user's trunk. Using the aforementioned configuration, a weight lifter, by bench pressing with his upper torso inclined upward from a horizontal position, is required to use certain muscle groups of the upper chest and shoulders, which muscle groups would not otherwise be exercised to the same extent.
Another prior art improvement to exercise benches was the addition of a leg exercising means. These prior art leg exercising means are of two types, although many contemporary benches comprise both types in a single embodiment. The first type of such leg exercise means enables the development of the front thigh muscles, and more specficically, the quadriceps femoris (rectus femoris, vastus intermedius, vastus medials) vastus internua, sartorius, and patella tendon. In this exercise, the user sits or lies on his back on the platform with his legs hanging downward over one end thereof. The user's legs are tucked behind a padded member which is connected to the end of a vertical bar extending downard, the vertical bar being pivotally connected at its other end to the frame of the bench near the user's knees, such that the said vertical bar may be rotated about its pivot axis to a position approximately planar with the platform. Thus, when the user straightens his leg by flexing the quadriceps, he pivots his lower leg forward approximately 90° so that it is planar with the platform. A resistance may be added to the pivoting bar such as weights, an elastic or spring means, hydraulic pressure resistance or a pulley system.
This leg exercise means is deficient in at least two respects. Firstly, the lower leg which has a pivoting range at the knee of 135° or more, is not provided with its full range of motion, and therefore, the full potential benefit of the exercise is not achieved. Generally, the greater the range of angular movement of a joint during an exercise, the more benefit is derived from that exercise. Secondly, there is a tendency for some bench users performing this leg exercise to lift the whole leg from the hip rather than just using the quadriceps (e.g. to cheat on the exercise). Therefore, proper isolation of the select muscle groups for which this exercise is designed is not achieved using the prior art device. The present invention solves the foregoing problems.
The second type of leg exercise means associated with the use of an exercise bench enables the development of the back thigh and buttocks muscles, and more specifically, the hamstrings (biceps femoris, semimembranosus) and gluteus maximus. In this exercise, a user lies on the bench platform on his stomach with his leg tucked under a padded portion of a horizontal bar extending approximately planar with the platform, which bar is pivotally connected to the frame in a manner similar to the aforementioned leg extension exercise bar. Weights or other resistance means are applied to the bar as previously described. The user curls his lower legs upward and towards his buttocks.
This prior art exercise bench is deficient in a number of respects in connection with the performance of the back leg and buttocks exercise described above. In performing this exercise on the prior art flat bench, as the horizontal bar is raised by the user's legs, the hips act as a fulcrum between the leg exercise bar pushing downward and backward on the leg, on the one hand, and the weight of the upper torso of the user, on the other hand. There is a tendency in this exercise to flex the back muscles to resist this fulcrum effect and to utilize the upper torso to rock or jerk the leg exercise bar upward. This rocking or jerking, in turn, can cause back muscle strain or more serious back injury. The present invention minimizes the risks of such strain or injury. The present invention also allows the user to isolate the muscle groups for which this exercise is intended, by making it difficult to utilize other muscles to cheat on the exercise.
To facilitate the performance of the leg extension exercise, there is a prior art exercise bench having a platform including head and foot sections divided by a hinge which is fixed in position at the horizontal plane of the platform, and a means for raising the end of the foot section of the platform. Using this bench, the above-noted deficiencies with regard to the leg extension exercise are avoided. However, this prior art bench cannot be used or adapted to aid in the performance of the leg curl exercise for which the hinge should be raised above the level of the platform.
A prior art bench is also available having a platform fixed in the shape of an upside down "V" to overcome the above-described deficiencies of a flat bench for performing the second type of leg exercise. However, this prior art bench is conveniently usable for performing the leg curl. Moreover, none of the prior art exercise benches disclose the selective vertical translation of the pivoting means in the middle section of the platform.
Prior art exercise benches are also known in the art which combine the two types of leg exercise means into a single apparatus. In such benches, the horizontal bar is attached perpendicularly to a downward extending vertical bar to form a combination leg exercise means, which attaches to the frame of the bench near the intersection between said bars. The foregoing deficiencies of the two leg exercise means applies equally to this combination system.
There is a trend in the improvement of these exercise benches toward providing improved safety, increasing the number of different muscle groups which can be developed by its use, and enabling the selective isolation of various muscle groups for exercise. Thus, a weight lifter can specfically strengthen desired muscle groups. Similarly, body builders who, unlike weight lifters, exercise to develop the size and appearance of specific muscle groups, rather than strength, can also selectively isolate desired muscle groups. The present invention enables exercise bench users to achieve their goals by providing safer exercise equipment and improved isolation of the muscle groups.
SUMMARY OF THE INVENTION
The present invention comprises an improved exercise weight lifting bench having a frame, a platform supported by said frame, said platform being divided into a head section and a foot section, each section having first and second ends, each of said sections being pivotable with respect to said frame at their respective second ends, a first pivot means interconnecting said first ends of said head and foot sections, said first pivot means having a generally horizontal pivot axis transverse to the length of said platform, a means for adjusting the horizontal distance between the second ends of said head and foot sections to compensate for horizontal loss when said first pivot means is vertically displaced, and a means for raising and/or lowering said fist pivot means in a generally vertical direction from a horizontal plane defined by the position of said head and foot sections when they are coplanar, said first raising and/or lowering means being coupled to said first pivot means, and a means for securing said platform in the above-described positions. In the preferred embodiment, the invented exercise bench comprises both a front thigh, and a back thigh and buttocks exercise means.
When said first pivot means is lowered below the plane defined by the head and foot sections when they are horizontal, the thigh of a user laying on his back is angled upward and the lower portion of the leg is vertical thus forming an angle of greater than 90°. This angle forces the user to limit his movements to the muscles involved, thereby concentrating on the exercise of his front thigh muscles. The invented exercise bench also provides a greater range of rotational motion of the leg during the exercise.
When the first pivot means is raised above the planar position, the user lies on the platform on his stomach and his waist is bent over the crest formed at the first pivot means so that his upper torso extends on the head section of the platform. Thus, when the user curls the back leg exercise means towards his buttocks, the backward pull of this action is resisted mainly by the force of the upper body against the downward slanting platform of the bench, rather than solely by the weight of user's torso. Due to the configuration of the invented bench, there is a lesser tendency for the user to arch or jerk his back, and consequently, there is less risk of injury.
Other features of this invention as well as further uses and advantages will become more readily apparent by reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the invented exercise bench in the planar position.
FIG. 2 is a top plan view of the invented exercise bench with the platform pads shown in phantom lines.
FIG. 3 is an end view of the invented exercise bench taken through lines 3--3.
FIG. 4 is an end view of the invented exercise bench taken through lines 4--4.
FIG. 5 is a side view of the invented bench showing the mid-platform hinge in the raised position in solid lines and in the lowered position in phantom lines, and showing the leg exercise means in rest position in phantom lines and in raised position in solid lines.
FIG. 6 is another embodiment of the invented bench taken through lines 6--6, wherein the coupling means is provided with a continuous adjustment.
DETAILED DESCRIPTION
Referring now to the drawings wherein like numerals identify like elements, the invented bench 10 generally comprises a frame 20 having a head end 24 and foot end 26, a platform 22 installed horizontally on said frame, and a leg exercise means 30 pivotally connected to said frame 20.
The frame 20 generally comprises a head end base 51 disposed on the ground at the head end transverse to the long axis of the bench, a long axis cross-member 28 attached perpendicularly to said head end base 51 and disposed on the ground along the long axis of the bench, a foot end base 53 attached perpendicularly to said long axis cross-member 28 and disposed on the ground parallel to said head end base, a vertical head end support means 25 comprising two vertical bars 54a and 54b extending vertically upward from the ends of said head end base 51, a horizontal head end cross-member 55 extending between said vertical bars 54a and 54b for structural support, and a foot end vertical support member 27 extending upward from the foot end base 53 approximately perpendicular to the ground. In the preferred embodiment, the foot end vertical support is slanted, having its top portion 59 further away from the head end 24 than its bottom portion 60 to permit a greater range of motion of the front leg exercise means, as will be explained below.
While the preferred embodiment of the frame 20 has just been described, it will be appreciated by one skilled in the art that many variations and modifications of the bench frame can be made without departing from the nature and scope of the present invention.
The frame is also provided with a horizontal supporting bar 32, which provides structural support for the bench as well as operatively engages and supports the platform 22. The horizontal supporting member 32 is connected, at one end, to said head end cross-member 55 and, at the other end, to said foot end vertical support member 27. In the preferred embodiment the horizontal support member 32 slopes downward from said head end 24 to said foot end 26 of said bench 10. A receiving portion 35 of said horizontal supporting bar 32 is designed to receive a vertical support bar 40 which partially supports said platform 22.
The platform 22 is bisected, transversely to the long axis, thereof by a first pivot means 42, into head platform section 44 and foot platform section 46. Preferably, the first pivot means 42 is disposed corresponding approximately to the position of the hips of a typical user lying on the platform 22 with his knees adjacent the foot end 26, such that the two above-described leg exercises can be performed. First pivot means 42 is designed to permit upward and downward movement thereof from the planar position defined by the position of the platform when said head and foot sections are substantially coplanar as shown in FIG. 1.
The foot platform section 46 is pivotable with respect to the foot end vertical support member 27 at 47. The head platform section 44 preferably engages the horizontal support member 32, such that it is free to pivot along a vertical plane and move horizontally along the length of said horizontal support member 32, to compensate for loss in horizontal length of said platform 22 when said first pivot means 42 is raised or lowered from the planar position (see FIG. 5 and compare with FIG. 1). In the preferred embodiment, this is achieved by the installation of a pin 45 in said head platform section 44, which engages said horizontal support member 32, either rolling or sliding thereon. In an alternative embodiment, said horizontal support member can be provided with a slot in which pin 45 is disposed.
The vertical support member 40 is preferably attached to said platform at the first pivot means 42, although coupling of said platform 22 to said vertical support bar 40 at any position along said platform 22 is contemplated within the scope of the present invention.
In the preferred embodiment, the vertical support member 40 has at least three detent positions. A first detent 51a is disposed furthest away from said first pivot means 42a, such that when said detent 51a engages said horizonal support member 32, said hinge 42a is raised above the planar level, as shown in solid lines in FIG. 5. When a second detent 52a engages said horizontal support member 32, the platform 22 is substantially horizontal and planar as shown in FIG. 1. When a third detent 53a engages said horizontal support member 32, as shown in phantom lines in FIG. 5, the head platform section 44a lies on the horizontal support member 32, and no significant amount of force is placed on said vertical support member 40b in this configuration.
The remaining portions of the invented exercise bench are substantially the same as hereinbefore described, the difference in position being identified by the letter "a" after the identification number denoting those previously described elements in the raised position above the aforementioned horizontal plane, and the letter "b" after the identification number denoting those elements in the lowered position below said plane.
As exemplified in FIG. 5, a cutaway view of the intersection between vertical support member 40 and horizontal support member 32, the vertical support member 40 passes through a slot in the horizontal support member 32 and is supported by a pin 33 passing through said vertical member 40 at a predetermined detent, said pin 33 thereby engaging said horizontal support member 32.
In another embodiment of this invention, shown in FIG. 6, the vertical support member 40 is continuously adjustable with respect to horizontal support member 32, without any predetermined detents. In this embodiment, the vertical support member 61 comprises a slot 63 through which a bolt assembly 64 passes to secure said vertical support member 61 in a selected position.
As further exemplified in the drawings, the platform 22 comprises a platform frame 65 and platform cushion 66 disposed thereover for obvious comfort reasons.
The preferred embodiment of the invented bench further comprises the following elements. At least one "J"-shaped hook 18 is disposed on said head end vertical stand for supporting barbell weights for bench pressing and similar exercises.
At the foot end of the invented exercise bench 10 is a combination leg exercise means 30 comprising a front leg extension bar 41 including a padded portion 34 and a back leg curl exercise bar 35 including a padded portion 36. The dual leg exercise 30 means is pivotally attached at 37 to extension 67 on frame 20. In using the leg exercise means 30 from resting position, leg exercise means 30 is moved in direction D into a second position denoted by 30'. The aforementioned leg exercise means components disposed in the raised position, are similarly numbered with a "'" after the identification numbers to indicate the raised position.
Weights 38, shown in phantom lines, may be installed on post 39, thereby increasing the resistance to pivoting. In other embodiments, resistance may be applied to said leg exercise means 30 by spring or elastic attachments, hydraulic means, pulley systems, gears and the like.
In another embodiment of the present invention, the head platform section 44 can be fitted with head end raising means, which is well known in the art, so that the head platform section 44 is raised to a predetermined height above the foot end 26, thereby allowing certain bench pressing and other exercises to be performed.
In the preferred use of the present invention for exercising the front thigh, a user positions the platform in the lowered position with the vertical support 40b set in detent 53b, as illustrated in FIG. 5. The user lays on his back with his hips preferably approximating first pivot means 42b, such that he comfortably bends at the waist near first pivot means 42. The user's legs must bend at the knees over the end 57 and are disposed behind padded member 34. The user then tenses his front thigh muscles thereby straightening his leg. During the lift, the back of the knee acts as a fulcrum so that his upper torso presses forward toward and against the head platform section 56b. Due to this forward force, it is more difficult for a user to raise his legs from the hip (and thereby cheat on the exercise). Therefore, the flexion of the front thigh muscles is specifically concentrated to those muscles in this front leg extension exercise using the present invention. Moreover, since the angle between the upper leg and lower leg of a user lying on the bench as described above, is greater than 90° angle disclosed in the prior art exercise benches, the well known benefits gained by this longer range of motion are also achieved.
In the preferred use of the present invention for exercising the hamstrings and other muscle groups in the back of the thigh, the user adjusts the platform 22, such that detent 51a engages horizontal support member 32. The user then lies on his stomanch on platform 22a, preferably bending at the waist near first pivot means 42a. The back of the users lower leg abuts the bottom side of padded member 36. The user flexes his leg at the knee by curling it upward and forward toward his buttocks. The forward motion of the leg is resisted by the upper torso pressing towards the foot end 26 of the bench 10 and against the downward sloping head end section 44a of the platform, so that the counteracting forces of upper torso against the platform substantially eliminate the need for the user to do the same work with his back, and thus, the risk of back strain is reduced. Accordingly, because the user's body is draped over the platform, it is also more difficult to arch or jerk the back in order to cheat on this exercise. Thus, the possibility of back strain is further reduced. In addition, the muscles of the back thigh and buttocks are particularly angled with respect to the resistance load, so that these muscles are isolated in this exercise.
It will also be apparent to one of ordinary skill in the art that while a preferred embodiment has now been shown and described, various modifications can be made without departing from the spirit and scope of the invention.
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An improved exercise bench is disclosed having a frame, a generally horizontal platform supported by the frame, the platform being divided into a head end and foot end which are hinged together transverse to the long axis of the bench, the head and foot ends being angularly movable with respect to each other so that the hinge can be raised or lowered from a horizontal position thereby improving the range of motion, safety, and muscle group isolation achieved when performing leg exercises thereon.
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CROSS REFERENCE TO RELATED APPLICATIONS
This document claims priority to and incorporates by reference all of the subject matter included in the provisional patent application, having Ser. No. 61/505,350, filed Jul. 7, 2011.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the use of a near field communication antenna and a touch sensing device, wherein the antenna and the touch sensing device are used in close proximity to each other such that the near field communication antenna can interfere with operation of the touch sensing device.
2. Description of Related Art
The present invention describes the use of a touch sensing device in combination with a near field communication (NFC) antenna. The use of the term “touch sensing device” should be considered as interchangeable with the terms “touchpad”, “touch screen” and “touch sensitive device”. Likewise, the term near field communication antenna should be considered as interchangeable with the terms “contactless card reader”, “RFID reader” and “blue tooth antenna”. Furthermore, the “systems” referred to will include a combination of a touch sensing device and a near field communication antenna, using all of the interchangeable terms.
There are several designs for capacitance sensitive touchpads. It is useful to examine the underlying technology to better understand how any capacitance sensitive touchpad can be modified to work with the present invention.
The CIRQUE® Corporation touchpad is a mutual capacitance-sensing device and an example is illustrated as a block diagram in FIG. 1 . In this touchpad 10 , a grid of X ( 12 ) and Y ( 14 ) electrodes and a sense electrode 16 is used to define the touch-sensitive area 18 of the touchpad. Typically, the touchpad 10 is a rectangular grid of approximately 16 by 12 electrodes, or 8 by 6 electrodes when there are space constraints. Interlaced with these X ( 12 ) and Y ( 14 ) (or row and column) electrodes is a single sense electrode 16 . All position measurements are made through the sense electrode 16 .
The CIRQUE® Corporation touchpad 10 measures an imbalance in electrical charge on the sense line 16 . When no pointing object is on or in proximity to the touchpad 10 , the touchpad circuitry 20 is in a balanced state, and there is no charge imbalance on the sense line 16 . When a pointing object creates imbalance because of capacitive coupling when the object approaches or touches a touch surface (the sensing area 18 of the touchpad 10 ), a change in capacitance occurs on the electrodes 12 , 14 . What is measured is the change in capacitance, but not the absolute capacitance value on the electrodes 12 , 14 . The touchpad 10 determines the change in capacitance by measuring the amount of charge that must be injected onto the sense line 16 to reestablish or regain balance of charge on the sense line.
The system above is utilized to determine the position of a finger on or in proximity to a touchpad 10 as follows. This example describes row electrodes 12 , and is repeated in the same manner for the column electrodes 14 . The values obtained from the row and column electrode measurements determine an intersection which is the centroid of the pointing object on or in proximity to the touchpad 10 .
In the first step, a first set of row electrodes 12 are driven with a first signal from P, N generator 22 , and a different but adjacent second set of row electrodes are driven with a second signal from the P, N generator. The touchpad circuitry 20 obtains a value from the sense line 16 using a mutual capacitance measuring device 26 that indicates which row electrode is closest to the pointing object. However, the touchpad circuitry 20 under the control of some microcontroller 28 cannot yet determine on which side of the row electrode the pointing object is located, nor can the touchpad circuitry 20 determine just how far the pointing object is located away from the electrode. Thus, the system shifts by one electrode the group of electrodes 12 to be driven. In other words, the electrode on one side of the group is added, while the electrode on the opposite side of the group is no longer driven. The new group is then driven by the P, N generator 22 and a second measurement of the sense line 16 is taken.
From these two measurements, it is possible to determine on which side of the row electrode the pointing object is located, and how far away. Using an equation that compares the magnitude of the two signals measured then performs pointing object position determination.
The sensitivity or resolution of the CIRQUE® Corporation touchpad is much higher than the 16 by 12 grid of row and column electrodes implies. The resolution is typically on the order of 960 counts per inch, or greater. The exact resolution is determined by the sensitivity of the components, the spacing between the electrodes 12 , 14 on the same rows and columns, and other factors that are not material to the present invention.
The process above is repeated for the Y or column electrodes 14 using a P, N generator 24
Although the CIRQUE® touchpad described above uses a grid of X and Y electrodes 12 , 14 and a separate and single sense electrode 16 , the sense electrode can actually be the X or Y electrodes 12 , 14 by using multiplexing.
One problem with integrating a near field communication antenna and a touch sensing device is interference. For example, the strong magnetic field necessary to power a near field communication antenna that is used as a contactless card reader may create strong eddy currents within electrodes of the touch sensing device, thereby causing operation outside of specifications, and malfunctions or inoperability is the result. Similarly, a near field communication antenna can electrically couple to the electrodes of the touch sensing device. Thus, a near field communication antenna may cause magnetic field inductance and electric field coupling with the touch sensing device.
In a related interference problem, the touchpad creates strong electrostatic fields that are necessary to detect a finger. These strong fields often cause the near field communication antenna to have insufficient signal integrity.
The adverse effects of the both electrostatic field coupling and magnetic field inductance may be a result of 1) the near field communication antenna signal causing non-linear effects due to noise/interference signal levels being large enough to trigger ESD diodes in touch sensing device circuitry, 2) difficulty for the touch sensing device front-end electronics or analog-to-digital converters (ADCs) in tracking the interference also causing non-linear effects and error in measurement, and 3) the amplitude modulation frequency of near field communications is often very close to the touch sensing stimulus frequency, thereby creating in-band ground bounce.
It would be a further advantage to dispose the circuitry of the near field communication antenna and the touch sensing device near enough to each other to prevent eavesdropping or tapping into the signals between them to thereby provide an integrated system that is more secure than existing integrated systems. Furthermore, it would be an advantage to remove the electrical and magnetic interaction between them. Finally, it would also be of benefit to integrate the electronics into a single package to address the very limited space of the touch sensing device and the NEAR FIELD COMMUNICATION antenna and associated routing space typical of today's electronic appliances.
BRIEF SUMMARY OF THE INVENTION
In a first embodiment, the present invention is a method and system for enabling a near field communication antenna to be disposed adjacent to electrodes of a touch sensing device, the near field communication antenna being operated, and the magnetic field inductance and electric field coupling between the electrodes and the near field communication antenna being minimized in order to substantially reduce or eliminate induced currents on the electrodes.
These and other objects, features, advantages and alternative aspects of the present invention will become apparent to those skilled in the art from a consideration of the following detailed description taken in combination with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a block diagram of the components of a capacitance-sensitive touchpad as made by CIRQUE® Corporation and which can be successfully operated in conjunction with a near field communication antenna.
FIG. 2 is a diagram that illustrates a layout for a near field communication antenna and electrodes of a touch sensing device.
FIG. 3 is a diagram that illustrates a different layout for electrodes of the touch sensing device.
FIG. 4 is a diagram of a near field communication antenna and a signal source that will couple currents to electrodes of a touch sensing device.
FIG. 5 is a diagram showing an alternative embodiment of a near field communication antenna.
FIG. 6 is a diagram showing additional detail of the electrode grid that is combined with the alternative near field communication antenna.
FIG. 7 is a diagram showing additional detail of the electrode grid that is combined with the alternative near field communication antenna.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made to the drawings in which the various elements of the present invention will be given numerical designations and in which the invention will be discussed so as to enable one skilled in the art to make and use the invention. It is to be understood that the following description is only exemplary of the principles of the present invention, and should not be viewed as narrowing the claims which follow.
FIG. 2 is a diagram of electrodes of a near field communication antenna and electrodes of a touch sensing device. The present invention may be implemented in electrodes 40 of a touch sensing device 42 that are adjacent to a near field communication antenna 50 . For the purposes of this document, the term adjacent implies that operation of the near field communication antenna 50 may influence operation of the electrodes 40 by inducing current flow in the electrodes.
In this first embodiment, the near field communication antenna 50 is disposed in a same plane as the electrodes 40 . However, the near field communication antenna 50 may be in a different plane but substantially parallel plane as the electrodes 40 , either above or below. Furthermore, the electrodes 40 may be part of a touchpad, a touch screen, or any other touch sensing device as is known to those skilled in the art.
The near field communication antenna 50 is shown as being a loop of wire that is wound twice around the electrodes 40 . This specific layout or configuration for the near field communication antenna 50 is for illustration purposes only and should not be considered as limiting. The near field communication antenna 50 may be formed as a partial loop, a single loop or multiple loops around the electrodes 40 .
The first embodiment is directed to minimizing, reducing or substantially eliminating interference between the near field communication antenna and the electrodes 40 of the touch sensing device 42 when the near field communication antenna is operated. Reduced, minimized or substantially eliminated interference is defined as interference that is too small to prevent operation of the near field communication antenna 50 or the electrodes 40 of the touch sensing device 42 .
In the first embodiment, functions of the near field communication antenna 50 include, but should not be considered limited to, wireless communication functions such as using a contactless card reader for communication with a smart card, reading a smart card at keyless entry systems, or any other functions that require near field communication. The near field communication antenna 50 may or may not use relatively high voltages when compared to the voltages on the electrodes 40 of a touch sensing device 42 . Near field communication antennas are known to use voltages at least as high as 60 volts, while touch sensing devices may operate nearer to 5 volts. These voltages are only examples, and the systems are capable of operating at other voltages.
FIG. 2 is a first embodiment that may reduce or substantially eliminate interference by a near field communication antenna 50 on the electrodes 40 . The near field communication antenna 50 is connected to near field communication circuitry 52 . The electrodes 40 are connected to touch sensing device circuitry 42 .
For this example, current is flowing through the near field communication antenna 50 as shown by arrows 60 . A magnetic field is generated around the near field communication antenna 50 in the direction as shown by curved arrow 62 . Electrodes 40 that are nearest to the near field communication antenna 50 may have induced currents caused by the magnetic field generated by the near field communication antenna 50 .
The electrodes 40 are arranged to form a sensing area that may be a series of parallel rows of electrodes extending from a top edge 30 to a bottom edge 32 of the sensing area, each of the plurality of electrodes being electrically separate from each other. Each of the plurality of electrodes 40 follows a path that is beginning at a first edge 34 and ends at an opposite second edge 36 of the sensing area.
To reduce or substantially eliminate the tendency of the magnetic field to induce currents on the electrode 46 , the electrode is made to pass through the magnetic field twice. This is accomplished by extending the length of the electrode 46 at location 48 so that it is now twice as long as other electrodes 40 in the sensing area that is used for detecting objects. Because the electrode 46 may be essentially folded back on itself so that it spans the distance between opposites sides of the near field communication antenna 50 two times, the sum of current at location 66 may be reduced or substantially eliminated.
The electrode 54 that is shown near the bottom of the electrodes 40 is also shown as spanning the distance twice between opposite sides of the near field communication antenna 50 . Thus, the sum of current at location 68 may be reduced or substantially eliminated.
The electrodes 40 that are not immediately adjacent to the top or bottom edges of the near field communication antenna 50 are not shown as being doubled in length. This is because the effect of the magnetic field around the near filed communication antenna 50 may diminish rapidly. However, any electrode 40 that experiences magnetically induced currents can be made to travel back and forth between sides of the near field communication antenna 50 so as to eliminate the effect of induced currents. Therefore, this example should not be considered as limiting, but only as an illustration of principles of the present invention that demonstrate how to reduce or eliminate induced currents in the electrodes 40 .
While FIG. 2 illustrates the ability to reduce induced currents because of magnetic fields generated by the near field communication antenna 50 , it may not address the problems of electrostatic fields that couple to the electrodes 40 . Current flow through the near field communication antenna 50 also creates an electrostatic field around the near field communication antenna 50 that can couple to the electrodes 40 and also induce current flow.
FIG. 3 is provided as a top view of a near field communication antenna 50 connected to near field communication antenna circuitry 52 , wherein the antenna is disposed around electrodes 40 that are connected to touch sensing circuitry 42 .
In FIG. 3 , a sensing area is now formed from a series of concentrically aligned partial electrode loops 38 , the partial loops all being electrically open at a first location 78 , and having a connection to touch sensing circuitry 42 at an opposite second location 88 . Each of the partial electrode loops 38 may have two arms of substantially equal length. The induced current in a first arm of each of the plurality of concentrically aligned partial electrode loops 38 may be equal and opposite to the induced current in a second arm.
There may also be an electrode 90 of the electrodes 38 that is not formed as a partial loop but is instead formed as a “T” shape. This electrode 90 will be affected by the coupling of current from the near field communication antenna 50 in the same manner as all of the partial electrode loops 38 because it also has two arms of substantially equal length.
In FIG. 3 , arrows 70 show the direction of current flow in the near field communication antenna 50 in a moment of time. The direction of current flow may change because the signal source is an AC current, but for this moment in time, current flow 70 is in the indicated direction. Electrode 44 is shown as being split into two arms of approximately equal length. The magnetic field induces current in electrode 44 as indicated by arrows 72 and 74 . The sum of the current at point 76 is thus reduced or substantially eliminated.
It should be understood that the scale and spacing of the electrodes 38 and the near field communication antenna 50 is for illustration purposes only and should not be considered as limiting.
With the magnetic field accounted for, it may be possible to also affect current that is coupled from electrostatic fields. The electrostatic fields generated by the near field communication antenna 50 can also be coupled into the electrodes 38 because the current on the near field communication antenna is an AC current.
FIG. 4 is an illustration of the application of a stimulus signal on the near field communication antenna 50 . One side of the near field communication antenna 50 may be grounded 80 , while the other side 82 has a stimulus signal applied. Disadvantageously, the result may be a coupling of a net change in voltage of approximately half of the maximum applied voltage on the electrodes 40 shown in FIG. 3 .
To overcome this problem of coupling voltage onto the electrodes 38 , a stimulus signal source is used as shown in FIG. 3 . FIG. 3 shows that there are stimulus signals 84 , 86 on each end of the near field communication antenna 50 . The stimulus signals 84 , 86 may be 180 degrees out of phase with respect to each other. The effect of the stimulus signals 84 , 86 may be a coupling of a net change in voltage of approximately zero volts on the electrodes 38 shown in FIG. 3 .
Another way to characterize the stimulus signals 84 , 86 is to say that they form a differential signal source. The same amount of current may still be applied to the near field communication antenna 50 , but by using the differential signals 84 , 86 , the near field communication antenna may no longer be radiating a signal that is being coupled to the electrodes 38 . Thus, the configuration of the near field communication antenna 50 still radiates a magnetic field, but the differential signals 84 , 86 may eliminate or substantially reduce the electrostatic field.
It is an aspect of the present invention that the design of the electrodes that will reduce or substantially eliminate induced currents caused by operation of the near field antenna may be changed from the examples illustrated herein. However, any such changes are considered to be within the scope of the principles of the present invention and should be considered to be within the scope of the claims herein.
It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention. The appended claims are intended to cover such modifications and arrangements.
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A method and system for enabling a near field communication antenna to be disposed adjacent to electrodes of a touch sensing device, the near field communication antenna being operated, and the magnetic field inductance and electric field coupling between the electrodes and the near field communication antenna being minimized in order to substantially reduce or eliminate induced currents on the electrodes.
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This application claims priority from U.S. Provisional Application Ser. No. 60/276,090 filed Mar. 16, 2001 and U.S. Provisional Application Ser. No. 60/314,101 filed Aug. 23, 2001. The entirety of those provisional applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fluorescent biosensor that functions by a novel Quencher-Tether-Ligand (QTL) mechanism. In particular, the present invention relates to improving the polymer-QTL approach by co-locating the fluorescent polymer (or polymer ensemble, including self-assembled polymers) and a receptor for the QTL bioconjugate and target analyte on the same solid support.
2. Discussion of the Background
The polymer-QTL (Quencher-Tether-Ligand) approach is a single-step, instantaneous, homogeneous assay where the amplification step is intrinsic to the fluorescent polymer. The polymer-QTL approach provides a system for effective sensing of biological agents by observing fluorescence changes. The key scientific basis is the amplification of quenching of fluorescence that can be obtained with certain charged conjugated polymers and small molecule quenchers. In addition, the process is uniquely simple because there are no reagents.
In the “biosensor” mode, the QTL approach functions by having a fluorescent polymer quenched by a specially constructed “quencher-tether-ligand” (QTL) unit as shown in the diagram set forth in FIG. 1 . Addition of an analyte containing a biological receptor specific to the ligand is expected to remove the QTL conjugate from the polymer which results in a “turning on” of the polymer fluorescence. A fluorescent polyelectrolyte-based superquenching assay has been shown to offer several advantages over conventional small molecule based fluorescence assays. For example, conjugated polyelectrolytes, dye-pendant polyelectrolytes, etc. can “harvest” light effectively both by absorption and by superquenching (1–5). The enhanced absorbing power of the polymers is indicated by the observation that even sub nanomolar solutions of some of these materials are visibly colored. The fluorescence of these polymers can be detected at even lower concentrations. Superquenching occurs in the presence of small molecules capable of serving as electron transfer or energy transfer quenchers to the polymer or one of its repeat units.
The “Stern-Volmer” quenching constants (K SV ) for these polymers have been shown to be as high as 10 8 –10 9 M −1 , and it is anticipated that values as high as 10 11 M −1 may be attainable (6). Such high values for K SV toward quenchers oppositely charged to the polyelectrolyte are initiated by strong nonspecific binding between the quencher and the polyelectrolyte. Subsequent amplified quenching occurs due to a combination of excitonic delocalization and energy migration to the “trapsite” where the quencher is in close proximity with the polymer.
It has also been shown that enhanced superquenching may be obtained when the polymers are adsorbed onto charged supports including surfaces, polymer microspheres, and inorganic nanoparticles (7,8). Superquenching has also been observed in the same supported formats for monomers or small oligomers self-assembled into “virtual” polymers. Polymer (and “virtual” polymer) superquenching has been adapted to biosensing by constructing QTL conjugates containing a potential superquenching component (Q) tethered (T) to a bioreceptor (L) or ligand for a specific biomolecule (1).
A fluorescence based assay is realized when the QTL conjugate is used to quench the polymer either in solution or in supported formats at solution-solid or solution-particle interfaces (1,7,8). For example, fluorescent polyelectrolytes, including conjugated and J-aggregate polymers, can be used for sensitive biodetection and bioassays in solution formats. The basis of this detection is the combination of the “superquenching” sensitivity of these molecules to quenchers of opposite or neutral charges with the synthesis of a quencher-recognition conjugate (e.g., a QTL molecule). In the original formulation, the QTL conjugate quenches the polymer ensemble by nonspecific binding. Addition of a target bioagent capable of binding with the L component of the QTL conjugate results in a removal of the QTL conjugate from the polymer and a turning on of the polymer fluorescence.
A fluorescence turn off (or modulation) assay has also been developed based on polymer superquenching (5). In this case, the target molecule is a bioagent L, or L′, corresponding to the L component of the QTL conjugate, and the receptor is a biomolecule that strongly associates with L, L′ or the QTL conjugate. One example is a direct competition assay in which L (or L′) in unknown amount is allowed to compete with the QTL conjugate for the binding sites of a measured amount of the receptor. The polymer fluorescence is quenched by non-bound QTL to an extent depending on the amount of L (or L′) present. In another example, the QTL conjugate is preassociated with the receptor; when all of the QTL conjugates are associated with the receptor sites, no quenching is observed. Addition of L (or L′) to the sample results in the release of the QTL conjugate with concomitant quenching of the polymer fluorescence.
All of the above assay formats depend on nonspecific quenching of the polymer fluorescence by association of the QTL conjugate with the polymer. A complication with these assays is the competing nonspecific interactions of other components of the assay sample with either the polymer, the QTL conjugate, or both, which result in a modulation of the quenching. In the present invention, modifications of the polymer superquenching allow the construction of improved assays which overcome these effects and provide for a more versatile and robust sensor.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a novel chemical moiety formed of a quencher (Q), a tether (T), and a ligand (L) specific for a particular bioagent.
It is another object of the invention to provide an assay to detect a target agent in a sample using the novel QTL molecule of the present invention and a fluorescent polymer.
It is yet another object of the invention to rapidly and accurately detect target biological agents in a sample.
It is a feature of the invention that the fluorescent polymer and the receptor for the target biological agent are co-located on a support.
It is another feature of the invention that the co-located fluorescent polymer and the receptor are tethered to the support.
It is yet another feature of the invention that the co-located fluorescent polymer and receptor are covalently linked to the support.
It is also a feature of the present invention to covalently link the receptor to the fluorescent polymer.
It is a further feature that the change in fluorescence is indicative of the presence of the target biological agent.
It is another feature of the invention that the quench event is a result of a specific interaction between the receptor and the QTL conjugate.
It is yet another feature of the present invention that the assembled monomers behave like polymers.
It is an advantage of the invention that the assays of the present invention can be carried out in operationally different formats.
A further advantage of the invention is the versatility provided by the ability to control the co-located assembly of a specific polymer ensemble-receptor either spatially as on a rigid support or on different particles.
It is another advantage of the present invention that assays according to the present invention are both homogeneous and near instantaneous.
It is yet another advantage of the invention that the ability to control the co-located polymer assembly either spatially (e.g., on a rigid support) or on different particles offers great versatility.
It is a further advantage that superquenching occurs due to specific ligand-receptor interactions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general illustration of the QTL approach.
FIG. 2 illustrates various fluorescent compounds, quenchers, and QTL conjugates used in the present invention.
FIG. 3 illustrates various fluorescent compounds, quenchers, and QTL conjugates used in the present invention.
FIG. 4 illustrates structures of dyes used with polysaccharides in inclusion complexes.
FIG. 5 is a general illustration of a displacement competition assay.
FIG. 6 is a general illustration of a direct competition assay.
FIG. 7 is an illustration of the competitive fluorescence “turn-on” assay with the polymer-biomolecule combination.
FIG. 8 illustrates the co-location of a polymer and a receptor by a covalent/adsorption sequence.
FIG. 9 illustrates the covalent tethering of both the polymer and the receptor binding site.
FIG. 10 illustrates a receptor covalently linked to a polymer.
FIG. 11 is an illustration of a sandwich QTL assay.
FIG. 12 illustrates various compounds used in the examples of the present invention.
FIG. 13 is a graphical illustration of the quenching of fluorescence as a function of the loading level.
FIG. 14 is a graphical illustration of a competition assay for goat anti-rabbit IgG antibody.
FIG. 15 is a graphical illustration of an IgG assay with polymer 25 linked covalently to a receptor.
FIG. 16 illustrates the synthesis of cyanine dye 26 covalently appended to a silica microsphere surface.
FIG. 17 is an illustration of the structure of QSY-21 Succinimidyl Ester.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A key scientific basis for the polymer QTL approach is the amplification of quenching of fluorescence (superquenching) that may be obtained with certain polymers (including, but not limited to, charged polymers, conjugated polymers and dye-pendant polyelectrolytes in which the chromophores are collected by non-covalent interactions (e.g., J-aggregation)) and small molecule quenchers. The fluorescent polymers provide amplification over conventional molecular fluorophores both by virtue of their light-harvesting properties (collective excitation) and their sensitivity to superquenching (i.e., one quencher may extinguish luminescence from an entire polymer chain or a collection of polymers, oligomers, or monomers). In some cases, enhanced quenching may be observed when mixtures of polymers are used or when the polymers are adsorbed or otherwise assembled onto surfaces. The same enhancement of quenching can be observed when monomers or oligomers of some of the chromophore repeat units are assembled either by covalent attachment or adsorption onto a support. The support may be, but is not limited to, any of the following: polymer or silica microspheres, organic or inorganic nanoparticles, magnetic beads or particles, semiconductor nanocrystals, tagged or luminescent particles, membranes and planar or corrugated solid surfaces.
Fluorescent polymer superquenching has been adapted to biosensing applications through the use of “QTL” bioconjugates (1, 4–6, 8). The QTL approach to biosensing takes advantage of the superquenching of fluorescent polyelectrolytes by electron transfer and energy transfer quenchers. In its simplest approaches, the fluorescent polymer, P, forms an association complex with a QTL bioconjugate, usually one with the opposite charge of P. QTL bioconjugates include a small molecule electron transfer or energy transfer quencher (Q), linked through a covalent tether to a ligand, L, that is specific for a particular bioagent or receptor. The binding of the QTL bioconjugate by the bioagent either removes the QTL bioconjugate from the fluorescent polymer, or modifies its quenching efficiency, thus allowing sensing of the bioagent in a readily detectable way.
Suitable examples of ligands that can be used in “QTL” methods include chemical ligands, hormones, antibodies, antibody fragments, oligonucleotides, antigens, polypeptides, glycolipids, proteins, protein fragments, enzymes, peptide nucleic acids (PNAs), and polysaccharides. Examples of suitable tethers include, without limitation, single bonds, single divalent atoms, divalent chemical moieties of up to approximately 100 carbon atoms in length, multivalent chemical moieties, polyethylene, polyethylene oxides, polyamides, non-polymeric organic structures of at least about 7–20 carbon atoms, and related materials. Suitable quenchers include methyl viologen, quinones, metal complexes, fluorescent and nonfluorescent dyes, and energy accepting, electron accepting, and electron donating moieties. These examples of the ligand, tethering elements, and quenchers are not to be construed as limiting, as other suitable examples would be easily determined by one of skill in the art.
Polymer-Polymer Ensembles and Their Application to Biosensing
The fluorescent polyelectrolytes typified by compounds 1 and 2 in FIG. 2 show, in addition to their adsorption properties, a very strong tendency to associate with oppositely charged macromolecules, including other polyelectrolytes and each other. Cationic conjugated polymer 8, together with compounds 1 and 2, form a series of three fluorescent polyelectrolytes with absorption maximum wavelengths that span the range from the near ultraviolet to the visible-infrared, especially by varying the cyanine substituent in compound 2.
The association of two oppositely charged fluorescent polyelectrolytes can lead to several interesting and potentially useful effects considering the association of compounds 1 and 2. For example, the association of nearly equimolar, in repeat units, amounts of compounds 1 and 2 results in an ensemble that is overall close to neutral, yet consists of discrete regions of negative and positive charges. Since compound 2 shows an emission at lower energies than compound 1, it is observed that energy transfer should occur. Thus, excitation into regions where the absorption should be primarily by compound 1 results in predominant emission by compound 2. Since compound 2 has a very sharp emission, the harvesting of energy within the ensemble provide possibilities to tune both the absorption and emission properties far beyond that which is available within a single polymer. A most striking advantage obtained by using an ensemble such as the combination of compounds 1 and 2 is that both anionic and cationic small molecule quenchers can quench the overall near-neutral polymer mixture. As a result, it is observed that the ensemble is quenchable (independently) by both anionic compound 4 and cationic compound 3. More importantly, the quenching can be observed at very low concentrations of either quencher such that the degree of superquenching shows only a slight attenuation compared to quenching of the individual polymers by the oppositely charged small molecule.
These results show that the polymer-polymer approach offers distinct advantages for biosensing by the polymer-QTL method. The polymer ensemble can be quenched by both positive and negatively charged QTL bioconjugates. Therefore, either in quench/unquench formats or in a competitive assay, the polymer-polymer ensemble provides a means of obtaining higher selectivity and specificity. Furthermore, the degree of quenching by either cationic or anionic quenchers can be tuned directly by varying the stoichiometry of the polymer mixture. For example, when polymer 1 and polymer 2 are mixed in a ratio of 100:1, the superquenching by cationic QTLs is maintained and no quenching by anionic QTLs is observed. However, efficient energy transfer is still observed to polymer 2 even at this low ratio. By going to a 2:1 ratio of polymer 1: polymer 2, superquenching by both cationic and anionic QTLs is observed. Thus, charge tuning of the QTL assay is achieved by altering the stoichiometry of the anionic and cationic polymer. Both the net charge of the supramolecular cluster and the energy transfer characteristics of the combination may be tuned in this manner.
Multiplexed Detection Using Mixtures Containing Supported Polymer
The interaction of anionic and cationic fluorescent polymers can be eliminated by first anchoring either polymer to a bead or other supported format. For example, it has been demonstrated that anchoring polymer 2 to a clay suspension, prior to the addition of polymer 1 prevents the association of polymers 1 and 2. In this way, independent superquenching of each polymer is achieved in a single solution upon addition of either cationic or anionic quenchers.
Supported Formats for Monomers, Oligomers and Polyelectrolytes
Fluorescent polyelectrolytes, including conjugated and J-aggregate polymers, can be used for sensitive biodetection and bioassays in solution formats. The basis of this detection is the combination of the “superquenching” sensitivity of these molecules to quenchers of opposite or neutral charges with the synthesis of a quencher-recognition conjugate (QTL). One improvement of the polymer-QTL approach involves anchoring the fluorescent polymer onto a solid support via adsorption. Several advantages can result from this adsorption.
Fluorescent polyelectrolytes, including, but not limited to, compounds such as those shown in FIGS. 2 and 3 may be readily adsorbed from aqueous or mixed aqueous-organic solutions onto oppositely charged surfaces such as slides, plates, oppositely charged polymer beads (such as, but not limited to, quaternary amine-derivatized polystyrene or sulfonated polystyrene), and natural or synthetic inorganic supports such as clays or silica, charged membranes, or other porous materials. Once adsorbed onto these supports, the polymers retain their intense fluorescence as well as their sensitivity to specific quenchers. The fluorescent polymers incorporated into these formats may be used in advanced assays as described below.
The incorporation of a fluorescent polymer onto a charged polymer bead can result in the reversal of the charge specificity in quenching of the polymer fluorescence as well as in improved performance in assays involving the polymer in either fluorescence quench or fluorescence unquench modes. In one example, the anionic conjugated polymer 1 is effectively quenched by low concentrations of the positively charged electron acceptor 3 in aqueous solution. However, its fluorescence is largely unaffected in solution by the addition of the negatively charged electron acceptor 4. When polymer 1 is treated with a suspension of quaternary amine (cationic) derivatized polystyrene beads (Source 30 Q), the polymer is removed from solution and is irreversibly adsorbed onto the beads. In this supported format, the highly fluorescent beads can be suspended in an aqueous solution and treated with the same quenchers. A reversal of the quenching sensitivity is observed; in the supported format, the anionic electron acceptor 4 quenches polymer 1, while the fluorescence of polymer 1 is no longer quenched by cationic electron acceptor 3.
The charge reversal of fluorescence quenching can be adapted to biosensing by the polymer-QTL approach. Thus, QTL conjugate 5, which contains an anthraquinone quencher similar to anionic electron acceptor 4 and a biotin ligand, is also observed to quench the fluorescence of polymer 1. Upon addition of the protein avidin (a specific receptor for biotin), the quenching produced by conjugate 5 is reversed and virtually complete recovery of the fluorescence of polymer 1 is observed. This contrasts with aqueous solutions where a viologen-based conjugate 6 has been shown to elicit a similar quench-recovery response with polymer 1. For both polymers 1 and 2, when dissolved in aqueous or partially aqueous solutions, nonspecific effects are frequently observed upon the polymer fluorescence by addition of macromolecules, particularly proteins leading to either partial quenching or enhancement. These interactions may occur with analyte proteins or with proteins not anticipated to interact with the specific QTL conjugate employed in the sensing and may interfere with specific effects due to the interaction of an “analyte” protein with the polymer QTL complex. These nonspecific effects maybe eliminated or attenuated by employing polymers in supported formats.
A second example involves the use of the QTL conjugate 7, which quenches the fluorescence of polymer 1 by energy transfer. While anionic compound 7 does not quench the fluorescence of anionic polymer 1 in pure aqueous solutions, adsorption of polymer 1 on beads results in its quenching upon the addition of compound 7 and fluorescence recovery upon addition of avidin.
Adsorbing a fluorescent polymer on a charged support may not always lead to charge reversal in the quenching of the polymer. The charge reversal, or lack thereof, can be tuned by the degree of “loading” of the polymer onto sites on the support. In a different example, it is demonstrated that enhanced quenching can be obtained for a supported polymer as a consequence of adsorption. Thus, when cationic polymer 2 is adsorbed onto anionic Laponite clay particles, the polymer fluorescence is still subject to quenching when small amounts of anionic acceptor 4 are added to the aqueous suspension. Under these loading conditions, polymer 2 is not quenched by cationic acceptors such as compound 3. Quantitative analysis of the extent of quenching by compound 4 under these conditions indicates that the clay-supported polymer 2 is quenched more effectively (in this example by more than 30%) than when it is in a pure aqueous solution. This example illustrates two concepts that lead to improved biosensing with the polymer-QTL approach using supported polymers. The first concept is that the supported polymer can be used to “sense” oppositely charged quenchers when supported on the clay particles and yet exhibit improved stability with respect to degradation and precipitation (observed for aqueous solutions). When the same polymer is supported on the clay at lower loading levels, its fluorescence is quenched by cationic compound 3, thus demonstrating a charge reversal similar to that cited above with polymer 1. The second concept from these experiments with clay-supported polymer 2 and its quenching by compound 4 is that increased quenching sensitivity can be obtained due to polymer-polymer association effects on the clay particles. This increased quenching sensitivity may result from an increase in the J-aggregate domain (or conjugation length for conjugated polymers).
The combination of enhanced quenching sensitivity and the ability to tune the quenching sensitivity in supported formats as described above greatly extends the potential of the polymer-QTL approach both in regards to sensitivity and versatility. Additionally, the anchoring of fluorescent polyelectrolytes on beads, surfaces, or membranes can expand the utility of the polymer-QTL approach. Thus, the strong adsorption of the polymers onto beads or membranes can provide detection of analytes in a “flow-through” mode using either liquid or vapor streams. Additionally, the tethering of the polymer onto plates in a multi-well array format by adsorption demonstrates the use of these formats in high throughput screening and rapid sampling applications. Furthermore, the elimination of nonspecific effects upon anchoring to a bead surface greatly enhances the practical usage of QTL-based assays.
Virtual Polymers Based on Covalent Attachment of Supramolecular Building Blocks
Enhanced superquenching provides a new means of obtaining superquenching from much smaller oligomers and even monomers in an adsorbed format. Thus, it is possible to synthesize polymer 2 in a range of repeat unit sizes varying from n=3 to n=1000. It would be anticipated that, to a first approximation, in solution, the higher molecular weight polymers should exhibit higher quenching efficiencies due to an “amplification factor” that should be directly proportional to the number of repeat units (6). However, as the number of repeat units increases, the solubility of the polymer decreases and the complexity of the polymer allows new channels for nonradiative decay to attenuate the effectiveness of quenchers. Therefore, in the case of polymer 2, the potential for attaining maximum sensitivity by using very high molecular weight polymers cannot be recognized. The use of smaller oligomers (or even monomers) in an adsorbed format permits the construction of effective higher order polymers by the formation of extended aggregates that bridge across adjacent polymer (or monomer or oligomer) molecules. This provides for enhanced levels of superquenching and thus new sensors of greatly enhanced sensitivity.
Assembly of cyanine dye monomer 15 or oligomers 10 on silica or clay nanoparticles results in the formation of “J” aggregates that exhibit high superquenching sensitivity (i.e., surface activated superquenching) to ionic electron transfer or energy transfer quenchers. This can be attributed to a combination of high charge density (and resulting Coulombic interactions) and excitonic interactions within the self-assembled units. These assemblies also can be used as biosensors in the QTL fluorescence quench-unquench mode. These virtual polymers can be easily assembled from a variety of monomer or small building blocks, often bypassing difficult steps of polymer synthesis, purification, and characterization. Although studies to date have shown self-assembled virtual polymers to be relatively stable with little sensitivity in their fluorescence to added macromolecules, it is clear that the small adsorbed units may be subject to desorption or rearrangement under certain conditions, most notably high ionic strength. An approach that combines the simplicity of using small building blocks assembled on a surface with a more robust analysis platform involves the covalent tethering of monomers on the surface of a neutral or charged nanoparticle, bead, or other rigid support.
In one example, a relatively simple synthetic scheme similar to that developed for the cyanine poly-L-lysine 10 was employed in the construction of cyanine dye 15 covalently attached to the surface of 0.2 μm diameter silica microspheres. The cyanine dye thus linked to the microsphere surface was found to exist both as small clusters of the monomer and as highly ordered aggregates. Efficient exiton migration/energy transfer between the dye clusters and aggregates was observed when the material was suspended in water containing 2% dimethylsulfoxide. The suspension also showed a 27% reduction in emission intensity in the presence of 27 nM anionic quencher 13, indicating that superquenching of the covalently-linked dye assemblies occurs. The modes of interaction between cyanine dye monomers on the microsphere may be controlled by varying the density and structure of functional groups present on the surface. Thus, the efficiency of biosensing can be optimized. Similar schemes may be used to append other cyanine dyes and other building blocks such as conjugated polymer oligomers onto a bead, particle, or other solid surfaces.
Virtual Polymers Appended onto Quantum Dots by Self-Assembly or Covalent Tethers: Coupling of Quantum Dots with QTL Bioassays
The assembly of cyanine dyes (including, but not limited to, the chromophore of structures 10 and 15) or other molecules capable of forming aggregates onto a particle or surface provides a platform for biosensing based on superquenching. The superquenching can be controlled by the charge of the assembled film or the surface or a combination thereof. Biosensing may be accomplished either by fluorescence “turn-on” or “turn-off” assays and in direct and competition modes. While the assembly may have relatively strong light-absorbing properties, in a number of cases, the absorption of J-aggregates is very sharp and limited to a very narrow portion of the visible spectrum. A significant enhancement of light-harvesting properties may be obtained by constructing the assembly on top of a layer or particle having strong absorption (and high oscillator strength) at higher energies. This can be accomplished in Langmuir-Blodgett Assemblies and complex multilayered films built up by layer-by-layer deposition.
The construction of an assembly of dyes or other molecules on a surface-capped semiconductor nanoparticle “quantum dot” offers a convenient and effective way of enhancing the biosensing capabilities of the virtual polymers described above. Although quantum dots have been investigated for several years, recent advances have made possible the preparation of quantum dots of high stability, variable size, versatile wavelength tunability for both absorption and emission properties, and controlled surface properties and functionality. Thus, it is possible to use an appropriately constructed and derivatized quantum dot as a support on which to construct a virtual polymer. The quantum dot “platform” is selected to have good energy donor properties towards a specific cyanine dye, cyanine dye aggregate, conjugated polymer oligomer, or other building block that can be used in a QTL bioassay. The combination affords an attractive, versatile, yet relatively simple way of enhancing the sensitivity and extending the wavelength range of the QTL biosensor. Both direct adsorption onto the quantum dot or covalent attachment or anchoring of dots and polymers on a microsphere surface may be used to construct the quantum dot-sensing ensemble. Examples of quantum dots include (but are not limited to) CdS, CdSe and ZnS.
QTL Bioassays Based on Assemblies and Inclusion Complexes of Dye Monomers, Oligomers, and Conjugated Polymer Oligomers in Natural and Functionalized Polysaccharides
A wide range of investigations have shown that the starch-derived polymers amylose and carboxymethylamylose (CMA), which consist of linear, unmodified or derivatized 1,4 glucose polymers, can form complexes with hydrophobic or amphiphilic molecules that can exist as moderately linear conformations. The complexed “guest” amphiphiles exhibit restricted mobility and, in some cases, a degree of protection from other reagents present in the same solution with the amylose (or CMA) and its guest. The entrapment is attributed to formation of a helical sheath of the glycoside which surrounds a guest within the cavity. Helices with different radii can be formed to entrap guests of different sizes. Unmodified amylose is overall neutral while CMA (which is reasonably easily synthesized with variable loading of the carboxymethyl groups) is anionic. Analogous derivatization processes are possible to prepare amylose derivatives with other functionalities and/or charge. Several amphiphilic or hydrophilic molecules incorporating dyes or aromatic chromophores and exhibiting low solubility in water or aqueous-organic mixtures can be solubilized in amylose or CMA solutions with the guest chromophores entrapped within amylose (or CMA). Among examples of the latter are photo- and thermochromic dyes, highly luminescent stilbene amphiphiles, and other photoreactive compounds.
Amylose, CMA, and other polysaccharides can form complexes with strongly absorbing amphiphilic molecules including appropriately derivatized squaraine dyes, bissquaraines, and some conjugated polymer oligomers such as poly (phenyl)ethynyl oligomers. Structures of some of these compounds selected are shown in FIG. 4 . In each case, the compounds are either actually or potentially highly fluorescent in homogeneous solution. Additionally, they are either insoluble in water or very slightly soluble. Structurally they are able to form complexes with either amylose, CMA, or other modified amylose polymers. When incorporated with a charged amylose polymer, they become soluble in water, strongly fluorescent, and somewhat protected from association (such as face-to-face interactions which quench fluorescence) and adventitious quenching by nonspecific interactions with other solutes. The ability of the amylose and CMA hosts to collect multiple guests allows the gathering of several molecules of the host chromophores shown in FIG. 4 . The high oscillator strength of the chromophores allows excitonic interactions to occur even when the chromophores are not in direct contact. These excitonic interactions provide a way of forming another “virtual polymer” similar to those described above. This virtual polymer may be subject to quenching by electron transfer or energy transfer quenchers that are brought into close proximity with the amylose or CMA helix containing the guest dyes or oligomers. This association may be obtained through Coulombic interactions between the quencher and complex or by other interactions that lead to strong association. Targeted superquenching by these quenchers can thus be obtained for included molecules such as those shown in FIG. 4 , even when the individual molecules are not subject to superquenching. As described above, it is straightforward to extend superquenching to the use of QTL bioconjugates and to apply these bioconjugates in extensions of the QTL fluorescence quench-unquench and competitive assay formats.
The present invention is a further extension of the use of superquenching in biosensing. By co-locating a bioreceptor and a fluorescent polymer (or “assembled polymer”) on a surface or colloidal particle, the interaction between the two components (quencher (Q) of the QTL and the polymer ensemble) is rendered a specific interaction by the ligand-receptor binding. Thus, the assay is not dependent upon nonspecific charge-based interactions between the quencher and the polymer ensemble. An additional advantage of the present invention is the versatility afforded by the ability to control the co-located assembly of a specific polymer ensemble-receptor either spatially (for example, on a rigid support) or on different particles. This greatly expands the ability of the QTL approach to be used for multiplexing several target agents.
All of the assay formats of this invention rely on a co-location of a fluorescent polymer (or fluorescent “self-assembled” polymer assembly) and an appropriate receptor for a target analyte on a support. The support can be a microsphere or nanoparticle, a membrane, cuvette wall or the surface of a microtiter plate or glass slide, or any surface that may be interrogated by continuous or intermittent sampling (illumination/detection). The direct advantage of this approach is that in each case, the superquenching occurs due to a specific ligand-receptor interaction. Several different examples are discussed in the following sections. Further, the assays may be carried out in operationally different formats depending upon the specific requirements.
Displacement Competition Assay
In the Displacement Competition Assay, the anchored fluorescent polymer-receptor is pretreated with the QTL conjugate, resulting in the binding of the QTL conjugate to the receptor and concurrent superquenching of the fluorescent polymer. As shown in FIG. 5 , the actual analysis involves the addition of an analyte to the ensemble. The fluorescence of the polymer increases quantitatively (turn on) with the level of the target agent in the analyte sample. Suitable examples include proteins, viruses, bacteria, spores, cells, microorganisms, antibodies, antibody fragments, nucleic acids, and toxins. In this example, the assay may be homogeneous and the actual time for the assay may be controlled by the “off rate” of the QTL from the receptor.
Direct Competition Assay
As shown in FIG. 6 , in the Direct Competition Assay, the anchored fluorescent polymer-receptor is treated with a mixture containing an analyte (an unknown amount of the target agent) and a known amount of QTL conjugate. The polymer fluorescence is quenched to an extent determined by the QTL:target agent concentration ratio. The stronger the fluorescence, the higher the concentration of the target agent. An advantage of this approach used is that the assay may be both homogeneous and near instantaneous. Since both the target agent and the QTL conjugate compete directly for “open” receptor sites, the response can be very rapid.
In another formulation, the anchored fluorescent polymer-receptor is incubated with an analyte sample before the fluorescence intensity of the sample is measured. The sample is then treated (following rinse steps as necessary) with an excess of a QTL conjugate. The initial reading of fluorescence following treatment with the QTL conjugate shows quenching due to binding of the QTL conjugate to unoccupied receptor sites. The stronger the initial fluorescence quenching, the smaller the level of target agent. Monitoring the polymer fluorescence as a function of time provides additional confirmation of the binding of the target agent and its replacement by the QTL conjugate at the receptor.
A “Turn on” Competitive Assay Based on Polymer-Biomolecule Combinations
Polymers that contain reactive end groups (e.g., polymer 10) may be covalently linked to a variety of materials, including small molecules, other polymers, and biomacromolecules. The resulting “hybrid molecule” may have similar solubility and will generally have the same ability as the individual polyelectrolyte component to adsorb to a surface. These surfaces include slides or plates, oppositely charged polymer beads (such as, but not limited to, quaternary amine-derivatized polystyrene or sulfonated polystyrene), natural or synthetic inorganic supports such as clays or silica, charged membranes, semiconductor nanocrystals, and other porous materials. Thus, either independently or as a component of a mixture, the use of a hybrid molecule can afford the preparation of a supported assembly containing a highly fluorescent species subject to superquenching. The hybrid molecule may also be employed in a solution-phase assay.
In one example, the carboxyl or amine terminus of an amino acid polymer such as polymer 10 may be linked to a primary amine of a protein or antibody or antibody fragment to give a fluorescent compound 23. (See FIG. 7 ). This compound can either be used in solution or can be deposited on a surface such as is described above. In either format, the biomolecule portion of compound 23 should retain its specific recognition function. Thus, treatment of compound 23 with a QTL bioconjugate results in formation of a complex that allows the quenching component to extinguish the fluorescence from compound 23. The exposure to molecules such as L or L′ that can compete with the QTL binding site can result in displacement of the bound QTL bioconjugate and a turning on of the fluorescence from compound. The most effective utilization of compound 23 will generally be on a surface or bead or other supported format where the aggregation of the fluorescent species can result in enhanced superquenching sensitivity. The hybrid molecule thus serves as a molecular or supramolecular (in supported formats) sensor whose function is shown schematically in FIG. 7 .
In another example, a sensor/assay may be achieved in a supported format by collecting individual (i.e., not covalently linked) polymer and biomolecule components on the same bead, particle, or nanostructure. For example, carboxyl functionalized beads or particles may be used both to covalently bind a protein, antibody, or antibody fragment via an amine group on the protein (as described above) and to bind a monomer (such as 15), oligomer or polymeric fluorescent dye such as 10 by adsorption or covalent attachment. Provided there is no significant quenching interaction between the dye ensemble and the biomolecule, the “dual coated” beads will be strongly fluorescent. Here again, a competitive fluorescence “turn-on” assay may be constructed by the use of a QTL bioconjugate that associates with the biomolecule. Further, the addition of the QTL bioconjugate will result in a quenching of the dye ensemble fluorescence. Addition of a reagent L or L′ that can compete with the QTL bioconjugate for the binding site will result in the expulsion of the QTL molecule from the bead or particle and an increase (or unquenching) of the dye ensemble fluorescence. Because the spatial range for quenching is increased, a preferred embodiment will be the case where Q is an energy transfer quencher. This will allow the quenching of all polymers within the Foerster transfer radius of the receptor-bound QTL molecule. For polymers bound on surfaces, this radius can be approximately 100 Angstroms or more.
The dual coated beads or particles can also be used in a fluorescence “turn-off” competitive or noncompetitive assay. Treatment of the beads (initially uncomplexed) with an antigen (L or L′) will result in the binding of the antigen to the biomolecule, but with negligible fluorescence changes. Addition of an aliquot of a QTL molecule that can bind, but not compete with L or L′ will result in a quenching of the polymer fluorescence in a “turn-off” response, that is proportional to the number of receptor sites not occupied by the antigen. A QTL molecule that can compete with antigen L or L′ will give a time-dependent response which can be used to measure both the level of antigen present and the strength of its binding to the biomolecule.
The central component of the above-mentioned assays is the supported (and co-located) fluorescent polymer-receptor ensemble. They may be constructed (but is not limited to) as outlined in the following examples. In the first example, a receptor, or “receptor binding site” is covalently attached to a support. Subsequently a fluorescent polymer may be adsorbed onto the same support as illustrated in FIG. 8 . Examples of receptors that may be covalently attached include proteins such as avidin, neutravidin or streptavidin or antibodies, peptides and nucleic acids. The degree of loading of both fluorescent polymer and receptor can be controlled to obtain sensors having varied sensitivity and dynamic range. In a second example, as shown in FIG. 9 , both the polymer and receptor may be covalently tethered to the support. In another formulation, illustrated in FIG. 10 , a polymer or oligomer doped with a reactive group is tethered to a receptor by a covalent linkage and adsorbed to a support. The polymer may be first adsorbed and then covalently linked to the receptor or vice versa. To take advantage of enhanced superquenching provided by “self-assembled” polymers, the fluorescent “polymer” ensemble can be constructed from monomers that may be collected by either self-assembly (adsorption) or covalent linkage. Depending upon the requirements of the assay and the component “polymer” and receptor, the receptor may be covalently linked to the support before or following generation of the self-assembled polymer.
In addition to the assays based on direct binding of a QTL conjugate to the fluorescent polymer-receptor ensemble, assays may also be constructed based on secondary recognition events. For example, the current platforms can be extended to a sandwich format in which a target agent having multiple binding sites for the same or other receptor is sensed. This format is illustrated in FIG. 11 . Binding of the target agent to a receptor site causes little or no change in the fluorescent polymer fluorescence. However, addition of a QTL conjugate which also binds to the receptor results in bringing the quencher close enough to quench the fluorescence in a direct assay. Such a sandwich assay can be adapted to sense a variety of agents including bacterial spores.
Having generally described the invention, a further understanding can be obtained by reference to certain specific examples provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLES
Example 1
Commercial polystyrene beads containing streptavidin covalently tethered to the surface(0.53 micron microspheres purchased from Bangs Laboratories, Inc., Fishers, Ind.) were coated with the anionic conjugated polymer 24, a derivative of poly(phenyleneethynylene) (PPE) (structures 24–27 are shown in FIG. 12 ). The level of loading of 24 on the surface can be controlled depending on the loading of the polymer. The number of biotin binding sites (maximum biotin-FITC binding capacity=1.42 ug/mg of microspheres) is also variable and controllable. For an initial assessment of the ability of the coated microspheres to function in biosensing, a QTL conjugate formed of an energy transfer quencher (Alexafluor 594, purchased from Molecular Probes) was conjugated to the streptavidin ligand biotin. In separate studies it was demonstrated that nonspecific quenching of the polymer fluorescence by non-biotinylated Alexafluor 594 does not occur. Depending on the level of coating, the K SV was found to vary between 3×10 7 and 3×10 8 M −1 over two logs of QTL concentration. The level of the QTL detected by direct binding to the receptor in a conventional 96-well plate was less than 100 femtomoles. For this assay, it was determined that an intermediate level of polymer loading onto the beads gave optimal initial quench sensitivity and a wide dynamic range. (See FIG. 13 ).
To generalize the assay using these beads, biotinylated antibodies can be used to tether specific receptors. The binding of the biotinylated antibodies produces little change in the fluorescence of the polymer. However, the addition of a conjugate recognized by the antibody and containing an energy transfer quencher does result in quenching of the polymer fluorescence. Thus, as shown in FIG. 14 , it has been demonstrated that a biotinylated capture antibody can bind to an antibody-based QTL conjugate (target antibody derivatized with an energy transfer quencher) and be detected at levels less than one picomole).
From this example, it is evident that the same beads can be used to construct a wide array of assays based on antibody-antigen interactions. In the general case, two additional components are required: a biotinylated antibody or other receptor and a QTL conjugate that is recognized by the antibody. All three of the assay paths described above can be used with these beads. The use of labeled beads (e.g., a polystyrene bead labeled in the interior of the bead with a fluorescent dye tag having distinct fluorescent wavelengths) or different polymers with different antibodies or receptors allows for the simultaneous assay of multiple target analytes.
Example 2
A somewhat lower molecular weight PPE oligomer, monofunctionalized with carboxylate 25, was adsorptively coated on quaternary ammonium-derivatized polystyrene microspheres. Following deposition, rabbit anti-goat IgG antibodies were covalently linked to the polymer through the available carboxyl functionality. The fluorescence of the polymer remained strong following the antibody coupling and showed little sensitivity toward photobleaching. However, the fluorescence of the ensemble of oligomers was quenched specifically by the addition of goat anti-rabbit IgG conjugated to the fluorescent energy transfer quencher, Alexafluor 532. Fluorescence quenching could be detected at <500 fmole levels in a 96-well plate format. (See FIG. 15 ). Additionally, goat anti-rabbit IgG antibodies coupled with the nonfluorescent energy transfer quencher QSY35 also exhibited quenching on association with the bead-anchored polymer-antibody receptor. In this case, a K SV =8×10 7 M −1 was measured in the sub to few picomoles concentration range.
Example 3
Cyanine dyes exhibit induced J-aggregation on anionic nanoparticles and microspheres. For simple cyanine monomers such as 26, adsorption onto clay or silica particles is reversible and thus individually coated particles coated with different cyanine dyes or cyanine mixtures exhibit exchange among the cyanines. It has been determined that the use of amphiphilic cyanine dyes such as the derivative of 26 where the N-ethyl groups have been replaced by N-octadecyl groups results in molecules that can be irreversibly adsorbed onto silica microspheres. Thus, individual amphiphilic cyanine dyes or mixtures of amphiphilic cyanines may be coated separately onto silica microspheres and then mixed with silica microspheres coated with other formulations of cyanine amphiphiles. The mixtures show no evidence of exchange of cyanines between different particles and thus permit the use of these mixtures for the simultaneous sensing of multiple agents. The use of energy accepting amphiphilic guests such as the corresponding amphiphilic cyanine to 4 results in the same emission wavelength shifting and affords the construction of several ensembles capable of emitting fluorescence at different wavelengths from the same host amphiphilic cyanine.
The fluorescence of the aggregated cyanine dye may be quenched by either cationic or anionic energy accepting cyanine dyes or by electron transfer quenchers. This quenching can be tuned by varying the level of coating of the cationic cyanine dye on the anionic nanoparticle or microsphere. At low loading of the particle with a cationic cyanine, the particle has regions of exposed negative charge and positively charged quenchers are attracted (and exhibit high superquenching constants) while potential anionic quenchers show low quenching via these nonspecific interactions. At high loading of the particles, the situation is reversed and anionic quenchers show attractive but nonspecific interactions and consequent high quenching constants while cationic quenchers are ineffective. For clay nanoparticles, optimum results occur with near 100% coverage of the clay surface by a cyanine or cyanine mixture. At this level of coverage, selective quenching by anionic quenchers occurs. For cyanine dye aggregates on the clay nanoparticles, the most effective quenching occurs when like-charged cyanines are co-adsorbed.
For example, the addition of energy accepting cationic cyanine 27 to excess cyanine 26 results in 50% quenching when the ratio of compound 26 to compound 27 ratio is 400:1. The quenching of 26 by 27 results in the sensitized emission of 27 and offers a potential advantage in separating the excitation and emission of the nanoparticle-supported ensemble. These particle-bound “self-assembled polymers” offer a convenient platform for sensing similar to those discussed above in Example 1 and 2. Coating of cyanine monomer or a mixture (such as 26 and 27) onto anionic microspheres or nanoparticles that already have a covalently anchored receptor such as streptavidin or an antibody can result in the formation of regions of J-aggregate or mixed aggregate on all accessible anionic surfaces of the support. This renders the ensemble overall slightly cationic and therefore of very low susceptibility to nonspecific association with cationic quenchers. However, cationic QTL conjugates can associate with the particles by specific ligand-receptor interactions in the same ways as described in the Examples 1 and 2 above. Thus, the superquenching of the self-assembled polymers can be harnessed in improved biosensing through specific association in the co-located receptor-self-assembled polymer ensembles.
Example 4
The same kind of self-assembled polymers may also be constructed by covalent linkage of cyanine (or other monomers) onto a densely functionalized surface. As shown in FIG. 16 a , the same cyanine chromophore present in 26 can be constructed by covalent attachment in two stages. It has been determined that amine functionalized silica microspheres can form a platform onto which a high level of coverage can be obtained. For microspheres coated only with the monomer, it is found that, depending on the surface derivatization and reaction conditions, different populations of at least three species are obtained. The first species has absorption and fluorescence close to those of the monomer. A second, longer-wavelength absorbing species shows very similar absorption and emission to the J-aggregate of 26 described above. The third species exhibiting a somewhat broadened emission at longer wavelengths is usually not prominent in absorption but frequently includes the predominant emission, regardless of the wavelength at which the mixture is excited. It has been found that quenching by non-specific interactions can be observed for anionic electron transfer dyes (AQS-Biotin (5) ( FIG. 2 ), K SV =3×10 7 M −1 ) and for a cationic energy transfer dye (QSY-21 (6) ( FIG. 17 ), K SV =5.3×10 8 M −1 ) at subpicomole levels of quencher. In order to construct a sensor analogous to those described in the Examples above, the covalently-linked cyanine was constructed with varying amounts of an additional functionalized site containing a carboxyl group as shown in FIG. 16 b . Once the dye has been tethered to the surface, the carboxyl sites may be used to append a receptor as outlined in Example 2 set forth above. The appending of a receptor on the surface of the covalently tethered “self-assembled polymer” has the advantage of shielding the dye from non-specific association with potential quenchers and restricting quenching interactions to QTL conjugates associating specifically with the receptor.
The invention of this application has been described above both generically and with regard to specific embodiments. Although the invention has been set forth in what is believed to be the preferred embodiments, a wide variety of alternatives known to those of skill in the art can be selected within the generic disclosure. The invention is not otherwise limited, except for the recitation of the claims set forth below.
REFERENCES
1. L. Chen, D. W. McBranch, H.-L. Wang, R. Helgeson, F. Wudl and D. G. Whitten, “Highly-Sensitive Biological and Chemical Sensors Based on Reversible Fluorescence Quenching in a Conjugated Polymer”, Proc. Nat'l Acad. Sci. USA, 96:12287 (1999).
2. L. Chen, D. McBranch, R. Wang and D. G. Whitten, “Surfactant-Induced Modification of Quenching of Conjugated Polymer Fluorescence by electron Acceptors: Applications for chemical Sensing”, Chem. Phys. Lett., 330:27–33 (2000).
3. L. Chen, S. Xu, D. McBranch and D. G. Whitten, “Tuning the Properties of Conjugated Polyelectrolytes Through Surfactant Complexation”, J. Am. Chem. Soc., 122:9302–9303 (2000).
4. D. Whitten, L. Chen, R. Jones, T. Bergstedt, P. Heeger, D. McBranch, “From Superquenching to Biodetection; Building Sensors Based on Fluorescent Polyelectrolytes” in “Molecular and Supramolecular Photochemistry, Volume 7: Optical Sensors and Switches”, Marcel Dekker, new York, eds. V. Ramamurthy and K. S. Schanze, Chapter 4, pp 189–208 (2001).
5. R. M. Jones, T. S. Bergstedt, C. T. Buscher, D. McBranch, D. Whitten, “Superquenching and its applications in J-aggregated cyanine polymers”, Langmuir, 17:2568–2571 (2001).
6. L. Lu, R. Helgeson, R. M. Jones, D. McBranch, D. Whitten, “Superquenching in cyanine pendant poly-L-lysine dyes: dependence on molecular weight, solvent and aggregation”, J. Am. Chem. Soc., in press.
7. R. M. Jones, T. S. Bergstedt, D. W. McBranch, D. G. Whitten, “Tuning of Superquenching in layered and mixed fluorescent polyelectrolytes”, J. Am. Chem. Soc., 123:6726–6727 (2001).
8. R. M. Jones, L. Lu, R. Helgeson, T. S. Bergstedt, D. W. McBranch, D. Whitten, “Building highly sensitive dye assemblies for biosensing from molecular building blocks”, Proceedings Nat'l. Acad. Sci. USA, 98:14769–14772 (2001).
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A chemical composition including a fluorescent polymer and a receptor that is specific for both a target biological agent and a chemical moiety including (a) a recognition element, (b) a tethering element, and (c) a property-altering element is disclosed. Both the fluorescent polymer and the receptor are co-located on a support. When the chemical moiety is bound to the receptor, the property-altering element is sufficiently close to the fluorescent polymer to alter the fluorescence emitted by the polymer. When an analyte sample is introduced, the target biological agent, if present, binds to the receptor, thereby displacing the chemical moiety from the receptor, resulting in an increase of detected fluorescence. Assays for detecting the presence of a target biological agent are also disclosed.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to building materials and more particularly to materials used for sound insulation.
[0002] In building modern structures, such as single-family houses or commercial buildings, an important factor to consider is noise control. In order to provide a quiet environment, sounds originating from sources such as televisions or conversation must be controlled and reduced to comfortable sound pressure levels. To achieve such an environment, builders and designers must address a multitude of factors, among them the construction and composition of building component assemblies that separate rooms from other rooms or from the outside environment. Such assemblies may, for example, take form as interior walls, exterior walls, ceilings, or floors of a building.
[0003] The term “transmission loss”: is expressed in decibels (dB) and refers to the ratio of the sound energy striking an assembly to the sound energy transmitted through the assembly. A high transmission loss indicates that very little sound energy (relative to the striking sound energy) is being transmitted through an assembly. However, transmission loss varies depending on the frequency of the striking sound energy, i.e., low frequency sounds generally result in lesser transmission loss than high frequency sounds. In order to measure and compare the sound performances of different materials and assemblies (i.e., their abilities to block or absorb sound energy), while also taking into account the varying transmission losses associated with different sound frequencies, builders and designers typically use a single-number rating called Sound Transmission Class (STC), as described by the American Society For Testing and Materials (ASTM). This rating is calculated by measuring, in decibels, the transmission loss at several frequencies under controlled test conditions and then calculating the single-number rating from a prescribed method. When an actual constructed system is concerned (i.e., where conditions such as absorption and interior volume are not controlled in a laboratory environment), the single-number rating describing the acoustical performance of such a system can be expressed as a field STC rating (FSTC), which approximates a STC rating when tested on-site. The higher the FSTC rating of a constructed system, the greater the transmission loss.
[0004] A conventional wall assembly 300 (called a wood stud wall) is shown in FIG. 3 and consists of two gypsum boards 303 (also referred to as drywall or sheetrock skins) attached directly to either sides of wood studs 301 . The space between the wood studs 301 may be filled with some type of fibrous insulation 305 (e.g., fiber glass batts). A wall assembly such as assembly 300 generally results in transmission loss values between STC 30 and STC 36 , because although the cavity area between the wood studs 301 is filled with sound insulation material 305 , sound energy can easily pass through the structural connections between the wood studs 301 and the gypsum boards 303 . Accordingly, assembly 300 is generally ineffective in reducing sound energy transmission.
[0005] Several methods are currently used by builders to produce wall and ceiling/floor assemblies with higher FSTC ratings than the performance of a basic wood stud configuration. One such method is the use of resilient channels in a wall assembly 400 , shown in FIG. 4 a . This method involves inserting one or more thin metal channels 407 between one of the drywall skins 403 and framing members 401 . The resilient channels 407 act as shock absorbers, structural breaks, and leaf springs, reducing the transmission of vibrations between a drywall skin 403 and the framing members 401 . However, the resilient channel technique is difficult to install correctly and requires excessive labor costs. It is very easy to “short out” a resilient channel 407 by improper nailing techniques (e.g., screwing long screws into the wood studs 401 behind the resilient channel 407 ). When this occurs, the sound isolation of wall assembly 400 remains unimproved. Similarly, problems relating to the difficulty of installing resilient channels may result when the technique is used to sound-isolate floor-ceiling assemblies.
[0006] The use of resilient channels also increases the overall thickness of a wall or floor-ceiling assembly by at least ½ inch. This increase may prevent a builder or designer from using standard components that typically interface with a wall or floor-ceiling assembly. An example of such a component may be a doorjamb, where the increase in a wall assembly may necessitate the use of an expensive, non-standard size door jamb.
[0007] Other current practices involve staggering the positions of wall studs 401 (as illustrated in FIG. 4 b ) or using double stud construction (as illustrated in FIG. 4 c ). These methods create a larger cavity depth and can reduce the structural connections between wall assembly components 401 and 403 , thereby allowing an assembly 400 to achieve relatively high FSTC ratings. However, both of these methods double the cost of framing and increase the thickness of wall assembly 400 by approximately two to four inches, which increases installation and material costs as described above.
[0008] In addition, various sound absorbing or barrier materials are currently used to provide a structural break between wall studs or floor-ceiling joists and the boards attached to them. Examples of such materials include GyProc® by Georgia-Pacific Gypsum Corporation and 440 Sound-A-Sote™ by Homasote and Temple-inland SoundChoice™. While capable of providing additional sound-transmission loss, these materials are generally dense and heavy, resulting in high handling and installation costs.
[0009] Accordingly, what is needed is a low-cost material between the framing members and building boards either in sheets or strips that can be installed in wall or floor-ceiling assemblies to provide additional substantial acoustical performance, while requiring less installation steps than current practices and allowing the use of standard size components to interface with the assemblies.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a combination sound-deadening board that is economical and provides relatively high acoustical performance improvement.
[0011] According to a first embodiment of the present invention, a combination sound-deadening board is provided, comprising a layer of structural skin, and a layer of sound-deadening material, wherein the material has an equivalent Young's Modulus (bulk modulus of elasticity) between 50 and 600 pounds per square inch (psi) and a thickness between ¼ and 1 inch, and is attached to the layer of structural skin to form a single laminate structure. This Young's Modulus may be achieved through means of basic material properties (true Young's Modulus), or by the physical alteration of the board to make the modulus appear lower when installed in the described manner. Kerfing, grooving, waffle cuts and boring are all examples of such alterations.
[0012] According to a second embodiment of the present invention, a building component assembly is provided, comprising at least one assembly framing member, and at least one combination sound-deadening board that is a single laminate structure comprising a structural skin layer attached to a sound-deadening material, wherein the sound-deadening material has an equivalent Young's Modulus (bulk modulus of elasticity) between 50 and 600 pounds per square inch and a thickness between ¼ and 1 inch, and that at least one combination sound-deadening board is attached to the assembly framing member such that the sound-deadening material faces the assembly framing member. Kerfing, grooving, waffle cuts and boring are all examples of such alterations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Other objects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments, when read in conjunction with the accompanying drawings wherein like elements have been represented by like reference numerals and wherein:
[0014] [0014]FIG. 1 illustrates a wall assembly built in accordance with the present invention;
[0015] [0015]FIG. 2 illustrates a floor-ceiling assembly built in accordance with the present invention;
[0016] [0016]FIG. 3 illustrates a conventional wall assembly;
[0017] [0017]FIGS. 4 a - b illustrate conventional methods of sound control in wall assemblies; and
[0018] [0018]FIG. 5 illustrates a combination sound-deadening board in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] [0019]FIG. 5 illustrates a combination sound-deadening board 503 , which includes a structural skin side 511 and a sound-deadening side 509 . Skin side 511 may be in the form of conventionally-known wallboards (also called leaves), such as plywood, plasterboard, or gypsum board. Sound-deadening side 509 is made of a sound-deadening material, which is described below. The two full-sheet sides 509 and 511 are attached or adhered in such a way that they form a single laminate, that is, board 503 . In other words, sides 509 and 511 can be transported and installed as a single multi-layer board 503 . The attaching process that creates multi-layer board 503 may occur either during the manufacturing of the structural skin or may occur as a secondary step.
[0020] [0020]FIG. 1 illustrates a wall assembly 100 including wall studs 101 and a combination sound-deadening board 103 . Studs 101 may be standard wall studs, made of either wood or metal (e.g., steel), and may be lightweight (25 gauge) or heavyweight (20, 18, or 16 gauge). As seen in the figure, board 103 is attached to studs 101 in such a way that sound-deadening side 109 is positioned between skin side 111 and each stud 101 . In this way, sound-deadening side 109 reduces vibration transmission between side 111 and the studs 101 , resulting in enhanced sound isolation between rooms located on either side of assembly 100 ., Analytical modeling and laboratory testing has shown that optimum sound control performance results when sound-deadening side 109 has a Young's Modulus (bulk modulus of elasticity) between 50 and 600 pounds per square inch, a value much lower than the stiffness values associated with conventional materials used in building wall or floor-ceiling assemblies (e.g., gypsum boards and wood studs). Modeling and testing also showed that materials with an equivalent Young's Modulus (bulk modulus of elasticity) between 50 and 500 pounds per square inch, were found to offer broadband improvements with a maximum of 6 to 8 dB improvement at the Hz one-third octave band. More specifically, materials with an equivalent Young's Modulus (bulk modulus of elasticity between 500 to 600 pounds per square inch, were found to offer broadband improvements with a maximum of 3 to 4 dB improvement at the 1600 Hz one-third octave band. Therefore, materials with Young's Moduli within the described range offer the best sound control performance, while materials with higher Young's Moduli offer some improvement in terms of sound transmission loss.
[0021] Existing materials that possess Young's Modulus values less than those of conventional wall or floor-ceiling assembly materials are not currently being used in sound-control applications. An example of such a material that is also non-resiliently compressible is isocyanurate foam sheathing (also called “iso foam”), which is currently used only for thermally insulating exterior walls and not for sound-deadening interior wall or floor-ceiling assemblies. Another example is blue closed cell sill seal foam, a non-resiliently compressional material also not normally used for sound-deadening interior wall or floor-ceiling assemblies. Of course, any material with Young's Modulus less than the Young's Modulus values of conventional wall or floor-ceiling assembly materials may be used in the present invention as sound-deadening side 109 . As described above, however, a preferred range of sound control performance results when the material has a Young's Modulus from 50 to 600 psi.
[0022] Sound-deadening side 109 preferably has a thickness of between about 0.125 to 1 inch and may be manufactured from a wide variety of materials, including, but not limited to, a cellulosic fiber material (e.g., recycled newsprint), perlite, fiber glass, EPDM rubber, or latex. Side 109 also is preferably manufactured to a density of 9 to 14 pounds per cubic foot, which is less than the density of current sound-control boards. For example, 440 Sound-A-Sote™ has a density of 26 to 28 pounds per cubic foot and Temple-inland SoundChoice™ has a density of 15 to 20 pounds per cubic foot. The material of side 109 is therefore much lighter and less stiff than current sound-control boards, resulting in higher ease of handling and lower installation costs. Testing has shown that the installation of a sound-deadening material such as sound-deadening side 109 between the skins and studs of a wall assembly can yield STC ratings of 41 or higher. In contrast, an unimproved wall assembly, as mentioned before, has a maximum STC rating of about 36.
[0023] [0023]FIG. 2 shows another application of combination sound-deadening boards having a sound-deadening side meeting the above-described requirements (i.e., the requirements for compressional stiffness, thickness, and density). In floor-ceiling assembly 200 , a board 203 is attached in such a way that a sound-deadening side 209 is positioned between a floor skin side 211 and joists 201 . Board 213 is attached in such a way that a sound-deadening side 219 is positioned between a ceiling skin side 221 and the other sides of joists 201 . Sound-deadening side 209 and sound-deadening side 219 may both be made of the same material, or may be made of two different materials, each meeting the above-described requirements. Of course, assembly 200 may include only one of the two combination boards 203 and 213 (meaning that only one board includes attached sound-deadening material), or may include both as shown. STC ratings of approximately 50 may be achieved in such a configuration as floor-ceiling assembly 200 .
[0024] The installation of combination sound-deadening board 103 (and board 203 ) is far less complex than conventional sound control methods for wall and floor-ceiling assemblies. In fact, installers using such a board would simply cut the board to a desired size and attach it (e.g., using conventional gas or fluid-powered automatic fasteners) to a stud or joist just as they would with conventional gypsum board, keeping in mind, however, that the side of the board made of sound-deadening material must be positioned against the stud or joist. In this way, the steps of installing structural skin and sound-deadening material are combined into one step, providing an economical method of achieving a high acoustical performance in a wall or floor-ceiling assembly. In addition, the simplicity of board installation also establishes high confidence that a wall or floor-ceiling assembly installed with the board will perform as specified by a building designer. Further, the use of a combination sound-deadening board as described above may allow a builder or designer to use standard size interfacing components (e.g., door jambs) because the installation of such a board would not greatly increase the thickness of a wall or floor-ceiling assembly. Also, a combination sound-deadening board possessing the above-described characteristics may also provide some type of thermal benefit (e.g., if the sound-deadening side is made of A/P foam sheathing) and/or moisture control.
[0025] It will be appreciated by those skilled in the art that the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the invention is indicated by the appended claims rather than the foregoing description and all changes that come within the meaning and range and equivalence thereof are intended to be embraced therein.
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A sound-deadening laminate, comprising a structural skin having a first face; and a layer of sound-deadening material, wherein the material has an equivalent Young's Modulus between 50 and 600 psi and is attached to the first face of the structural skin to form a laminate structure. The sound deadening laminate may be attached to framing members of a building.
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FIELD OF THE INVENTION
This application describes a new process for the production of polysaccharides, especially xanthan gum, by fermentation. Xanthan gum is a polyanionic polysaccharide used as a thickener and emulsifier in the food, pharmaceutical and cosmetic industries. It is also used by the oil industry as a component of drilling mud and as an agent for tertiary oil recovery. The present world market for xanthan gums is about 10,000 tonnes per annum valued at about 70,000,000.
BACKGROUND OF THE INVENTION
Xanthan gum is produced commercially by batch fermentation in submerged culture. Xanthomonas juglandis and X. campestris are examples of suitable organisms. Culture fluids develop extremely high viscosity and pseudoplasticity, which have a seriously detrimental affect on the oxygen transfer capabilities of conventionally designed and operated fermenters. This inevitably leads to the fermentation becoming limited by the oxygen transfer rate supported by the reactor and results in low xanthan yields and extended fermentation times.
The above difficulties could, in theory, be overcome in two different ways:
(i) by improvements in fermenter design, resulting in higher aeration efficiencies.
(ii) by controlling the oxygen demand of the culture without affecting productivity.
This invention is concerned with the latter approach. Polysaccharide biosynthesis is an energy-consuming process and oxygen is therefore required during fermentation for both growth and xanthan biosynthesis, which occur simultaneously in the conventional batch processes. The oxygen requirements for the two processes may be estimated as follows:
(i) Oxygen required for cellular biosynthesis
When a typical prokaryotic microorganism grows aerobically on a medium in which glucose is the sole carbon source, approximately 50% of the carbon is catabolised to produce carbon dioxide and water with the generation of ATP. ##STR1## The remaining carbon is metabolised to produce cellular material. Thus for every mole of glucose utilised for cellular biosynthesis, 3 moles of diatomic oxygen are required. The figure of 16 moles of ATP per mole of glucose is a generally accepted figure for prokaryotic microorganisms.
(ii) Oxgen required for xanthan biosynthesis
The biosynthetic pathway of xanthan gum is not fully understood but it is generally considered that the addition of a single hexose monomer unit to the xanthan polymer requires two molecules of ATP. ##STR2## Thus, for every 9 moles of glucose utilised for xanthan biosynthesis, 6 moles of diatomic oxygen are required.
From these estimates it can be deduced that cellular biosynthesis requires 4.5 times more oxygen than xanthan biosynthesis.
The objective of the present invention is to regulate the oxygen demand by the separation of growth and product biosynthesis using a two-stage fermentation process. In the first stage, conditions are employed that permit growth of the organism but not xanthan biosynthesis. Since a high viscosity will not develop in the absence of polysaccharide, the relatively high oxygen demand, similar to that experienced to conventional fermentations, can be met without problems. In the second stage, growth will be prevented and only polysaccharide biosynthesis will occur. Although a high viscosity will inevitably develop, the oxygen demand of the culture will be significantly lower than in conventional processes since energy will not be required for growth but only xanthan biosynthesis. The oxygen requirement of the organism will thus be more easily satisfied. Furthermore, by controlling the amount of growth occurring in the first stage, the oxygen demand during the second stage may actually be regulated.
DISCUSSION OF THE PRIOR ART
No. GB-1513061 discloses a process for the continuous production of polysaccharides of the alginic acid type in which a bacterium of the species Azotobacter vinelandii is cultivated under conditions such that the concentration of saccharide carbon source is limiting on growth of the bacterium, polysaccharide biosynthesis being simultaneous with bacterial growth. In this process, oxygen supply is related to the efficiency with which the monosaccharide or disaccharide carbon source is converted into the polysaccharide product, limitation of the oxygen supply limiting growth of the bacteria.
U.S. Pat. No. 3,328,262 describes a continuous process for polysaccharide synthesis in which cells of an appropriate organism are initially grown in a low carbohydrate medium, with little formation of the polysaccharide. The cells were then fed to a reactor for the formation of polysaccharide, in a continuous procedure, fresh culture medium being fed into the reactor as the polysaccharide-containing product was run off. In such a process, continued growth of the micoorganism will proceed with the synthesis of the polysaccharide. In this way a continuous culture was possible without the organisms losing their ability to synthesize the polysaccharide.
SUMMARY OF THE INVENTION
The present invention provides a method for the synthesis of polysaccharides by culturing polysaccharide-producing microorganisms in a nutrient-containing medium which comprises culturing said microorganisms in a first stage under conditions such that growth of the microorganisms takes place preferentially with restricted polysaccharide synthesis, and in a second stage, polysaccharide synthesis takes place with substantially no growth of the microorganisms.
DETAILED DESCRIPTION OF THE INVENTION
In one preferred embodiment, the first stage is conducted until growth of the microorganism substantially ceases in the presence of a predetermined quantity of carbon-containing nutrient, which do not support polysaccharide biosynthesis, e.g. glycerol or xylose.
In another embodiment, the first stage is accomplished in at least two consecutive fermentation vessels, in the first of which a continuous culture is employed, and in the second of which growth is restricted by the rate of supply of carbon-containing nutrients until such time as further growth of the culture becomes limited by an element other than carbon. The growth of the microorganisms in the continuous culture can also be limited by carbon containing nutrients.
In a preferred embodiment, a carbohydrate is added in the first stage continuously at a rate that increases exponentially as the multiplication of the microorganisms takes place.
In all embodiments, the second stage can be conducted by adding a carbohydrate to the medium, in a single portion or at intervals as synthesis of the polysaccharide takes place, in the exclusion of one or more nutrients required for growth of the microorganisms.
Preferably the microorganisms are of the genus Xanthomonas, more preferably of the species Xanthomonas campestris or Xanthomonas juglandis. Other Xanthomonas species that can be used include Xanthomonas begoniae, Xanthomonas carotae, Xanthomonas hederae, Xanthomonas incanae, Xanthomonas malvacearum, Xanthomonas papavericola, Xanthomonas phaseoli, Xanthomonas pisi, Xanthomonas translucens, Xanthomonas vasculorum and Xanthomonas vesicatoria.
Whilst the invention is especially applicable to production of xanthan gum using organisms of the Xanthomonas genus, it is also applicable to the production of other microbial exopolysaccharides, e.g. the production of pullulan by organisms of the Aureobasidium genus, and the production of Alginic acid by organisms of the genus Azotobacter.
A number of methods of implementing the invention are possible. In each, the first objective is, of course, to permit rapid growth whilst preventing xanthan production. Having achieved this, the second objective is then to permit xanthan production whilst preventing growth. The first objective is the more difficult of the two to achieve.
One method of achieving growth without xanthan biosynthesis involves the use of carbon sources that do not support xanthan production, the composition of the medium being carefully balanced so that one element that is essential for growth (other than carbon, which is also essential for xanthan biosynthesis) becomes exhausted at the end of the first stage. This element is preferably nitrogen, although other minerals such as phosphorus, potassium, sulphur, magnesium or calcium may also be used.
In a second method, a carbon source that supports both growth and xanthan production is used. The method of cultivation is, however, designed to limit the specific growth rate below the maximum by restricting the supply of the carbon substrate. When the supply of carbon substrate is restricted, that material which is available will be diverted to cellular biosynthesis at the expense of xanthan production. As before, growth is maintained until a selected element, again preferably nitrogen, is exhausted, at which point further growth cannot occur.
The second stage is the same for both methods; excess nutrient, preferably glucose, is added and the culture is incubated with aeration and agitation whilst xanthan production occurs. This is illustrated below in Example 1. It is not essential to use glucose at this stage; any carbon source that will support gum production, for example, fructose, sucrose, lactose or starch, may also be used.
In the first method, care must be taken in the selection of the organism and carbon source so that the carbon source supports good growth of the organism but not xanthan biosynthesis. In selecting a combination of organism and carbon source for use in the first stage, both the cost of the carbon source and the productivity of the organism when grown on glucose were taken into consideration.
Combinations that may be employed include:
______________________________________Organism Carbon Source______________________________________X. juglandis NCPPB 413 GlycerolX. juglandis NCPPB 1447 GlycerolX. juglandis NCPPB 1059 GlycerolX. juglandis ICPB XJ 107 GlycerolX. campestris NClB 11781 GlycerolX. juglandis ICPB XJ 107 XyloseX. campestris NClB 11781 Xylose______________________________________
Another version of this process may involve supplementing the carbon source used in the first stage with a crude protein or protein hydrolysate. Providing this does not radically alter the overall elemental balance such that carbon becomes limiting at the end of the first stage, this may improve the process by increasing the specific growth rate and reducing the duration of the first stage.
Processes employing the second method rely on the specific growth rate being limited throughout the first stage by the supply of carbon-containing nutrients. The conventional method to achieve this is by continuous culture. Example 2 is a demonstration of the first stage of such a process; stage 2 was omitted. The second stage will require one or more additional fermenters in which the overflow from the continuous fermenter is collected and growth without xanthan biosynthesis continued (by any of the other methods described) until an element other than carbon becomes limiting. Finally the culture will be mixed with a carbon-containing nutrient, e.g. glucose or other carbohydrate e.g. lactose that will support xanthan biosynthesis, and incubated with aeration and agitation. Whilst the first stage must be operated continuously the second stage may be operated either continuously or semi-batchwise.
Alternatively, the entire process may be carried out batchwise by limiting the specific growth rate by means of a concentrated feed of the carbon containing nutrients. If the rate of feeding is increased exponentially, that is, governed by a relationship such as:
f=f.sub.o e.sup.kt
where
t=time
f=feed rate at time t
f o =feed rate at t=o
k=exponential constant with units of reciprocal time
then whilst growth will be limited throughout the first stage by the feed, the specific growth rate will be maintained at a constant predetermined level numerically equal to or less than the constant k. The feed is maintained until growth is stopped by the exhaustion of an element not present in the feed, typically nitrogen. At this point the second stage is commenced simply by adding an excess of glucose or other suitable carbon source to the fermenter and incubating with aeration with agitation. A process of this particular type is compared directly with a conventional fermentation in Example 3.
Further versions of both continuous and fed-batch processes may be devised by supplementing the feed with a small amount of protein or protein hydrolysate as a source of growth factors enabling higher specific growth rates to be achieved. This will result in increased output of the continuous process or reduced fermentation times of the batch process. The latter type of process is demonstrated by Example 4.
Hybrid processes employing both methods are also possible.
Proteins and protein hydrolysates are known to support high specific growth rates without xanthan biosynthesis taking place. Unfortunately, the carbon to nitrogen ratio of this class of nutrients is such that carbon always becomes limiting first. It is possible, however, to devise processes which employ proteins or protein hydrolysates providing that a short intermediate stage is introduced; making the process a three stage one. During the first stage the organism grows at its maximum specific growth rate, utilising the proteinaceous material, until carbon becomes limiting. Then, during the short intermediate stage, the growth rate is limited by a nitrogen-deficient carbon containing nutrient supplied as a concentrated feed until nitrogen becomes exhausted. At this point growth can no longer take place and the final stage can be commenced by adding an excess of glucose or other suitable carbon source to the fermenter and incubating with aeration and agitation. The entire process takes place within a single fermentation vessel. It is an advantage of this invention that, except in the embodiment involving continuous culture, a single vessel can be used for the entire fermentation process.
The product may be separated from the culture by any convenient method known in the art or the whole culture may be used with or without previously killing the bacteria, depending on the intended use.
In the following Examples, the following media are used:
______________________________________ % (w/v)______________________________________Agar AOxoid meat extract 3.00Oxoid peptone L37 0.50Oxoid yeast extract 0.50Oxoid Bacto agar 2.00Distilled water to volumepH adjusted to 7.4 with sodium hydroxidesterilisation: 20' at 121° C.Dispense: 7 ml per bijou bottle andslope whilst allowing agar to set.Medium - BKH.sub.2 PO.sub.4 0.65MgSO.sub.4.7H.sub.2 O 0.0375FeSO.sub.4.7H.sub.2 O 0.005ZnSO.sub.4.7H.sub.2 O 0.001MnSO.sub.4.4H.sub.2 O 0.001Oxoid Bacto Peptone 0.64Distilled water to volumepH: 7.0Medium - CKH.sub.2 PO.sub.4 0.65MgSO.sub.4.7H.sub.2 O 0.0375FeSO.sub.4.7H.sub.2 O 0.005ZnSO.sub.4.7H.sub.2 O 0.001MnSO.sub.4.4H.sub.2 O 0.001Sigma Casein Hydrolysate 0.715(enzymatic)Mains water to volumepH: 6.5______________________________________
Growth was estimated spectrophotometrically at 600 nm, and by measuring the dry weight of a 25 ml sample. Oxygen demand was calculated from the time taken for the dissolved oxygen content of a saturated sample to fall to zero.
Crude polysaccharide yields were measured by precipitatable material from culture broth by the addition of 0.1 volumes of 22% (w/v) potassium chloride and 2 volumes of isopropanol, filtering, washing with 67% aqueous isopropanol, and drying.
Oxygen uptake was determined by comparative analysis of the oxygen content of the entry and exit gas streams, to and from the fermenter.
The Xanthomonas campestris used in the following Examples is of the strain NC1B 11781 deposited at the National Collection of Industrial Bacteria, Aberdeen.
EXAMPLE 1
Cells of X. juglandis NCPPB413 prepared as a slant culture on Agar A were suspended in 9 ml of sterile 0.9% saline solution. Two 500 ml conical flasks each containing 100 ml of sterile medium B were each inoculated with 2 ml of the saline suspension. These seed cultures were incubated with aeration by shaking for 1 day at 30° C. Each seed culture was then used to inoculate a New Brunswick model F-05 fermenter, each fermenter being identically batched with 3.4 L of sterile medium containing glycerol, 20 g/L; potassium dihydrogen phosphate, 5 g/L; ammonium sulphate, 2 g/L; citric acid, 2 g/L; boric acid, 6 mg/L; magnesium sulphate (heptahydrate salt) 0.2 g/L; zinc sulphate (heptahydrate salt, 21.2 mg/L; ferric chloride (hexahydrate salt), 2.4 mg/L; calcium chloride (dihydrate salt), 43.8 mg/L; in distilled water. Sterile air was supplied at the rate of 2 L per minute and the culture stirred at 400 r.p.m. The temperature was maintained at 30° C. and the pH at 7.0. The sole source of nitrogen was ammonium sulphate and when this had been fully utilised, a sterile concentrated solution containing 102 g of glucose was added to each fermenter. This level was chosen entirely arbitrarily and there is no reason why a higher level could not be used in a commercial production process. The results are given in Table 1 in which the two fermenters are identified as fermenter A and fermenter B. The final yields of polysaccharide were 2.7-3.0%.
It will be seen that, once the first stage has been completed, as shown by the reduction of the ammoniacal nitrogen content to zero, and the glucose has been added, the formation of xanthan takes place, as shown by the disappearance of glucose, and the increase in the consistency coefficient.
EXAMPLE 2
Cells of X. campestris, (NC1B 11781) prepared as a slant culture on Agar A were suspended in 9 ml of sterile 0.9% saline solution and 2 ml of the suspension used to inoculate 100 ml of sterile medium B in a 500 ml conical flask. This seed culture was incubated with aeration by shaking for 1 day at 30° C. after which 45 ml was then used to inoculate a 1 liter fermenter containing 900 ml of sterile medium composed of glucose, 6.67 g/L; Oxoid casein hydrolysate (L41), 5 g/L; ammonium sulphate, 4.0 g/L; potassium dihydrogen phosphate, 5.0 g/L; magnesium sulphate (heptahydrate salt), 0.46 g/L; boric acid, 12 mg/L; zinc sulphate (heptahydrate salt), 21.2 mg/L; ferric chloride (hexahydrate salt), 58 mg/L; calcium chloride (dihydrate salt), 110 mg/L; and distilled water. The culture was allowed to grow batchwise for 21 hours at 30° C. and then flow of the feed medium was started to give a dilution rate of 0.07 per hour. The feed medium was of the same composition except that the level of casein hydrolysate was lower; 1 g/L. The culture was maintained at 30° C. and the pH controlled automatically at 7.0 throughout the fermentation which was terminated after six days. Under steady-state conditions the culture broth was non-viscous (the consistency coefficient was 0.065 g cm -1 sec n-2 ; the flow behaviour index was 0.83), the dry cell weight was 2.0 g/L and the glucose concentration less than 0.1 g/L.
EXAMPLE 3
Cells of X. campestris (NC1B 11781) prepared as an agar slant culture were suspended in 9 ml of sterile 0.9% saline solution and 2 ml of the suspension used to inoculate 100 ml of sterile medium B in a 500 ml conical flask. This seed culture was incubated with aeration by shaking for 1 day at 30° C. This seed was then used to inoculate 1 L of sterile medium B in a 4 L conical flask. This secondary seed culture was again incubated with aeration by shaking for 1 day at 30° C. This was then used to inoculate 400 L of sterile medium C in a fermenter of conventional design. This culture was grown at 30° C.; sterile air was supplied at the rate of 200 L per minute and the culture was stirred at 153 r.p.m. After 27 hours two further fermenters of identical design (fermenter C and fermenter D) each containing 360 L of sterile medium were each inoculated with 40 L of culture. The medium in fermenter C was composed of glucose, 43 g/L; ammonium sulphate, 1.5 g/L; potassium dihydrogen phosphate, 5 g/L; magnesium sulphate (heptahydrate salt), 0.46 g/L; boric acid, 12 mg/L; zinc sulphate (heptahydrate salt), 21 mg/L; ferric chloride (hexahydrate salt) 58 mg/L; calcium chloride (dihydrate salt), 110 mg/L; in mains water. The medium in fermenter D was identical except that the glucose was omitted at batching and the same amount added during the course of the fermentation by means of a feed and an addition of sterile glucose solution. Immediately after inoculation a feed to fermenter D of a sterile glucose solution containing 93.4 g/L was commenced at an initial flow rate of 1 ml per minute. The flow was increased exponentially under computer control with an exponential constant of 0.07 per hour. Once the flow rate reached 50 mls per minute it was held constant until a total volume of 50 L had been fed into fermenter D. At this point an addition of a concentrated sterile solution containing 10.8 Kg. of glucose was made to the fermenter. The operation of both fermenters was identical; sterile air was supplied at the rate of 200 L per minute and the cultures stirred at 153 r.p.m. The temperature was maintained at 30° C. and pH at 7.0 by means of automatic control. The results are given in Table 2.
In fermenter C, where a conventional process is taking place, the glucose concentration drops throughout the process, and the consistency coefficient rapidly increases, showing that xanthan production is taking place. The oxygen demand and transfer rate are also initially high.
In fermenter D, in which the process of the invention is carried out, the consistency coefficient is low until the content of ammoniacal nitrogen falls substantially to zero, and the glucose addition is made, showing that during the exponential addition of glucose, substantially only cell formation is taking place.
The total amount of polysaccharide produced was substantially the same in each case as indicated by the measured rheology and polysaccharide precipitates. Fair comparisons can only be made at times of equivalent glucose concentration, that is, when equal amounts of glucose have been utilised in both processes.
Most importantly, the oxygen demand of the culture in Fermenter D was substantially lower than the control (Fermenter C) throughout the process.
By comparing the oxygen demands with the oxygen transfer rates actually achieved, it can be seen that the amount by which the oxygen transfer rate fails to meet the demand is substantial in the case of Fermenter C, whereas in the case of Fermenter D, the two are substantially equal.
EXAMPLE 4
The inoculum development procedure described in Example 3 was used to provide 400 L of seed culture, 40 L of which was used to inoculate 360 L of sterile medium in fermenter D. The medium had the same composition is that used in Fermenter D in Example 3. Immediately after inoculation a feed of sterile solution containing 93.4 g of glucose per liter and 4.3 g of casein hydrolysate (Oxoid L41) per liter was commenced at an initial flow rate of 2 ml per minute. The flow was increased under computer control with an exponential constant of 0.14 per hour. Once the flow rate had reached 100 ml per minute the feed was stopped and an addition of a concentrated sterile solution containing 10.8 Kg of glucose was made to the fermenter. The operation of the fermenter was identical to that described in Example 3. The results are given in Table 3.
After 48 hours, the polysaccharide yield was 1.6-2.0%. It will be seen that there is little polysaccharide formation until the glucose is added, as shown by the small increase in the consistency coefficient. Once the ammoniacal nitrogen had fallen nearly to zero and growth had stopped, the glucose was added, and polysaccharide synthesis took place, as shown by the considerable increase in the consistency coefficient.
TABLE 1__________________________________________________________________________FERMENTER A FERMENTER BLOG LOGHOURSI II III IV V HOURS I II III IV V__________________________________________________________________________ 0 .05 .30 0 .08 .24 6 .18 .32 6 .23 .3212 .35 .25 12 .59 .2418 .75 .15 181/2 .65 .2121 1.3 .28 21 .85 .3524 1.5 .20 24 1.1 .2330 2.1 .26 30 1.3 .2236 2.9 .19 36 1.7 .23 413/43.9 .08 413/4 2.1 .15 451/44.7 .01 451/4 2.3 .2148 5.5 0 48 2.6 .18 483/4GLUCOSE ADDITION 54 3.4 .14 503/45.0 0 .37 .65 60 4.9 .0654 5.2 0 .99 63 5.9 .01 .51 .6460 5.3 0 .66 63 GLUCOSE ADDITION 653/45.4 0 .54 653/4 5.6 0 1.1572 4.3 .71 72 4.5 .2890 5.0 .02 90 4.9 .15114 5.1 .03 114 5.1 .03138 3.7 .01 51.2 .24 138 3.5 .02 92.5 .21__________________________________________________________________________ I = Optical Density 600 nm II = Ammoniacal Nitrogen mg ml.sup.-1 III = Glucose % w/v IV = Consistency Coefficient gm cm.sup.-1 V = Flow Behaviour Index (n)
TABLE 2__________________________________________________________________________FERMENTER C (For Comparison) FERMENTER DLOG LOGHOURSI II III IV V VI VII HOURS I II III IV V VI VII VIII__________________________________________________________________________0 .27 3.9 .57 0 .39 <.01 .36 61/2.50 3.8 .016 .98 1.0 61/2 .61 .01 <.01 1 .47121/21.1 121/2 .76 .01181/41.6 3.5 .31 .68 .77 181/4 .95 .01 <.01 1 .67211/22.3 12 6.7 211/2 1.3241/23.2 3.1 241/2 1.4 .07 .30 3.2 <.5301/23.4 2.7 4.3 .49 1.2 301/2 1.7 .08 .28 .04 .85 .68361/25.1 2.3 361/2 2.6 .05 .27421/45.6 2.0 22 .35 1.8 421/4 2.8 .06 .23 .32 .67 .85481/26.7 1.5 29 12 481/2 3.1 .06 .18 13 9541/25.6 1.2 39 .31 1.9 541/2 3.4 .21 .08 3.9 .49 1.0571/25.8 571/2 4.8 GLUCOSE ADDITION601/26.0 1.0 601/2 4.9 2.1 0661/45.4 1.0 58 .28 2.1 661/4 5.2 1.7 26 .33 1.4691/25.5 24 8.5 691/2 4.8721/27.1 .85 721/2 5.7 1.5 13 10781/25.6 .73 83 .26 2.4 781/2 4.8 1.3 47 .29 2.0841/26.0 .51 841/2 4.8 .61901/45.6 .48 117 .24 2.6 901/4 4.7 .81 74 .25 2.4933/4 18 7.4961/25.7 .35 961/2 4.7 .71 13 7.81021/24.4 .23 142 .21 2.8 1021/2 4.2 .57 95 .23 2.31141/44.5 .04 179 .20 2.7 1141/4 3.7 .21 130 .21 3.0__________________________________________________________________________ I = Optical Density 600 nm II = Glucose % w/v III = Oxygen Demand ml O.sub.2 (STP)/100 ml/hour IV = Oxygen Transfer Rate ml O.sub.2 (STP)/100 ml/hour V = Consistency Coefficient gm cm.sup.-1 VI = Flow Behaviour Index (n) VII = Polysaccharide Precipitate % w/v I = Optical Density 600 nm II = Glucose % w/v III = Ammoniacal Nitrogen mg IV = Oxygen Demand ml O.sub.2 (STP)/100 ml/hour V = Oxygen Transfer Rate ml O.sub.2 (STP)/100 ml/hour VI = Consistency Coefficient gm cm.sup.-1 VII = Flow Behaviour Index (n) VIII = Polysaccharide Precipitate % w/v
TABLE 3__________________________________________________________________________ FLOW DRY AMMONIACAL CONSISTENCY BEHAVIOUR WEIGHT GLUCOSE NITROGEN COEFFICIENT INDEXLOG HOURS % w/v % w/v mg ml.sup.-1 gm cm.sup.-1 sec.sup.n-2 (n)__________________________________________________________________________ 0 .08 .29 4 .08 .26 .01 1 8 .07 .26 .03 .9012 .02 .24 .08 .8016 .03 .26 .23 .7020 .06 .19 .60 .6224 .05 .18 1.6 .56 27.9 .21 .18 .0228 GLUCOSE ADDITION28 2.430 1.936 1.540 1.4 413/4 .2244 1.348 1.2 45-50 0.25-0.3__________________________________________________________________________
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Polysaccharides, such as xanthan gum, are produced by culturing microorganisms, e.g. of the Xanthomonas genus, in a two stage process. In the first stage, growth of the microorganism is favored, e.g. by using a predetermined quantity of a carbon-containing nutrient which does not support biosynthesis of the polysaccharide. In the second stage, the conditions are such that biosynthesis of the polysaccharide takes place with substantially no growth of the microorganism, e.g. by adding carbohydrate in the absence of nutrient required for polysaccharide growth.
By this process, the requirement for oxygen is greatly reduced at the time when the culture medium has its highest viscosity, thereby minimizing problems of low oxygen transfer capability in viscous media.
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This invention relates to light transmissive doors and windows and more particularly to such that have a plurality of panels outlined by a corresponding plurality of muntins.
BACKGROUND OF THE INVENTION
Panelled glass doors and windows have found widespread use because of their see-through character, their usefulness in passing light and because they are aesthetically appealing. Originally, such doors and windows took the form of main frames with criss-crossing mullions for producing a plurality of openings into which individual panes of glass were fitted. Illustrative of such construction is that described in U.S. Pat. No. 190,225 granted to L Landeker on May 1, 1877. A more recent example is that of U.S. Pat. No. 4,845,911 granted to Winston et al. Jul. 11, 1989. In addition to such examples, a variety of other proposals have been made to improve facility of production and of pane replacement.
In addition to the foregoing, proposals have been made for adding false muntins to a windowpane so as seemingly to divide such pane into at least two lights. Illustrative of such proposal is that set forth in U.S. Pat. No. 3,678,651 granted to Glen Hicks on Jul. 25, 1972.
While the proposals of the prior art have produced seeming divisions of a glass light into sub-divisions, they have been relatively complex, relatively costly to manufacture, and relatively difficult to repair. Accordingly, there has continued to be a need for a simplified construction that is simple, relatively quick and easy to assemble, and cost-effective to produce.
BRIEF SUMMARY OF THE INVENTION
The proposals of the present invention envision a simple construction embodying a plurality of muntins (e.g. grids) assembled with a sheet of light transmissive material (e.g glass), the sheet and muntins having therein aligned apertures through which Christmas-tree type fasteners are installed and within which such fasteners are fastened. A gasket-like strip is applied to the periphery of the transmissive material sheet and special staple-like members are employed to secure in place muntin strips at spaced locations corresponding to positions at which muntin strips are to be positioned. Staples are provided in or near the ends of the horizontal muntins to provide for holding the muntins in place when the framing stiles are applied. Thus, the sheet of light transmissive material and muntins are locked or secured together, and when the mounting frame is applied, there is provided a cost-effective closure, e.g., door or window.
OBJECTS AND FEATURES OF THE INVENTION
It is one general object of the invention to improve multi-light doors and windows.
It is another object of the invention to simplify manufacture of multi-light doors and windows.
It is still another object of the invention to improve the cost effectiveness of manufacturing multi-light doors and windows.
Accordingly, in accordance with one feature of the invention, a pane of light transmissive material is provided with a pattern of apertures therethrough, thus making provision for ready attachment of muntins.
In accordance with another feature of the invention, pairs of muntins are provided with mirror-image mating recesses thereby facilitating assembly with unitary fastening members.
In accordance with yet another feature of the invention, improved unitary fastening members are provided, thus facilitating assembly of the muntins.
in accordance with still another feature of the invention, a unitary sheet of light transmissive material is polywrapped prior to attachment of muntins, thus effectively masking the material partitions for painting, and thus simplifying painting preparation and reducing finishing costs.
In accordance with yet another feature of the invention, a gasket-like member is applied to the periphery of the sheet of light transmissive material, thus providing for a snug and dependable fit within a surrounding frame.
In accordance with still another feature of the invention, a plurality of staple-like members are positioned at spaced predetermined locations to engage portions of the muntins thereby to hold the muntins in position when peripheral frame members are attached.
In accordance with yet another feature of the invention, Christmas Tree type fasteners are installed in the muntins and sheet of transmissive material to cost-effectively provide for securing these members together.
These and other objects and features of the invention will be apparent from the following detailed description, by way of preferred examples, with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a multi-panelled door according to the principles of the invention.
FIG. 2 is a detailed perspective view illustrating the interlocking of vertical and horizontal muntins of the door;
FIG. 3 is a view illustrating details of the improved Christmas tree fastener according to the invention;
FIG. 4 is a front elevation view of the door of FIG. 1;
FIG. 5 is an exploded partial sectional view taken along the lines 5--5 of FIG. 4;
FIG. 6 is an enlarged detail view illustrating a representative one of the apertures within the light transmissive sheet of the door of FIG. 1;
FIG. 7 is a partial sectional view taken along the lines 7--7 of FIG. 4 and illustrating the engagement of the muntins with position-retaining staples and the stiles of the door of FIGS. 1 and 4;
FIG. 8 is an exploded view illustrating the interrelationships of the light transmissive member, peripheral gasket, muntins, staples and stiles of the door of FIGS. 1 and 4; and
FIG. 9 is a flow diagram of the steps in the method of assembly of a door according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Now turning to the drawing, and more particularly FIG. 1 thereof, it will be seen to depict a door having a peripheral frame 10 comprising top rail 11, bottom rail 12, left hand stile 13 and right hand stile 14. Within frame 10 and attached thereto are rear horizontal muntins 15, 16, 17 and 18 which appear to be segmented respectively into sections 15a-15c, 16a-16c, 17a-17c and 18a-18c by rear vertical muntins 23 and 25. In complementary relationship thereto are front muntins 19, 20, 21 and 22 which appear to be segmented into sections 19a-19c, 20a-20c, 21a-21c and 22a-22c by vertical muntins 24 and 26. As will be observed from further inspection of FIG. 1, the vertical muntins 23-25 have continuous faces extending top to bottom. However for ease of description the indicated portions of these vertical muntins may be considered as sections 23a-23e,24a-24e,25a-25e and 26a-26e. Thus, the upper left hand simulated pane of light transmissive material is seen to be bounded by horizontal muntin sections 15a/19a, 23a/24a and the indicated portions 28 and 29 of top rail 11 and left hand stile 13 respectively. The remaining simulated panes of light transmissive material are seen to be bounded by muntin, stile and top rail segments as shown.
Now turning to FIG. 2, a detailed view of the locking interrelationship of the horizontal and vertical muntins is shown. There, it will be seen, are vertical sections 24a and 24b of vertical muntin 24, together with sections 19a and 19b of horizontal muntin 19. Although for reasons of clarity and conciseness, only one typical muntin crossing is illustrated in FIG. 2, the principles therein illustrated are applicable to all the muntin crossings, both rear and front.
it will be noted that both the front and rear horizontal muntins are unitary members and extend continuously between the positions where their ends engage stiles 13 and 14. Correspondingly, both the rear and front vertical muntins are unitary members and extend continuously between the positions where their upper and lower ends engage top and bottom rails 11 and 12. However, at each point of crossing where horizontal and vertical muntins cross, mating notches such as notches 30a and 30b are formed thereby providing for convenient crossovers that also serve to lock the muntins to each other and to the unitary sheet of light transmissive material as is described below.
Further inspection of FIG. 2 reveals that surfaces forming notches 30a and 30b are of complementary geometry thus to provide for contiguous engagement when the muntins are assembled. Thus, looking at the top of muntin section 24a in FIG. 2, when muntin 24 is turned clockwise through 90 degrees and then brought into engagement with muntin 19, the complementary sections 30a and 30b mate together in surface contiguous relationship thus to form the composite as illustrated in FIG. 1.
Additional inspection of FIG. 2 reveals the presence of segmented "Christmas-tree" fasteners 33a and 33b. These fasteners are shown in greater detail as illustrated by fastener 33 in FIG. 3. Ends corresponding to end 34 (FIG. 3) are fitted into circular recesses that extend only part way into the vertical muntins 23-26 at spaced intervals, it being preferred that there be such a recess and fastener adjacent each simulated pane at about the locations shown in FIG. 4.
FIG. 3 depicts the fasteners (hereinafter, Christmas-tree fasteners) that preferably are used in practicing the invention. The principal axis x--x is essentially rectilinear, with the remaining parts of the fastener extending in an essentially radial geometry thereabout. The fasteners themselves are well known in the art and are preferably made of flexible plastic. Thus, the extending bell-shaped members 35 and associated washer-like extensions, or flutes, 36 are flexible so that when an end of the fastener is pressed into a cylindrically shaped recess (such as recess 37a or 37b of FIG. 2) that is slightly smaller in diameter than the outside diameter of the extensions 36, the outside edges of members 35 and extensions 36 bend toward the center of the fastener and thus present a correspondingly smaller effective diameter. However, when an attempt is made to withdraw the fastener, the longitudinal thrust results in an opposite effect whereby the ends of the extensions 36 attempt to return to their normal diameter, thus digging into the interior wall surface of the recess and strongly resisting withdrawal. For a more complete identification of the fasteners, reference is hereby made to part number F 2610 -00-0078 as supplied by ITW Fastex Company of 195 Algonquin Road, Des Plains, Ill. 60016.
FIG. 4 depicts the door of FIG. 1 in a partly assembled state. Thus, it will be observed that FIG. 4 depicts the door with only the rear muntins in place against the unitary sheet 40 of light transmissive material. As mentioned earlier, the unitary sheet of light transmissive material completely fills the central part of the door, that is, the interior which is bounded by top rail 11, bottom rail 12, left side stile 13 and right side stile 14. Although the sheet is a single unitary member, the placement of the muntins creates the simulated appearance as if the door was constructed with a plurality of individual smaller panes.
Cylindrical recesses 33a-33e are provided in rear muntin 23, and similar recesses 43a-43e are provided in rear muntin 25, thus making provision for insertion of fasteners thereinto through corresponding apertures 44a-44e and 45a-45e extending through unitary light transmissive sheet 40. The apertures in sheet. 40 may be provided by any of a variety of ways known in the art such as by molding, cutting, drilling, abrading and the like prior to tempering. Although in accordance with the preferred method of practicing the invention, the apertures in sheet 40 are formed before tempering and before sheet 40 has been wrapped with one or more layers of thin plastic sheet material 50 (FIG. 5) such as for example a polyethylene wrap. In the preferred embodiment, the plastic sheet wrap over the locations of the apertures are pierced when fasteners 33 are inserted so as to facilitate the insertion of fasteners 33.
FIG. 5 is seen to be a partially cut-away and partly exploded section taken along the section lines 5--5 of FIG. 4. In addition, there is added to FIG. 5 a part of right front muntin 26 that is illustrated in FIG. 1 but which is omitted from FIG. 4 in order to add clarity of presentation. FIG. 5 shows one of the fasteners 33 in place within recess 43c with the outwardly projecting end 47 ready for insertion into recess 48c of front muntin 26 through aperture 49 through unitary light transmissive sheet 40 and plastic sheet wrap material 50.
FIG. 6 illustrates the foregoing aperture 49 in greater detail. There, it will be seen, are portions of unitary light transmissive sheet 40 adjacent aperture 49, as well as corresponding portions of plastic sheet wrap 50 that, as mentioned previously, is used to cover unitary sheet 40 to provide protection from scratching during construction as well as to provide for masking during any subsequent desired painting of the wooden portions of the door. As will be evident to one skilled in the art, after construction and painting, the plastic material may be removed as by cutting or tearing so as to clear the light transmissive simulated panels of the door.
FIG. 7 illustrates additional features which have been found to facilitate construction of the door. Again, as with FIG. 5, there is included a part of front muntin 21 which is not shown in FIG. 4. Referring further to FIG. 7, there are seen a part of unitary sheet 40, plastic wrap 50, rear muntin 17, front muntin 21, right hand stile 14 and stile trim or profile 52. In addition, there are seen a part of a gasket 53 which extends about the entire periphery of sheet 40 and is attached thereto as by press fit, gluing or the like. Also shown is generally u-shaped staple 54 that may be attached to gasket 53 or positioned with stile trim or profile 52. One such staple is provided for each pair of horizontal front/back muntins (e.g., muntins 17/21, 15/19, 16/20 18/22) and for each pair of vertical muntins (e.g., muntins 23/24 and 25/26. The staples engage corresponding recesses to hold the muntins in place while stiles and rails are pressed into place around the periphery of sheet 40 and gasket 53. Thus, there is provided one such staple at each location around the periphery of glass sheet 40 where a pair of horizontal and vertical front/back muntins abut adjacent surfaces of the stiles and rails.
Further reference to FIG. 7 reveals that the staple-engaging recesses 55a and 55b within the muntins are shown as being slightly longer than the projecting ends 56a and 56b of staple 54 thus providing for manufacturing tolerances. However, it is not necessary that such be the case, for the recesses could readily be made the same length so that the projecting ends of the staples would entirely fill the recesses
Now turning to FIG. 8, it will be seen to illustrate further the interrelationships of the muntins, light transmissive sheet, gasket, staples and stiles/rails. Although the illustration of FIG. 8 will be described in terms of the association of the aforementioned parts with right hand stile 14, it will be evident that the principles also apply to the left hand stile 13, top rail 11 and bottom rail 12.
FIG. 8 shows parts in exploded form, and trim 52 is shown separated from stile member 14 to aid in illustration. However, it will be evident to those skilled in the art that trim 52 and stile member 14 could be (and preferably would be) made as one unitary member.
As mentioned above, the staples such as staple 54 could be attached or otherwise held in place on the gasket 53. Alternatively, they could be press fitted into or otherwise positioned within notches (e.g., preformed or formed by force fit) such as notch 57a/57b provided at the desired predetermined locations in trim member 52.
FIG. 9 illustrates steps in the manufacture and assembly of a door, window or similar product while practicing the foregoing principles of the invention. There, it will be observed are shown steps 60 of selecting or otherwise producing the above-described sheet 40 of light transmissive material and producing apertures in the sheet. Such sheet may be produced initially with the aforementioned apertures therethrough or subsequently provided with such apertures. Next, the above-described peripheral gasket is attached and sheet 40 is wrapped with a thin layer of plastic protective material as represented by step 61.
Step 62 illustrates attachment of the alignment/holding members, e.g., staples 54 to the periphery of the light transmissive sheet 40 as described above. Such attachment may be made using any of a variety of well-known techniques such as by a force fit, the use of glue, rubberized cement or the like which will not be adversely affected by the remaining steps of manufacture and the environment in which the product is to be used.
Steps 63 and 64 illustrate assembly of the muntins to the front and rear of the plastic wrapped light transmissive sheet 40 with the use of the previously described segmented fasteners; and step 65 illustrates the assembly (preferably press fitting) of the stiles and top/bottom rails to the remaining parts. In this connection, it should be noted that steps 62-65 contemplate assembly with the aforementioned staples 54 being attached or held in place on the gasket 53. However, in order to illustrate the alternative construction in which the staples 53 are held in place within recesses such as recess 57a/57b (FIG. 8), alternative step 65a is also shown.
It will now be evident to those skilled in the art that there has been described herein an improved multi-panelled door, window or the like which simplifies manufacture and reduces cost.
Although the invention hereof has been described by way of example of a preferred embodiment, it will be evident that other adaptations and modifications can be employed without departing from the spirit and scope thereof. For example, translucent sheet material could be wholly or partially employed, or two or more unitary sheets of light transmissive material could be used and segmented into simulated separate panes using the foregoing principles. Moreover, if parts such as the muntins, stiles and rails were pre-painted, and if care were employed in handling the unitary sheets, wrapping with the plastic sheet material could be eliminated. In addition, it will be recognized that the order in which some of the steps of manufacture are conducted could readily be changed.
The terms and expressions employed herein have been used as terms of description and not of limitation; and thus, there is no intent of excluding equivalents, but on the contrary it is intended to cover any and all equivalents that may be employed without departing from the spirit and scope of the invention.
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A door/window construction in which a unitary sheet of light transmissive material such as transparent or translucent glass or plastic is covered with masking material and provided with a plurality of small holes spaced apart at predetermined intervals. Fasteners are inserted in the holes and project outwardly to engage corresponding recesses in muntins that are thereby positioned and fastened on the sheet so as to give the appearance of a multi-panelled door/window. Fastening staples are provided to hold exposed portions of the muntins in place when stiles and rails of the doors/windows are attached. Also included is the method of manufacture and assembly of the doors/windows.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to digital processing units and more particularly, to the test and debug of a target processor by an emulation unit.
[0003] 2. Background of the Invention
[0004] In the past, testing and debugging digital signal processors was performed using interface electronics with a fixed voltage capability. Older test and debug units such as emulation units were designed to work only with 5 volt digital signal target processors. When the digital signal processor under test operates with a different supply voltage, the user has to provide interface logic apparatus to translate between the older style emulation unit signal levels and the signal levels of the processor under test. Emulation units soon started using 3.3 volt logic apparatus with a tolerance of 5 volts which reduced the effort in providing interface apparatus for the digital signal processor.
[0005] Advanced emulators are designed to operate over a wide range of supply voltages, typically between 0.5 volts and 5 volts. To determine the operating voltage of the emulation unit, a sense pin is provided to detect the target processor I/O voltage and to scale the emulation unit drive signals and set the logic threshold voltages.
[0006] A need has therefore been felt for apparatus and an associated method having the feature of providing improved test and debug capabilities. It is a further feature of the apparatus and associated method to provide an emulation unit that is able to sense the voltage of the target processor and adjust the output voltage levels of an emulation unit. It is yet another feature of the apparatus and associated method to create a threshold voltage for received signals that is based on the target I/O voltage level. It is a still further feature of the apparatus and associated method to provide an emulation unit that can detect the loss of power by the target processor. It is still a further feature of the apparatus and associated method to provide a clamping voltage to protect the emulation unit against electrostatic discharge. It would be a more particular feature of the apparatus and associated method to limit voltage excursions by signals from the target processor.
SUMMARY OF THE INVENTION
[0007] The aforementioned and other features are accomplished, according to the present invention, by providing an interface circuit associated with the emulation unit to sense the target I/O voltage, to limit the output voltage of the emulation unit to a maximum value, to provide a suitable threshold voltage and a clamping voltage, and to detect the loss of target power.
[0008] Other features and advantages of present invention will be more clearly understood upon reading of the following description and the accompanying drawings and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a block diagram of the interface circuit invention illustrating the relationship of the various components of the present invention.
[0010] FIG. 2 is a schematic diagram of the voltage sensing device for sensing the target voltage according to the present invention.
[0011] FIG. 3 is a schematic diagram of the clamp voltage generator according to the present invention.
[0012] FIG. 4 is a schematic diagram of the target voltage limiting circuit according to the present invention.
[0013] FIG. 5 is a schematic diagram of the threshold generation circuit according to the present invention.
[0014] FIG. 6 is a schematic diagram of the power loss detection circuit according to the present invention.
[0015] FIG. 7 is a schematic diagram of the input comparator circuit according to the present invention.
[0016] FIG. 8 is diagram of the output switches according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0000] 1. Detailed Description of the Figures
[0017] Referring to FIG. 1 , the block diagram of the interface circuit between the emulation unit 10 and the target processor 12 , according to the present invention, is shown. The output terminals of the emulation unit 12 are coupled to an input terminal of an FET output switch 80 and to the control terminals of the FET switch 80 . The output terminals of the FET switch are coupled to the target processor 12 , through ESD protection diode 114 connected to ground potential, and through ESD protection diode 113 connected to an output terminal of clamp generator 30 . The target processor applies the I/O voltage to an input terminal of the target sensing device 20 . The output voltage of the target sensing device is coupled to the clamp generator 30 , to the limiter 40 , to the power loss detection 60 . The power loss detection 60 applies an output signal to the emulation unit 10 . The limiter 40 applies an output voltage to the threshold generation unit 50 and output signal to the power terminal of FET output switch 80 . The target processor output terminals are coupled to the positive terminal of comparator 70 , are coupled through diode 116 to ground potential, and are coupled through diode 115 to the output terminal of clamp generator 30 . An output terminal of the threshold generation unit is coupled to a negative input terminal of comparator 70 .
[0018] Referring to FIG. 2 , the schematic diagram of the target voltage sense circuit 20 is shown. The I/O voltage from the target processor 12 is applied through ESD protection diode 21 to ground potential, through ESD protection diode 22 to the 5 volt supply voltage, through resistor 23 to ground potential, and to a first terminal of resistor 24 . A second terminal of resistor 24 is coupled to the positive terminal of operational amplifier 26 and through capacitor 25 to the ground potential. The power terminal of operational amplifier 26 is coupled to a 5 volt supply voltage. The output terminal of operational amplifier 26 is coupled to the negative input terminal of operation amplifier 26 , and to a first terminal of resistor 27 . The second terminal of resistor 27 is coupled through capacitor 28 to ground potential and provides the TREF signal.
[0019] Referring to FIG. 3 , a schematic diagram of the clamp voltage generation circuit 30 is shown. The TREF signal is applied to the positive terminal of an operational amplifier 31 . The negative input terminal of the operational amplifier 31 is coupled to through resistor 32 to the ground potential and through resistor 33 to the output terminal of operational amplifier 31 .
[0020] The power terminal of operational amplifier 31 is coupled to a 5 volt supply voltage. The output terminal of operational amplifier 31 is coupled through resistor 34 to the terminal providing the TVS CLAMP signal and to a first terminal of capacitor 35 , the second terminal of capacitor 35 being coupled to ground potential.
[0021] Referring to FIG. 4 , a schematic diagram of the target voltage limiter circuit 40 , according to the present invention, is shown. The TREF signal is applied to an input terminal of output switch 41 while the ground potential is applied to the control terminal of output switch 41 . A 5 volt supply voltage is coupled through resistor 43 to the substrates of output switches 41 , 42 , 44 and 45 , and to the output terminals of output switches 41 and 42 . This same signal is output as TREF2DRIVER. A 5 volt supply is coupled to the input terminals of output switches 44 and 45 . The ground potential is applied to control terminals of output switches 42 , 44 and 45 are coupled to the ground potential. The output terminal of output switch 44 provides the MAX THRESH signal while the output terminal of output switch 45 is coupled through resistor 46 to ground potential, through capacitor 47 to ground potential, and supplies the TVR_LIMIT signal.
[0022] Referring to FIG. 5 , a schematic diagram of the threshold generator circuit 50 , according to the present invention is shown. The MAX THRESH signal is applied through resistor 51 to grounded capacitor 52 , to grounded resistor 53 , to the positive input terminal of operational amplifier 54 , and to the terminal providing the TVR THRESH signal. The power terminal of operational amplifier 54 is coupled to a 5 volt supply. The output terminal of the operational amplifier 54 is coupled to the negative input terminal of operational amplifier 54 , and is coupled through resistor 55 to grounded capacitor 56 and to the TVR TERM signal terminal.
[0023] Referring to FIG. 6 , a schematic diagram of the target power loss detection unit 60 , according to the present invention, is shown. The TREF signal is applied to a positive input terminal of comparator 67 , to a positive input terminal of comparator 66 , and through resistor 61 to a terminal of grounded capacitor 62 and the positive input terminal of operational amplifier 63 . The power terminals of operational amplifier 63 and comparators 66 , and 67 are coupled to a 5 volt supply. The output terminal of operational amplifier 63 is coupled to a negative input terminal of operational amplifier comparator 63 and through resistor 64 to a negative input terminal of comparator 66 and to grounded resistor 65 . The negative input terminal of comparator 67 is coupled through capacitor 601 to ground potential, through resistor 69 to the ground potential, and through resistor 68 to a 5 volt power supply. The output terminals of comparators 66 and 67 are coupled together to provide a TV_GOOD signals and are coupled through resistor 602 to a 5 volt supply.
[0024] Referring to FIG. 7 , the configuration of the input comparator 70 is shown. The input comparator 70 has the TVR_THRESH signal is applied to the positive input terminal of comparator 70 , while the INPUT signal is applied to the negative input terminal of comparator 70 . The power terminal of comparator 70 is coupled to a 5 volt supply.
[0025] Referring to FIG. 8 , the configuration of the output switch 80 is shown. An input signal (e.g., from the emulation unit signals) is applied to an input terminal of FET switch 80 while the output terminal FET switch 80 provides the output signal (e.g., to the target processor. The control terminal of the FET switch has the control signal applied thereto. The TREFZDRIVER signal is applied to the power terminal of the FET switch. The FET switch limits the output voltage to TREF2DRIVER-1V.
[0000] Operation of the Preferred Embodiment
[0026] Referring once again to interface apparatus of FIG. 1 , the inputs to the apparatus are protected by electrostatic discharge (ESD) clamp diodes. The target I/O voltage is sensed, filtered and fed to the remaining analog circuitry. The clamp generator generates the ESD clamping voltage for input and output signals. The limiter sets the maximum voltage into the threshold circuit. The threshold generator creates threshold and termination voltages. The power loss detection unit senses when the target voltage is off. As will be clear, the signal path between the target processor and the emulation unit will actually be comprised of a multiplicity of paths, i.e., a multiplicity of output switches will be used.
[0027] Referring once again to the target voltage sensing circuit shown in FIG. 2 , the input signal to this circuit has the ESD protection diodes clamped to ground and to the op amp power supply. The input circuit has a high value resistor 23 coupled to ground so that when disconnected, the output TREF signal will go to zero volts. The input signal is applied to the low pass-filter of resistor 24 and capacitor 25 , buffered by op amp 26 , and then applied to low pass of resistor 27 and capacitor 28 . The output TREF signal is a buffered and filtered equivalent of the target voltage. The time constants are chosen to reduce noise, but allow a reasonable response time when the voltage is turned on.
[0028] Referring once again to the clamp voltage generation circuit shown in FIG. 3 , this circuit multiplies the target reference voltage, TREF, by 1.33 to increase the clamping voltage for the ESD diodes on all of the other input and output signals. The clamping voltage is applied to a low pass filter and is decoupled.
[0029] Referring once again to the target voltage limiter shown in FIG. 4 , this circuit routes TREF through FET switch 41 . It also routes the 3.30 volt power supply through FET switch 42 . These two switches are in the same package and share the same substrate. The output voltage is limited to the lesser of the two input signals plus approximately 1 volt. This voltage, TREF2DRIVER, is used to power FET switches 44 and 45 , as well as the FET output switch 80 . The outputs of those switches are limited to TREF2DRIVER-1 volt. The output from FET switch 45 is low pass filtered by resistor 46 and capacitor 47 to become TUR_LIMIT. The TUR_Limit voltage can be used for pulling up target signals if required.
[0030] Referring once again to the threshold generator as shown in FIG. 5 , this circuit takes the MAX_THRESH voltage and divides the voltage using two resistors 51 and 53 and a low pass filter including capacitor 52 to provide the TVR THRESHOLD signal. For all target voltages 3.3 volts and less, the threshold is set to 50% of the target voltage, the standard CMOS threshold. For target voltages greater than 3.3 volts, typically 5 volts, the threshold is set to 1.65 volts, which is close to the nominal 1.4 volt TTL threshold voltage level. The TVR_THRESHOLD is buffered, passed through a low pass filter and is decoupled using resistor 55 and capacitor 56 to generate the TERMINATION voltage, TVR_TERM. The terminal voltage can be used to terminate signals from target processor to the Target I/O voltage/2 to minimize the DC current loading.
[0031] Referring to the power loss detection circuit shown in FIG. 6 , this circuit has two methods for detecting power loss. The first method is by comparing the target reference voltage to a fixed threshold of 0.35 volts. The threshold is provided by resistors 68 and 69 , capacitor 601 providing low pass filtering. The second method of power loss detection is to detect a drop in power from the existing level. This detection is accomplished by filtering the TREF voltage with a low pass filter of resistor 61 and capacitor 62 with a very large time constant. This signal is buffered and divided by resistors 64 and 65 to 75% of the target voltage. The comparator detects drops in the target voltage exceeding 25% of nominal. When the target processor loses power, the emulation unit is notified by an interrupt signal in order for the software to make appropriate adjustments.
[0032] Referring to the input comparator circuit shown in FIG. 7 , all of the active signals from the target are routed to input comparators to sense whether they are high or low. The threshold levels are derived from the target I/O voltage.
[0033] Referring to the output switch logic as shown in FIG. 8 , the input signals are applied to the target processor through FET switches in order to provide voltage level adjustment. The FET switches are controlled by control signals applied to the FET control terminal. The FET transistors can be used to stop the exchange of data signals between the emulation unit and the target processor. The FET switches are used in this implementation for several reasons, these switches have virtually no propagation delay, consume virtually no power, and the output voltage is constrained to no greater than the supply voltage minus the gate to drain voltage. Because the TREF2DRIVER voltage is applied to the power supply input of the FET switches, the output voltage can not exceed the target I/O voltage.
[0034] As will be clear, the interface can be implemented using analog-to-digital converter to sense the target I/O voltage. A digital-to analog converter or programmable power supply can be programmed to supply the output voltage levels and threshold levels.
[0035] While the invention has been described with respect to the embodiments set forth above, the invention is not necessarily limited to these embodiments. Accordingly, other embodiments, variations, and improvements not described herein are not necessarily excluded from the scope of the invention, the scope of the invention being defined by the following claims.
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An emulation unit/target processor interface apparatus senses the target processor I/O voltages using filters to reduce the noise level and provides the rest of the interface apparatus with a target reference voltage level. The reference voltage is used to create threshold voltages, termination voltages and drive levels appropriate to provide an interface with the target processor. Power loss in the target processor is also detected so that drive signals can be removed from the target processor to avoid damaging the target processor and to prevent the target processor from being energized by the emulation unit.
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BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to a ladder warning system, and more particularly relates to a warning system that warns a user when the user steps on the lowest step of the ladder as the user descends the ladder.
[0002] Presently, over 200,000 people are injured each year in ladder-related accidents, and many of these people are injured when they are descending a ladder. However, current ladder designs do not include a warning system that warns a user as he or she steps on the lowest step of the ladder.
[0003] As can be seen, there is a need for a warning system to warn a user as he or she steps on the lowest step of the ladder.
SUMMARY OF THE INVENTION
[0004] In one aspect of the present invention, a ladder warning system comprises: a first pressure sensor attachable to a first step of a ladder; one or more warning device; and a battery that distributes current to the one or more warning devices upon the first pressure sensor sensing pressure exerted on the first step of the ladder.
[0005] In another aspect of the present invention, a ladder comprises: a first pressure sensor attached to a first step of the ladder; one or more warning devices; and a battery that distributes current to the one or more warning devices upon the first pressure sensor sensing pressure exerted on the first step of the ladder.
[0006] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows a ladder warning system on a ladder in accordance with an embodiment of the present invention;
[0008] FIG. 2 shows a wiring diagram of the ladder warning system of FIG. 1 in accordance with an embodiment of the present invention; and
[0009] FIG. 3 shows a ladder warning system in an alternate configuration on a ladder in accordance with al alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0011] Various inventive features are described below that can each be used independently of one another or in combination with other features.
[0012] Broadly, embodiments of the present invention generally provide a ladder warning system that provides both visual and audio warnings upon sensing pressure being placed by a user on the lowest step of a ladder.
[0013] FIG. 1 shows a ladder warning system on a ladder in accordance with an embodiment of the invention. The ladder warning system 10 may comprise a pressure sensor 105 , a battery 110 , warning lights 115 , a sound indicator 120 , and wiring 125 . As shown in FIG. 1 , the pressure sensor 105 may be attached on top of a step 130 of the ladder 100 , such as the lowest step on a ladder 100 . The warning lights 115 may be placed on the ladder 100 so that when a user steps on the lowest step of the ladder 100 , the warning lights 115 may be at eyelevel with the user. Similarly, the sound indicator 120 may also be placed on the ladder 100 such that when the user steps on the lowest step of the ladder 100 , the sound indicator 120 may be at ear-level of the user. The battery 110 may be connected to the pressure sensor 105 , the warning lights 115 , and the sound indicator 120 via wiring 125 .
[0014] FIG. 2 shows a wiring diagram of a ladder warning system 10 in accordance with an embodiment of the present invention. The pressure sensor 105 may be attached to a step of the ladder. When the pressure sensor 105 senses that pressure is being applied to the step of the ladder that it is attached to, such as when a user steps onto that step with his foot, the pressure sensor 105 may cause for the battery 110 to send current to the warning lights 115 and the sound indicator 120 via the wiring 125 . The current may then cause the warning lights 115 to turn on, thereby emitting light or flashing light, and may also cause the sound indicator 120 to emit a sound, such as buzzing. The light emitted by the warning lights 115 and the sound emitted by the sound indicator 120 may serve to warn the user that he is at a certain level of the ladder.
[0015] In an exemplary embodiment of the present invention, the ladder warning system may be used to warn a user descending from a ladder that he is stepping on the lowest rung of the ladder and about to step off of the ladder. The pressure sensor 105 may be attached to the lowest step of the ladder, the warning lights 115 may be attached to the ladder at a position so that it is at eyelevel with a user when that user steps on the lowest step of the ladder. Similarly, the sound indicator 120 may be attached to the ladder at a position so that it is at ear level with the user when that user steps on the lowest step of the ladder. Thus, as the user descends the ladder, when the user steps on the lowest step of the ladder, the pressure sensor 105 may sense the user's weight and thus cause the sound indicator 120 to buzz and the warning lights 115 to turn on and flash, thus warning the user that he is about to step off of the ladder.
[0016] FIG. 3 shows the ladder warning system in an alternate configuration on a ladder in accordance with an alternate embodiment of the present invention. In the alternative exemplary embodiment of the present invention, the ladder warning system 10 may be used to warn a user that he is at the top of the ladder 100 . The pressure sensor 105 may be attached to the topmost step of the ladder 100 . When the pressure sensor 105 senses that the user is stepping onto the topmost step of the ladder, the pressure sensor 105 may cause the sound indicator 120 to turn on and emit a periodic buzzing sound and may further cause the warning lights 115 to turn on and flash.
[0017] In another alternative exemplary embodiment of the present invention, pressure sensors 105 may each be attached to the topmost step of the ladder and the lowest step of the ladder 100 , thereby warning a user both when the user reaches the topmost step of the ladder 100 or when the user reaches the lowest step of the ladder 100 .
[0018] In use, the warning lights may be light emitting diodes (LEDs) or any other methods of lighting. The sound indicator can be a buzzer, a speaker, or any other method of producing a warning sound. The wire connecting the components together can be contained within a wire harness.
[0019] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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A ladder warning system comprises a pressure sensor attachable to a first step of a ladder; one or more warning devices; and a battery that distributes current to the one or more warning devices upon the pressure sensor sensing pressure exerted on the first step of the ladder.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is entitled to the benefit of, and claims priority to, provisional patent application 61/053,054 filed May 14, 2008, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. The present disclosure invention is related in general to cable systems and, in particular, to wireline cables.
Typical wireline cable designs consist of a cable core of one or more insulated conductors (packed in an interstitial filler in the case of multiple conductors) wrapped in cabling tape followed by the application of two armor wire layers. The armor wire layers are applied counterhelically to one another in an effort to minimize torque imbalance between the layers. These armor wires provide the strength needed to raise and lower the weight of the cable and tool string and protect the cable core from impact and abrasion damage. In an effort to provide additional protection against impact and abrasion damage, larger-diameter armor wires are placed in the outer layer. Torque imbalance between the armor wire layers, however, continues to be an issue, resulting in cable stretch, cable core deformation and significant reductions in cable strength.
In pressurized wells, gas can infiltrate through gaps between the armor wires and travel along spaces existing between the inner armor wire layer and the cable core. Grease-filled pipes at the well surface typically provide a seal at the well surface. As the wireline cable passes through these pipes, pressurized gas can travel through the spaces between the inner armor wires and the cable core. When the cable then passes over and bends over a sheave, the gas may be disadvantageously released.
Typical wireline designs have approximately 98% coverage with each layer of armor wire. If the coverage is too low, the armor wires may disadvantageously move along the cable and the cable may have loose wires.
Torque for a layer of armor wire can be described in the following equation.
Torque=¼ T ×PD×sin 2α
Where:
T=Tension along the direction of the cable PD=Pitch Diameter of the Armor Wires α=Lay angle of the wires
Referring now to FIG. 1 , since the outer armor wire layer 12 of the cable 10 carries more loads and has a larger pitch diameter, the torque generated by the outer armor wire layer 12 (indicated by an arrow 13 ) is generally larger than the torque generated by inner armor wire layer 14 (indicated by an arrow 15 ), which disadvantageously results in torque imbalance for the cable 10 .
Torque imbalance in the cable 10 is disadvantageous because a cable core 16 may deform into the interstitial spaces between the inner armor wires 14 , reducing the diameter of the cable 10 . The cable 10 may disadvantageously have more stretch and the core 16 may be damaged. As the diameter of the cable 10 is reduced, the pitch diameter of inner armor 14 has a larger percentage reduction than the pitch diameter of outer armor 12 , which may further complicate torque imbalance.
It is desirable, therefore, to provide a torque-balanced and damage resistant wireline cable.
SUMMARY
An embodiment of a wellbore cable comprises a cable core, at least a first armor wire layer comprising a plurality of strength members and surrounding the cable core, and at least a second armor wire layer comprising a plurality of strength members surrounding the first armor wire layer, the second armor wire layer covering a predetermined percentage of the circumference of the first armor wire layer to prevent torque imbalance in the cable. Alternatively, the predetermined percentage comprises about 50 percent to about 90 percent of the circumference of the first armor wire layer. Alternatively, the strength members of the second armor wire layer comprise at least one stranded armor wire member. Alternatively, the cable further comprises at least one layer of a polymeric material surrounding the cable core, the first armor wire layer and at least a portion of the second armor wire layer. The polymeric material may bond to the first armor wire layer, the second armor wire layer, and the cable core. The cable core further may comprise a polymeric insulating layer and the polymeric material may bond to the insulating layer of the cable core.
Alternatively, the cable further comprises a polymeric jacket forming an outer layer of the cable, the jacket bonded to at least the outer strength members. The polymeric jacket may comprise a fiber-reinforced polymer. Alternatively, the cable core comprises one of a monocable, a coaxial cable, a triad cable, and a heptacable. Alternatively, a diameter of the strength members in the outer armor wire layer and the inner armor wire layer are substantially equal. Alternatively, a diameter of the strength members in the outer armor wire layer is greater than a diameter of the strength members in the inner armor wire layer. Alternatively, at least one of the conductors of the cable core comprises an optical fiber.
An embodiment of a wellbore cable comprises at least three conductors each comprising a cable core encased in a polymeric jacket, at least one armor wire layer disposed against the cable core at a lay angle, and a polymeric layer encasing the at least one armor wire layer, the conductors cabled together helically at a lay angle opposite the lay angles of the respective strength members to prevent torque imbalance in the cable. Alternatively, torque balance between the cables is achieved by adjustments in the opposing lay angles of the armor wires and the completed cable. Alternatively, the cable further comprises a polymeric jacket encasing each of the three cables. Alternatively, the cable further comprises a soft polymer central element disposed between the three cables. Alternatively, a diameter of a circle passing through the centers of each of the conductors is approximately the same size as the individual diameter of each of the three conductors. Alternatively, the cable cores comprise at least one of a monocable, a coaxial cable, a triad cable, and a heptacable. Alternatively, at least one of the cable cores comprises an optical fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
FIG. 1 is a is a radial cross-sectional view of a prior art wireline cable;
FIGS. 2 a through 2 d are radial cross-sectional views of an embodiment of a cable.
FIGS. 3 a through 3 d are radial cross-sectional views of an embodiment of a cable.
FIGS. 4 a through 4 d are radial cross-sectional views of an embodiment of a cable.
FIGS. 5 a through 5 d are radial cross-sectional views of an embodiment of a cable.
DETAILED DESCRIPTION
Referring now to FIGS. 2 a through 2 d , an embodiment of a cable is indicated generally at 200 . FIGS. 2 a - 2 d show a cable 200 a , 200 b , 200 c , and 200 d , respectively. The cables 200 a , 200 b , 200 c and 200 d comprise damage-resistant outer armor wires 202 , which may advantageously be applied to any basic wireline cable configuration or core. In non-limiting examples, FIG. 2 a shows a monocable cable core with stranded wires 206 a , FIG. 2 b shows a coaxial cable core 206 b , FIG. 2 c shows a heptacable cable core 206 c , and FIG. 2 d shows a triad cable core 206 d having multiple cable conductors as part of the core 206 d . The conductors forming the cable cores 206 a , 206 b , 206 c , and 206 d may be any combination of (but not limited to) monocables, coaxial cables, copper conductors, optical fibers (such as those shown in FIG. 2 d ) or the like and be insulated with any suitable polymeric material or materials as will be appreciated by those skilled in the art. As shown in FIGS. 2 a - 2 d , the inner armor layer 204 carries more load since its pitch diameter is smaller than outer armor layer 202 .
The outer armor wires 202 shown in FIGS. 2 a - 2 d are sized similarly to the inner armor wires 204 but the layer of the outer armor wires 202 covers a predetermined percentage of the circumference of the inner armor wires 204 in order to prevent torque imbalance in the cable 200 . The predetermined percentage of coverage may be, but not limited to, about 50% to about 90% coverage of the circumference of the inner armor wire layer 204 , which is smaller than the percentage coverage of the armor wire layers 12 and 14 shown in the prior art cable 10 in FIG. 1 . The predetermined percentage of coverage may be, but not limited to, about 50% to about 90% coverage of the circumference of the cable cores 206 a , 206 b , 206 c , and 206 d , which is smaller than the percentage coverage of the armor wire layers 12 and 14 and cable core 16 shown in the prior art cable 10 in FIG. 1 . This smaller percentage of coverage of the outer armor wires 202 with respect to the inner armor wires 204 advantageously maintains the torque-balance of the cable 200 a - 200 d and increases the ability of the outer armor wires 202 to withstand abrasion damage. In a non-limiting example, the number of armor wires in the inner armor layer 204 and the number of armor wires in the outer armor layer 202 are equal, providing a predetermined coverage in direct relation to the respective diameters of the individual armor wires 202 and 204 and radial spacing of the armor wire layers 202 and 204 . The predetermined coverage may be selected by a number of factors which may include, but are not limited to, the size and/or diameter of the cable 200 a - 200 d , the size and/or diameter of the cable core 206 a - 206 d , the size and/or diameter of the individual members of the armor wire layers 202 and 204 , and the radial spacing between the armor wire layers 202 and 204 . The inner armor wires 204 may cover a predetermined percentage of the circumference of the cable core 206 a - 206 d that may be, but is not limited to, about 98% to about 99% of the circumference of the cable core 206 a - 206 d.
A polymeric insulating material 208 may be disposed on the inner armor wire layer 204 , the cable core 206 a , 206 b , 206 c , and 206 d and a portion of the outer armor wire layer 202 and may bond the armor wire layers 202 and 204 to the cable core 206 a - d , including the insulating layer of the cable core 206 a - d . The insulating material 208 may be formed from any suitable material such as, but not limited to, the following: polyolefin or olefin-base elastomer (such as Engage®, Infuse®, etc.); thermoplastic vulcanizates (TPVs) such as Santoprene® and Super TPVs and fluoro TPV (F-TPV); silicone rubber; acrylate rubber; soft engineering plastics (such as soft modified polypropylene sulfide (PPS] or modified Poly-ether-ether-ketone [PEEK]); soft fluoropolymer (such as high-melt flow ETFE (ethylene-tetrafluoroethylene) fluoropolymer; fluoroelastomer (such as DAI-EL™ manufactured by Daikin); and thermoplastic fluoropolymers. The radial thickness of the insulating material 208 and thus the radial spacing between the armor wire layers 202 and 204 may be varied to achieve torque balancing of the cables 200 a - 200 d and/or prevent torque imbalance of the cables 200 a - 200 d , as will be appreciated by those skilled in the art.
FIGS. 3 a - 3 d show the of cables of FIGS. 2 a - 2 d having an outer jacket 320 bonded to the insulating material 208 to form a jacketed cable 300 a , 300 b , 300 c , and 300 d that correspond, respectively, to cables 200 a , 200 b , 200 c , and 200 d . Referring now to FIG. 3 , there are shown embodiments of torque-balanced cables 300 a , 300 b , 300 c , and 300 d that comprise the cables shown in FIGS. 2 a - 2 d having with damage-resistant outer armor wires with a bonded outer jacket 320 . By providing the bonded outer polymeric jacket 320 over the embodiments shown in FIG. 2 , the cable is preferably more easily sealed at the well surface. The outer jacket 320 may comprise any suitable material such as, for example, carbon-fiber-reinforced Tefzel®, carbon-fiber-reinforced ETFE (ethylene-tetrafluoroethylene) fluoropolymer or similar suitable material that is applied over the outer armor wire layer, bonding through the gaps in the outer strength members 204 , which creates a totally bonded jacketing cable system 300 a - 300 d . The addition of the fiber-reinforced polymer 320 also provides a more durable outer surface. The outer jacket 320 may be bonded to the insulating material 208 and/or to the outer armor wires 202 .
FIGS. 4 a - 4 d show the of cables of FIGS. 3 a - 3 d comprising optional stranded wire outer armor wire layers 420 to form cable embodiments, indicated generally at 400 a , 400 b , 400 c , and 400 d . As an option to the embodiments shown in FIGS. 2 a - 2 d and 3 a - 3 d described above, any solid armor wire 202 or 302 in the outer layer may be replaced with similarly size stranded armor wires 420 . The replacement of solid armor wire 202 with stranded armor wires 420 makes the cable 400 a , 400 b , 400 c , and 400 d more flexible. In addition, the stranded armor wires 420 have more friction and bonding with the jacket 320 and the jacket 320 over the stranded wires 420 also protects the small individual elements from abrasion and cutting.
Embodiments of the cables 200 a , 200 b , 200 c , 200 d , 300 a , 300 b , 300 c , 300 d , 400 a , 400 b , 400 c , and 400 d have a lower coverage, from about 50% to about 90%, in the outer armor layer 202 . The cables maintain the size and durability of outer strength members 202 while creating torque balance between inner armor layers 204 and the outer armor layers 202 . The weight of the cables is reduced because of the lower coverage percentage. The cable is preferably a seasoned cable and requires no pre-stress and also has less stretch. Because all interstitial spaces between the armor wires 202 and 204 are filled by polymers 208 and 320 , the cables need less grease for the seal (not shown) at the well surface (not shown). Embodiments of the cables may comprise an outer layer of polymer 320 to create a better seal.
Embodiments of the cables 200 a , 200 b , 200 c , 200 d , 300 a , 300 b , 300 c , 300 d , 400 a , 400 b , 400 c , and 400 d minimize the problems described above by filling interstitial spaces among armor wires and the cable core with polymers 208 and 320 , by using large diameter armor wires but a low coverage (50% to 90%) for the outer armor layer to reach torque balance, and by using a triad configuration, discussed in more detail below.
The polymeric layers 208 and/or 320 provide several benefits including, but not limited to, filling space into which the inner armor wire might otherwise be compressed thereby minimizing cable stretch, keeping cable diameter while cable at tension, reducing torque since the reduction in pitch diameter is minimized, eliminating the space in the cable along which pressurized gas might travel to escape the well, protecting the cable core from damage caused by inner armor wires, cushioning contact points among armor wires to minimize damage caused by armor wires rubbing against each other, sitting low coverage outer armor wires to avoid loose wires, and produces seasoned alloy cables.
The low coverage (about 50% to about 90%) of armor wire in the outer layer 202 or 420 provides several benefits including, but not limited to, maintaining torque balance, maintaining the size and durability of outer armor wires 202 or 420 , and lowering the weight of the cable by reducing the coverage of the armor wire 202 or 420 .
Referring now to FIGS. 5 a - 5 d , there is shown an embodiment of a torque-balanced triad cable configuration 520 in which the armor wire may be any kind of strength member. The cable may be constructed as follows:
As shown in FIG. 5 a , individual conductors 500 may be constructed with a copper, optical fiber or other conductor or conductors 502 at the center contained in a hard polymeric insulation 504 . Armor wires 506 may be cabled helically in a direction indicated by an arrow 507 over the polymer 504 and a second layer of softer polymer 508 is extruded over the armor wires 506 .
As shown in FIG. 5 b , preferably three conductors 500 , as shown in FIG. 5 a , are cabled together at a lay angle, indicated by an arrow 509 , opposite to that of the lay angle 507 of the armor wires 506 in the individual conductors 500 . Alternatively, a central member 510 with soft polymer insulation 512 is placed at the center of the three conductors 500 .
As shown in FIG. 5 c , when the three conductors 500 are cabled together, the soft polymer 512 on the central element deforms to fill the interstitial space between the three conductors 500 . The diameter of a circle passing through the centers of each of the three conductors 500 (indicated by an arrow 514 ) is preferably approximately the same size as the individual diameter of each of the three conductors 500 , which allows the cable to achieve torque balance by slight adjustments in the opposing lay angles of the armor wires 506 and the completed cable 500 .
As shown in FIG. 5 d , a final hard polymeric jacket 516 , which may be pure polymer or short-fiber-amended polymer or another suitable material, is extruded over the cabled conductors 500 to complete the cable 520 .
The cable 520 comprises a low weight torque balanced cable in a triad cable configuration. This embodiment comprises only one layer of armor 506 in each conductor 500 of the triad cable. The lay direction of the armor wire 506 is preferably opposite to the lay direction of the triad 509 to reach torque balance. The triad configuration of the cable 520 provides several benefits including, but not limited to, keeping torque balance of the cable 520 , minimizing the contact points of armor wires to minimize damage caused by armor wires 506 rubbing against each other, and lowering the weight of the cable 520 by using only one layer of armor wire 506 in each conductor 500 .
The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood as referring to the power set (the set of all subsets) of the respective range of values. Accordingly, the protection sought herein is as set forth in the claims below.
The preceding description has been presented with reference to presently preferred embodiments of the invention. Persons skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structures and methods of operation can be practiced without meaningfully departing from the principle, and scope of this invention. Accordingly, the foregoing description should not be read as pertaining only to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope.
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An embodiment of a wellbore cable comprises a cable core, at least a first armor wire layer comprising a plurality of strength members and surrounding the cable core, and at least a second armor wire layer comprising a plurality of strength members surrounding the first armor wire layer, the second armor wire layer covering a predetermined percentage of the circumference of the first armor wire layer to prevent torque imbalance in the cable.
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FIELD OF INVENTION
This invention relates to a high precision fluid pump, and more particularly to a stepper-motor driven precision pump which includes nitrogen purging for clean environment application.
BACKGROUND OF THE INVENTION
In semiconductor substrate processing or medical applications, it is necessary to provide blended processing fluids of acids, alkalies, and organic solvents, which may include, e.g., mixtures of hydrogen peroxide with sulfuric acid, ammonium hydroxide, or water, or mixtures of hydrofluoric acid blended with water, acidic acid, nitric acid, or phosphoric acid. A pump is used to direct desired amounts of fluid to a processing chamber in which semiconductor wafers, photomasks, other products are being treated or processed.
The pump must be able to withstand the hostile environment created by the aggressive processing fluids. Further, contaminants in the processing fluid need to be kept to a minimum to achieve the clean environment required in high purity applications. Moreover, it is also critical that bacterial growth be inhibited.
Finally, because of the precision required of the mixed fluids, the pump must be able to deliver unusually accurate amounts of processing fluid to the processing chamber. The fluid must also be dispensed with accurate repetition.
Conventional mechanical methods of controlling the pumping action have problems dealing with these precision semiconductor applications. The accuracy needs to be improved, the cleanliness needs to be improved, and the number of particles generated can be reduced. Although electronics can be used, accuracies can still be limited by the inherent imperfection of the mechanical structure. Moreover, there still remains a concern of contamination and pump reliability because of the hostile pump environment.
There is a need, therefore, for a pump that can dispense accurate amounts of fluid with accurate repetition and provide a clean environment for the processing of the fluid therethrough.
SUMMARY OF THE INVENTION
The present invention uses a stepper-motor drive system that includes a stepper motor with electronic control to extract and dispense precise amounts of fluid with accurate repetition. The stepper motor is disposed in a motor chamber and drives a piston in a piston chamber to expel a controlled amount of fluid from the piston chamber into a processing tank.
A personal computer, programmable controller or other type of programming devices as known in the industry can be used to program the controller to control the movement of the drive system to achieve precise extraction and displacement volume and rate.
To protect the stepper-motor drive system and electronics from the aggressive processing fluids, an isolation rolling diaphragm is used to separate the motor chamber from the piston chamber. The rolling diaphragm is preferably made of chemrez and cyclically deforms with every stroke of the piston, isolating the stepper-motor drive system.
To further maintain low particle count, nitrogen is directed through the interior of the pump on both sides of the rolling diaphragm. The nitrogen purging impedes migration of contaminants into the processing chamber, and prevents oxidation inside the pump, and acts to cool the stepper motor and the controller.
In one embodiment of the present invention, the fluid pump comprises a body including a fluid inlet and a fluid outlet, and a fluid chamber, a stepper motor controllable by electronics, a piston reciprocally mounted in a chamber and driven by the stepper motor, and an isolation diaphragm separating the fluid and the motor. The fluid inlet has an inlet valve and the fluid outlet has an outlet valve. The piston is driven by the stepper motor to move between an extracting position and a dispensing position. When the piston moves from the dispensing position to the extracting position, the inlet valve is configured to open and the outlet valve is configured to close. When the piston moves from the extracting position to the dispensing position, the inlet valve is configured to close and the outlet valve is configured to open. The isolation diaphragm is disposed between the stepper motor and the piston to prevent fluid transfer therebetween. With regard to the diaphragm acting to protect the motor, fluid is defined to include liquid, fumes or gas or any combination thereof.
Another embodiment of the present invention includes an on-board controller comprising stepper-motor electronics for controlling the stepper motor.
The components of the pump which have wetted surfaces exposed to the fluids, including the piston and piston chamber, are made of PTFE (polytetrafluoroethylene), a fluorocarbon resin material that is essentially inert to most aggressive acids, alkalies, and organic solvents. Advantageously, other components of the pump are also made of PTFE. PTFE also can tolerate processing temperatures of over 100° C. Processing fluids do not leach into, through, or out of PTFE. Nor does PTFE support bacterial growth. Materials other than PTFE may be suitable for use in the same portions of the pump as PTFE. These other materials include high density polyethylene, poly propylene, PEEK and TFM.
The pump of this invention is believed to limit the particle count to less than 0.2 micron particle per liter of fluid pumped. For fluid volume of less than 9999.9 milliliter (ml), the stepper-motor drive system can achieve resolution of 0.1 ml.
This invention further comprises an advantageous method of accurately pumping fluid while reducing the contaminants the pump adds to the fluid. This process is achieved by providing and placing a piston and a chamber in a housing and reciprocating the piston in the chamber between an extracting position which increases the volume of the chamber and a dispensing position which decreases the volume of the chamber. An inlet valve is placed in fluid communication with the chamber to provide fluid to the chamber when the piston is in an extracting position, and the inlet valve is closed when the fluid is not in an extracting position. An outlet valve is placed in fluid communication with the chamber to provide fluid to the chamber when the piston is in a dispensing position, with the inlet valve being closed when the fluid is not in a dispensing position. A stepper motor is placed inside the housing and in driving communication with the piston to reciprocate the piston. An isolation diaphragm is disposed between said stepper motor and said piston to prevent fluid transfer therebetween. With regard to the diaphragm acting to protect the motor, fluid is defined to include liquid, fumes or gas or any combination thereof.
Advantageously the method further includes the steps of placing a first gas inlet and outlet in fluid communication with a first portion of the housing between the diaphragm and the piston to purge that first portion of the housing with an inert gas; and placing a second gas inlet and outlet in fluid communication with a second portion the housing between the diaphragm and the motor to purge that second portion of the housing with an inert gas. Further, the method advantageously includes the steps of placing an electronic controller inside the housing and in electronic communication with a plurality of sensors and data inputs, and automatically controlling the operation of the pump without external control.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view illustrating a pump in accordance with a first preferred embodiment of the present invention;
FIG. 2 is a cross-sectional view illustrating a pump with an on-board controller in accordance with a second preferred embodiment of the present invention; and
FIG. 3 is a cross-section view illustrating an adaptable pump in accordance with a third preferred embodiment of the present invention.
FIG. 4 is a cross-section view illustrating a further variation of the pump of FIG. 2.
FIG. 5 is a basic block diagram of the controller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates the first preferred embodiment of a pump. The pump includes a baseplate 10 which supports a base 12 attached to a body 14. The body 14 is connected to a diaphragm housing 16 attached to a motor housing 18. A cover 20 cooperates with the motor housing 18 and is enclosed by a cap 22. An inlet valve assembly 24 is provided to regulate fluid flow into a fluid cavity 26 inside the body 14. An outlet valve assembly 28 controls fluid flow out of the cavity 26 of the body 14. Piston manifolds 30 and motor manifold 32 provide flow connections to sources of purging gas, such as nitrogen.
Referring to FIG. 1, the baseplate 10 has sufficient surface area to support the base 12 of the pump in a vertical position. The baseplate 10 can also be mounted in other orientations and angles (not shown). The base 12 provides support for the body 14, and inlet assembly 24 and outlet valve assembly 28. The base 12 and baseplate 10 are made of sufficiently strong material to support the pump during operation, and are advantageously made of PTFE.
The body 14 is desirably a circular cylinder with an internal cylindrical cavity 26 enclosed at one end of the cavity by the cavity end fitting 33 that is mounted to the base 12. A piston 34 is disposed inside the cavity 26 of the body 14 and configured to move back and forth along the cavity. The cavity 26 is cylindrical in shape and is desirably a circular cylinder with a first opening 36 near the enclosed end in fluid communication with the outlet valve assembly 28. The movement of the piston 34 is along the longitudinal axis of the cavity 26 in the body 14.
The cavity 26 is used for accumulating the fluid for distribution. The fluid enters through the inlet valve assembly 24 and exits through the outlet valve 28, which are both desirably check valves that employ a pneumatic spring-biased diaphragm adjacent an orifice. Other valve configurations could be used, such as spring-loaded ball valves. For compactness, the valves 28 and 24 are advantageously disposed at a 90° bend as shown in FIG. 1. The operation of the valves 28 and 24 is discussed in more detail below in conjunction with a pumping cycle or stroke.
The piston 34 desirably includes a cylindrical piston having a diameter slightly smaller than the inner diameter of the cavity 26 to provide a sliding fit. The spacing between the piston head and cavity wall should be as small as possible while still allowing smooth sliding motion for the piston 34. An O-ring seal 40 interposed between the piston 34 and the cavity 26 provides a fluid-tight seal. The O-ring 40 is made of chemrez 570 to reduce particle generation while providing a good sliding seal. The flat piston head 42 faces the enclosed end of the cavity 26, and is wetted by the fluid during the pumping cycle.
The piston 34 has a piston shaft 44 attached to the piston which is opposite the front side. The piston shaft moves in and out of the cavity 26 during pumping cycles. The piston shaft is advantageously a round shaft with a diameter smaller than the diameter of the piston head.
As seen in FIG. 1, the cavity 26 of the body 14 has a front portion through which the fluid enters and exists, and a back portion in which the piston shaft is disposed. The volume of the front and back portions change as the piston 34 moves back and forth during pumping. The piston 34 moves between two fully extended positions, a fully extracted position where the volume of the rear position is at a minimum, and a fully dispensed position where the volume of the front portion is at its minimum and the volume of the back portion reaches its maximum. The piston 34 undergoes a full stroke as it moves from a fully extended position, say the extracting position, to the dispensing position and back to the extracting position. FIG. 1 shows the piston 34 approaching its fully extended position, with the piston head 42 almost contacting end fitting 33. Actual contact should be minimized as it can generate particulate contaminants.
A clocking plate 49 is provided near the back end of the body 14. It has two flanges anchored at two opposing grooves provided in the body 14 to prevent rotational motion. The clocking plate 49 partially encloses the open end of the back portion of the cavity 26 and has a hole at the center through the piston shaft 44 reciprocates. The plate 49 has tangs that cooperate with grooves in shaft 44 to limit rotation of shaft 44. Alternatively, the shape of shaft 44 can have flat sides that cooperate with the shape of the aperture in clocking device 49 through which the shaft 44 slides to prevent rotation of the piston 34 and shaft 44.
The piston 34 is driven by a motor 46 via the piston shaft 44. In FIG. 1, the motor 46 is housed in the motor housing 18 and provides a drive bar 48 which is attached to a distal end of the piston shaft 44 to transfer motion to the piston 34. The drive bar 48 can be attached to the piston shaft 44 in various ways, but is desirably affixed to a cavity at the center of the piston shaft near its free end. The drive bar 48 conveys a translation motion to move the piston shaft 44 along the longitudinal axis of the body 14, and is advantageously a straight, rigid tube disposed parallel to the longitudinal axis of the body 14, with a first end affixed to the piston shaft and a free, second end 50. A portion of the drive bar cooperates with the motor 46 for transfer of a driving force on the piston shaft.
The motor 46 is preferably a rotary stepper motor that engages a threaded rod thereby translating the rotary motion to linear motion to provide precise displacement of the piston 34 for dispensing an accurate amount of fluid through the outlet valve 12. The mechanics and precision of stepper motors are known in the art. Any suitable stepper motor with at least one-dimensional movement can be used. A commercial available stepper motor 46 has enabled the pump to extract and displace fluid with accurate repetition at a resolution of better than 0.1 ml per volumes of less than 9999.9 ml. The stepper motor 46 is preferably controlled by an electronic controller 76 (not shown). The controller generates a signal to the stepper motor 46 to instruct it to move accordingly drive bar 48, piston shaft 44 and piston 34 a predetermined distance that results in a predetermined change in the volume of cavity 26, to precisely expel fluid from the cavity. The piston 34 is controllable throughout its entire stroke. Various feedback control mechanisms are known for ensuring the stepper motor accuracy and are not described in detail herein.
The motor housing 18 is enclosed by the cover 20 and cap 22 as shown in FIG. 1. The cover 20 has an elongated protrusion near the cap 22 to permit displacement of the drive bar 48 thereto so that the free end 50 of the drive bar does not hit the cover 20, even when the piston 34 and the drive bar have a long stroke. The cap 22 has an opening which leads to an elbow 52 to form a flow channel for nitrogen purging. The details of the structure and operation of nitrogen purging is discussed in more detail below.
The piston 34 preferably has a sufficiently long stroke relative to the volume of cavity 26 so that it can pump the desired volume of fluid in one stroke, which is more accurate than requiring several cycles of short strokes that refill the cavity 26 between strokes. The elongated protrusion of the cover 20 therefore has the advantage of accommodating a piston 34 with longer strokes without substantially enlarging the size of the pump.
It is important to maintain the motor housing 18 free of contamination. One source of contamination is the wetted surface along the cavity wall of the body 14 when the piston 34 is moved to the fully extended dispensing position. To prevent the contamination from the motor 46 from reaching the cavity 26, an isolation diaphragm 54 is disposed in the diaphragm housing 16 near the second end of the piston shaft 44. The diaphragm 54 is desirably a rolling diaphragm which is affixed to the diaphragm housing 16 and the distal end of the piston shaft 44 to completely block the space therebetween, thereby preventing fluid communication between the body 14 and motor housing 18. With regard to the diaphragm 54 acting to protect the motor 46, fluid is defined to include liquid, fumes or gas or any combination thereof. The rolling diaphragm 54 is advantageously made of chemrez, which can deform repeatedly between a concave shape and a convex shape over numerous piston strokes, and is inert to the aggressive processing fluids.
In the diaphragm housing 16 is provided a diaphragm retainer 56 disposed near the junction between the diaphragm housing 16 and the motor housing 18 to constrict the deformation of the diaphragm 54 for smooth movement through the piston stroke. As seen in FIG. 1, the diaphragm 54 is desirably also attached to a portion of the drive bar 48 since the drive bar is connected to the second, distal end of the piston shaft 44. The diaphragm housing 16 abuts the motor housing 18.
The operation of the piston 34 driven by the stepper motor 46 in conjunction with the inlet valve assembly 24 and outlet valve 28 to effect fluid pumping is described as follows. The default position of the piston 34 is shown in FIG. 1, i.e., at the fully extended dispensing position. The inlet valve assembly 24 and outlet valve 28 are closed with the spring-biased diaphragms block the orifices. A bleed-out orifice (not shown) is provided between the valves 24 and 28 near the end fitting 33 to let all the air out of the cavity 26 for priming the pump prior to pumping operation, and to increase the pump accuracy by eliminating compressible air from the cavity 26. To bleed air out of the cavity 26, the inlet valve assembly 24 is connected to a fluid source and the stepper motor 46 is activated to drive the piston 34 open toward the diaphragm housing 16. Fluid accumulates in the cavity 26. The piston 34 is then pushed back to its closed position, thereby driving out most of all of the air out through the outlet valve 28.
After the inlet valve assembly 24 is connected to a fluid source and the outlet valve 28 is connected to the appropriate output such as a processing chamber, the stepper motor 46 drives the piston 34 with the drive bar 48 and moves it toward the diaphragm housing 16. The inlet and outlet valves 24 and 28 are actuated by a pilot valve located elsewhere (not shown). These are pneumatic valves and can be actuated to open and close at any given time. With inlet valve 24 opened and outlet valve 28 closed, the piston 34 can be retracted to cause the fluid to flow into the front portion of the cavity 26 between the piston head 42 and end fitting 33, filling the cavity 26 at the top of the piston stroke. To dispense the fluid from the cavity 26, the inlet valve 24 is closed, outlet valve 28 is opened, and piston 34 is pushed toward the base 12 to a desired position determined by the desired amount of fluid to be dispensed.
Alternatively, the inlet valve 24 can be closed, the outlet valve 28 opened, and the piston 34 retracted to create a predetermined volume in the cavity 34. The outlet valve 28 is then closed, the inlet valve opened, and the piston 34 driven toward the base 12 expelling any gases in the chamber 26 through the inlet valve 24. The piston 34 is then retracted to refill chamber 26 with fluid passing through the inlet valve 24.
To dispense or displace the fluid, the controller reverses the direction of stepper motor 46 and moves the piston 34 toward the end fitting 33, exerting a compressive pressure on the accumulated fluid. The inlet valve assembly 24 remains closed while the spring-biased diaphragm at the outlet valve 28 is pushed open by the pressure. The fluid is dispensed as the piston 34 completes one stroke of whatever length is determined by the controller. For the pump shown in FIG. 1, the maximum capacity of volume dispensed is 200 ml per stroke. The next pumping cycle can being after all fluid is dispensed by one, or several controlled expulsions. Alternately, a partially empty cavity 26 can be filled before expelling additional fluid. The precise sequence can be controlled by the computer activated controller.
To ensure proper functioning of the piston 34 and prevent collision of the end 50 drive bar 48 with the cover 20 or cap 22, or other parts of the pump, sensors are provided to detect the position of the drive bar 48. The presence or absence of the drive bar 48 at a certain location is detected by the sensors. The presence of the drive bar 48 at a particular location may signal a need to limit the minimum volume motion (i.e., toward the dispensing position), while the absence of the drive bar 48 at another location may indicate a need to limit the maximum volume motion (i.e., toward the extracting position).
Advantageously, one limit sensor 58 is positioned to detect the absence of the drive bar 48 to limit the maximum extended stroke of piston 34 and prevent the piston head 42 from being forced into the end fitting 33. A photodetector has proven suitable. Another limit sensor 60 can detect the presence of the drive bar 48 to limit the maximum retraction of the piston 34 and prevent the piston head from hitting the clocking plate 48. A photodetector is suitable for this limit sensor 60.
Gas pursing is advantageously used to impede migration of contaminants into the processing chamber, and to remove particles generated by the pump and cool the stepper motor 46 and the controller 76. Nitrogen is a preferable gas. Nitrogen purging is advantageously provided at both sides of the diaphragm 54, i.e., in the piston region between the piston 34 and diaphragm 54, as illustrated by the single lines 62, and the motor region between the diaphragm 54 and the motor 46, as illustrated by the dashed lines 64.
Manifolds 30 and 32 desirably provide flow connections for nitrogen purging. For the purging shown in single lines 62, nitrogen gas enters through a hose or tube provided at the manifold 30 into the back portion of the body 14 and cavity 26 via a first inflow channel 66. The gas exits through a first outflow 68 channel disposed at the opposite side from the first inflow channel.
For the purging shown in dashed lines 64, nitrogen gas enters through another tube or hose into the motor housing 18 via a second inflow channel 70 and circulates around motor 46, through the motor housing 18 and the diaphragm housing 16. The gas exits the motor housing 18 through the opening 72 provided at the cap 22 and turns at the elbow 52 as it follows a second outflow channel disposed on the opposite side from the second inflow channel.
Second Embodiment
FIG. 2 shows a second preferred embodiment. The operation of the second embodiment is essentially the same as that of the first embodiment of FIG. 1 and the parts are numbered accordingly, but with a single prime. The description of those like-numbered parts will not be repeated. The main difference in this second embodiment is that the pump has a higher capacity, 750 ml per stroke. Because the size of the second pump is larger, a controller 76' is advantageously included inside the pump and is disposed on a circuit board adjacent the motor 46' in the region defined by the cover 20' and cap 22'. The controller 76' could be similarly located in the other embodiments of this invention. A commercially available controller 76' can be used as long as it can provide the desired precision. Note that no protruded portion need be provided at the cover 20' because the pump is sufficient long for the piston stroke without concern for interference between the drive bar 48' and the cover 20'.
Third Embodiment
While the pumps in accordance of the first and second embodiments (FIGS. 1, 2) are free-standing, the pump provided in the third embodiment, as shown in FIG. 3, is not free-standing, but rather adaptable to a fluid container such as a standard chemical bottle. Like parts are numbered alike in FIG. 3, but with a double prime, ", notation. The description of those like-numbered parts will not be repeated.
The significant change from the first embodiment of FIG. 1 is that the inlet valve 24" is configured in a different way. As seen in FIG. 3, the baseplate 10 is replaced by an insert 80 adaptable to a standard chemical bottle via the bottle cap, which provides quick connection and disconnection to the bottle. The inlet valve 24" is desirably a check ball valve instead of a pneumatic valve as in the embodiment of FIG. 1, but it is disposed at the tip of an elongated, tubular pickup formed by axially connected tubes 82, 84. Gravity biases the check ball in a closed position blocking an orifice as the pump is oriented vertically downward. For other arrangements, spring-biased check ball or pneumatic valves can also be used. The tubular pickups 82, 84 are sufficiently long to reach the bottom of a chemical bottle to which the pump is attached. The check ball is desirably 1/4 inch in size.
The tube 84 fits into a quick disconnect bottle-cap 86. The cap 86 screws onto a chemical bottle through threads 88. A first end of the cap 86 is configured to receive one end of the tube 84. A second end of the cap 86 is configured to slide into a mating end of the pump body 14", through a mating adapter 90. The adapter 90 is threaded into the end of the body 14" adjacent the end fitting 33", and contains an aperture configured to receive the second end of the cap 86. An O-ring seal 92 between the second end of the cap 86 and the adapter 90 provides a sliding, but sealed, quick disconnect arrangement. A tubular aperture 94 through the center of the end fitting 33" places the inlet valve 24" in fluid communication with the cavity 26".
Advantageously, the inlet valve 24" of the adaptable pump is directly inserted into a chemical bottle which places it in fluid communication with the pump and no additional tubing is needed to connect the bottle to the inlet valve 24". The pickup tube 82, 84, and the quick-disconnect cap 86 are desirably made of PTFE, as they come into direct contact with the aggressive fluid. The third embodiment therefore provides a convenient way of supplying the fluid to the pump.
At the opposite end of the pump a tubular wire shield 95 is shown attached to, and in fluid communication with, aperture 72". The free end of reciprocating drive bar 48" can enter the center of shield 95. When electrical wires (not shown) connect to the pump through the cap 22, the shield 95 prevents the drive bar 48" from entangling the wires.
Controller Variation
A further embodiment of this invention has an enhanced, internally located controller as shown in FIG. 4, and will use the nomenclature of the embodiment of FIG. 2 for similar parts. This controller 76' is equally suitable for use with the other embodiments of this invention.
The controller 76' is enclosed within the pump housing 18'. To allow easy access to the controller 76' the cover 20' may be removably connected to the housing 18', as by threading a cylindrical cover 20' onto the remainder of the housing 18'. An end cap 22' at the end of the generally cylindrical cover 20' is also removable, and advantageously has a centrally located, removable cap or cover 23' to allow access through the end of the cover 20'. Depending on the power and operational requirements of the controller 76', a fan 96 may be added inside the housing 18 to ensure circulation of the nitrogen which in turn maintains the temperature of the stepper motor 46' and the controller 76' within the desired temperature ranges.
The controller 76' controls multiple functions of an electromechanical device, and may take the form of a circuit board with appropriately configured integrated circuits. Preferably, the controller 76' is a electronic micro-controller based control system. A basic block diagram of the controller 76' is shown in FIG. 5. A power input line 100 provides power to the controller 76'.
The controller 76' has data inputs 102-106 to receive and transmit data signals that control the stepper motor 46' and the pump inlet and outlet valve assemblies 26', 28'. The controller 76' advantageously has both parallel data lines 104 and serial data lines 102 to allow for integration with a variety of control topologies. But preferably, the controller 76' has a balanced differential serial data port 106 thereby providing additional input-output flexibility. Further, a balanced differential serial data port allows for multi-drop capabilities at remote locations without noise interference or data signal degradation.
The controller 76' also has a processor 101 and memory 126. The processor 101 and memory 126 work in conjunction with software (not shown) to control operations of the pump. Given the present disclosure, one of ordinary skill in the art could devise numerous software programs and thus the software is not disclosed in further detail. Customized firmware could be used to enhance pump operation so that the pump could be completely controlled from a location internal to the pump housing. Additionally, the preferred embodiment includes an eight position dipswitch 110 that identifies each of several pumps by providing address information for each pump in multiple pump installations, or to provide mode selectability if a variety of firmware modes for different pump models and applications are used. Advantageously, the firmware controls the entire operation of the pump without the need for external data input, although the controller 76' is adaptable to external control, to autonomous internal control, and to various combinations of internal and external control for various functions.
The controller 76' has additional data inputs to receive data from sources within the pump. A first internal data input 112 receives data from extended piston limit sensor 58'. Likewise, a second internal data input 114 receives data from the retracted piston limit sensor 60'. A third data input 116 receives data from a piston location sensor (not shown) to determine the location of the piston 34' between the limit sensors 58', 60'. Advantageously, these sensors, in conjunction with the controller 76', control the stepper motor 46' thereby achieving precise fluid dispersement and motor protection.
A fourth data input 118 provides for additional motor control capabilities by accepting data for motor control, including data related to motor or piston direction, the number and direction of steps, disable, and test modes. Additional data inputs 120 may receive feedback from external data sensors (not shown) that will vary with the particular use of the pump. For example, a fluid level sensor on the fluid supply to the inlet valve assembly 24' could provide feedback to the controller 76' to cease pump operation if the fluid is exhausted. In a further example, a feedback device such as a flowmeter (not shown) could be used in conjunction with the controller 76' to provide closed-loop control of volume and flow through the pump. As known by those with skill in the art, the flowmeter feedback loop can be used in conjunction with calibration algorithms that are specific to each application to adjust pumping speed to achieve the desired volume output over time. In all cases though, all data inputs are optically coupled and filtered to provide noise and electrical immunity between the controller 76' and outside electromagnetic interference. In yet another example, a voltage regulator may standardize the magnitude of the input voltage thereby enabling the controller to accept inputs of varying voltage.
The controller 76', with the data received from data inputs 102-120, operate to precisely actuate the stepper motor 46' thereby extending or retracting the piston to effectuate fluid flow. Advantageously, the controller 76' is capable of driving the motor 46 using full step, half step, or micro-step techniques depending on the pumping requirements or application. The availability of such precise motor control allows for a variety of torque capabilities and the avoidance of unwanted first order resonance that can occur in stepper type motors.
The electrical signals actuating the stepper motor 46' are synchronized with an optional electric intake valve data line 122 and an optional electric outlet valve data line 124. The synchronization ensures that the electrical outlet valve 28' is open and the electrical intake valve 24' is closed when the stepper motor 46' is extending the piston. Conversely, synchronization ensures that the electrical outlet valve 28' is closed and the electrical intake valve 24' is open when the stepper motor 46' is retracting the piston. Advantageously, the electrical valves 24,28 which are normally in a closed position, also prevent siphoning of fluid through the pump.
It will be understood that the above described arrangements of apparatus and the method therefrom are merely illustrative of applications of the principles of this invention and many other embodiments and modifications may be made without departing from the spirit and scope of the invention as defined in the claims.
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A high precision fluid pump for accurately delivering desired amounts of processing fluids, particularly for use in semiconductor processing and semiconductor processors. The fluid is dispensed by a piston driven by a stepper motor with precise electronic control. A rolling diaphragm isolates the stepper motor from the fluid, fumes or gas. To provide a clean environment for high purity applications, the pump is preferably made of PTFE and nitrogen purging is provided on both sides of the rolling diaphragm to reduce particle count and maintain the motor and controller temperature.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention refers to a shaft seal ring formed of a polytetrafluoroethylene (PTFE) compound or of a material which is similar with regard to the sealing behaviour or durability, comprising a sealing lip and a protective lip integrally formed therewith, as well as to a method and a device of manufacturing a shaft seal ring of that kind.
2. Description of Prior Developments
It is known (from DE-OS 24 60 185) to provide a shaft seal without a protective lip. On the side of the sealing lip facing the shaft embossed recesses having the shape of screw lines or threads are formed for returning oil to the oil side of the seal.
The recesses are embossed by a separate embossing tool into a seal wafer cut from a PTFE compound tube. The wafer is subsequently brought into final shape with a final embossing tool.
A shaft seal ring of the above-mentioned kind is also known from DE 33 27 229 A1 in which a protective lip integrally formed with the sealing lip is first peeled out of the PTFE compound on the front side of a plate. After forming a recess into the front side of the sealing lip adjacent the protective lip, cuts are made in the radial and in the axial direction. These cuts increase the flexibility of the seal and generate a return flow effect of the oil away from the sealing edge.
Finally, a shaft seal ring made of a PTFE compound is known from DE 36 07 662 A1 wherein the flexibility of the sealing lip is increased by cuts made on the two sides of the sealing lip the cuts are offset with respect to one another by half of the cut distance.
SUMMARY OF THE INVENTION
The object of the invention is to provide an easy to manufacture shaft seal ring of the above-mentioned kind as well as a method and a device of manufacturing the same, by means of which an increased sealing function and dust repelling function in a one-piece sealing element can be achieved.
The invention includes a seal lip with wavy recesses which can have the shape of one-threaded or multiple threaded helical grooves. The wavy recesses are embossed through the protective lip down to the sealing lip at least on the front side of the shaft seal ring, with the sealing lip portion facing the shaft. An embodiment is preferred in which the wavy recesses are completely embossed through the seal wafer in such a manner that constant bending flexibility is provided so the sealing lip as well as to the protective lip across the longitudinal extensions thereof. An embodiment is preferred in which the wavy recesses are offset on the rear side to the recesses on the front side in such a manner that a wave trough opposes a wave crest. An approximately constant wall thickness across the length of the sealing lip or protective lip is achieved thereby, which is responsible for a constant bending stress of the shaft seal ring during operation.
The method according to the invention requires a minimum of working steps. The shaft seal ring is brought to its final shape by embossing the wavy recesses. In contrast to DE-OS 24 60 185, a further shaping step that requires a further embossing shape is not necessary.
For assembly, it is of advantage to insert a spreader ring between the sealing lip and the protective ring. The spreader ring is made of a solid material having lubrication properties and melting at an operating temperature of the shaft seal ring, as can be derived from DE 43 24 529 C1.
A device for manufacturing a shaft seal ring according to the invention is very simple. It is necessary for this device that at least the one formed part facing the front side of the PTFE-plate or seal wafer is provided with the wavy recesses in negative contour, wherein the formed part facing the rear side of the plate or wafer can be smooth. It is ensured thereby that the wavy recesses are embossed through the protective lip down to the front side of the sealing lip to guarantee the formation of wavy recesses on the side of the sealing lip facing the shaft.
It is preferred if the other formed part facing the rear side is provided with the wavy recesses, which are preferrably displaced radially offset with respect to the one formed part. This guarantees a complete embossing through all effective areas of the shaft seal ring.
The wavy recesses create a hydrodynamic return flow effect, wherein a conveying effect in the counter direction of the conveying effect of the wavy recesses on the front side of the sealing lip is achieved on the rear side of the protective lip opposite the other formed part. Whereas the sealing lip has a conveying effect in the direction of the oil side of the shaft seal ring to be sealed, the protective lip convey outwardly towards the air side of the seal and thereby ensures an additional dynamic sealing effect against dust entering from the air side. This is a decisive non-foreseeable functional advantage of the shaft seal ring according to the invention, which is based on the "inverse" configuration of the recesses, which are necessarily formed on the rear side of the protective lip on one hand and on the front side of the sealing lip on the other side during embossing.
The PTFE compound materials for the protective lip on one side and the sealing lip on the other side can be different. In practical application this can be achieved in that the seal wafer is cut of two tubes inserted into each other which have differently defined PTFE compounds, the tubes being fixedly connected to one another during a sintering process. This enables an optimization of the sealing and wear behaviour of the shaft seal ring because the front side of the sealing lip engaging the shaft is formed of a PTFE compound especially adapted to the preconditions of operation during oil lubrication and the protective lip is formed of a different PTFE compound especially adapted to the preconditions of the dry run of the protective lip.
If required, a holding member for the shaft seal ring can be found of an inexpensive PTFE compound, which does not have to fulfill the high sealing and wear requirements in the contact region of the seal ring.
A layer of an elastomeric material can be provided in the region of the outer diameter of the shaft seal ring in order to hold the shaft seal ring, the layers serving as a seat in a carrier body or as a housing. The bonding of a sealing element made of PTFE by an elastomeric material vulcanized to a metallic carrier body is known from DE 33 09 538 C2. According to the invention, the elastomeric material, that is required for the bond between the shaft seal ring and the metal of a carrier body, provides a partially or fully rubber covered region at the outer periphery of the shaft seal ring and forms a seat for the shaft seal ring in a housing.
The geometry of the recesses embossed through the shaft seal ring according to the invention can be varied in accordance with the purposes of application of the shaft seal ring. The geometry can be adapted to the objects of sealing fluids of high or low viscosity or for reducing the air suction below the sealing edge.
Recent research noted in SAE Technical Paper, No. 930531, Mar. 01, 1993 has revealed that the distribution of the pressure of the sealing lip to the shaft at the oil end of the sealing lip no longer has a pressure maximum, even though the highest deformation occurs at this location. The pressure maximum is rather displaced towards the air end. An additional statical seal should preferrably be provided at the air end and not at the oil end of the sealing lip, since otherwise the contact surface between the seal and the shaft, biased by the highest pressure, would run dry.
Even though the cross-section of the hydrodynamically acting wavy recesses is so large that during operation a proper dynamic sealing is guaranteed, difficulties occur with regard to the static tightness when the shaft is standing still. According to a further development of the invention, a transverse web is provided at the air end of the abutting sealing lip in the recess or in any recess, the transverse web serving as a bulkhead in particular for the static sealing when the shaft is standing still. The transverse web or the transverse webs prevent any medium from reaching and from draining in an area outside the sealing lip through the recesses preferrably provided in the shape of one-threaded or multiple threaded threads. It is furthermore ensured by this measure that the area of the sealing lip abutting the shaft is constantly wetted with the medium to be sealed and that a dry run of the sealing lip is excluded thereby.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by the aid of schematical drawings of embodiments including further details.
FIG. 1 is a view of the manufacture of a shaft seal ring according to the invention with a device according to the invention;
FIG. 2 is a partial axial view through a half of a shaft seal ring according to the invention in assembled condition;
FIG. 3 is a modified shaft seal ring according to the invention in a view as in FIG. 2.
Equal or equally acting components are indicated by equal reference numerals in the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a blank for a shaft seal ring is indicated by reference numeral 1. This blank is in the form of a plate or wafer made of a PTFE compound, which is cut off a tube. Furthermore, a cut is made along line 2 so that a protective lip portion 3 is peeled from the plate 1 and is thus separated from a sealing lip portion 4. This sealing lip portion protrudes radially over the inner end of the protective lip portion towards the interior of the seal ring.
At its radial outer end, the annular plate 1 on the protective lip side 5 of the blank is adhered to the radial flange 6' of a metallic carrier body 6 or is connected in a different manner.
The blank 1 designed in this manner is inserted into a mold having left and right formed parts 7, 8. The formed parts 7, 8 are movable parallel to the axis A against the blank 1 in the directions of arrows f, f'. The formed parts 7,8 have wavy recesses on their sides facing the blank 1. The recesses have the shape of threaded grooves 9, 10 of different profiles. Thus, the threaded grooves (one-threaded or multiple threaded) of the formed part 7 are inclined with regard to the axial direction, whereas the threaded grooves 10 of the formed part 8 are oriented parallel to the axis a in depth direction and are radially such a manner that the crests of the threaded grooves 9 seen in the axial direction approximately oppose the troughs of the threaded grooves 10.
The recesses 9, 10 serve for embossing respective wavy recesses into the front side 5 and the rear side 11 of the blank 1, by driving the two formed parts 7, 8 in the axial direction (f, f') against the blank 1. The formed parts are punched into the blank for embossing the respective recesses.
Instead of the contours of the recesses 9, 10, as shown in FIG. 1, these contours can also be provided laterally reversed. A radial displacement of the recesses is preferred in a manner that the wall thickness of the plate 1 is basically equal over the radial extensions thereof.
FIG. 2 shows a shaft seal ring 20, which is manufactured according to FIG. 1 and which is mounted on the periphery 21 of a shaft 22. In assembled condition, the protective lip 23 is spread in the direction toward the air side away from the sealing lip 24, which is bent backwards towards the oil side "a". Sealing lip 24 is pressed to the shaft with the front sealing section 25 corresponding to the front side 5 thereof according to FIG. 1. It is evident that owing to the offset of the recesses 9, 10 of the formed parts 7, 8 the cross-sections of the lips 23, 24 are provided with complementary or matching wavy, embossed recesses 32 to 35 and have a constant cross section over the length thereof and thus have approximately constant flexibility. The "inverse" complementary recesses 33 provided on the rear side 26 of the protective lip 23 convey or pump in the direction of the air side "i", whereas the recesses provided on the front side 27 of the sealing lip 24 convey or pump in the direction of the oil side "a" of the seal. This suprisingly improves the dust-repelling as well as oil returning effect of the shaft seal ring 20.
FIG. 3 shows two modifications of the shaft seal ring manufactured in the same manner as in FIG. 2. The metallic carrier body 6 having a radial flange 6' is vulcanized with the radially outer end of the shaft seal ring 20 by interposition of a layer made of an elastomeric material, wherein this layer provides in a radially outer region 29 a seat for holding the shaft seal ring in a housing.
Moreover, a spreader ring 31 made of a solid material having lubricating properties is inserted between the protective lip 23 and the sealing lip 24 as an aid to assembly. Ring 31 melts upon reaching the operating temperature of the shaft seal ring 20.
In the embodiments according to FIG. 2 and in the embodiment according to FIG. 3, the sealing lip 24 in the press part 25 includes a transverse web 30 in at least one recess toward the air end for preventing penetration of fluid to be sealed and in particular when the shaft 22 is standing still. In case of multiple threaded screw-line shaped recesses, a transverse web 30 of that kind is provided in each thread.
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A shaft seal ring as well as a method and a device of manufacturing same.
A shaft seal ring made of a PTFE compound comprises a sealing lip and a protective lip integrally formed therewith, wherein the sealing lip as well as the protective lip are provided with wavy recesses embossed during a manufacturing step.
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This application is a division of Ser. No. 278,982, filed Jul. 21, 1994, now U.S. Pat. No. 5,470,292, which is a continuation of U.S. patent application Ser. No. 08/023,340, filed Feb. 26, 1993, now abandoned.
FIELD OF INVENTION
This invention relates to exercising devices and to methods appertaining thereto.
BACKGROUND
Exercising devices of the same general type as provided in accordanc with the instant invention are to be found in U.S. Pat. Nos. Des. 330,057; 3,641,647; 4,253,661; 5,050,861; 5,116,044; 5,125,646; 5,125,647; and 5,118,096.
In U.S. Pat. No. Des. 330,057 (Oct. 6, 1992), Saunders et al. disclose an aerobic step bench design. No explanation is given for the use of the same, and it appears that the design consists of a single bench having a single supporting surface.
William T. Sieg reveals in U.S. Pat. No. 3,641,601 Feb. 15, 1972) an exercising device usable to simulate walking and the like. The device has a base which carries a pad of elastic compressible material, and the pad has a longitudinal slot along the top dividing the pad into separate upwardly extended sections. No adjustment is provided with respect to the resulting surfaces.
Brian Russell reveals in U.S. Pat. No. 4,253,661 Mar. 3, 1981) a thick, flexible pad with a sloped top surface and sloped sides which provides for leg exercises involving running, squatting, and so forth.
In U.S. Pat. No. 5,050,861 Laurie Thomas discloses an adjustable bench-step for use in exercising. This device is provided with an upper platform which is insertable into a base with upper platform being adjustable vertically and being approachable from any horizontal axis. This device does not actually show adjustable steps as will be disclosed in connection with the instant invention hereinbelow.
W. Wilkinson reveals in U.S. Pat. No. 5,116,044 an aerobic climbing step-bench. This device includes a base consisting of a horizontal platform with a plurality of spaced legs mounted on the base to support the same. Each of the legs is detachably mounted so as to be movable from an active position to a stored condition. This device similarly fails to reveal adjustable steps as will be found in connection with the instant application.
W. Wilkinson furthermore reveals in U.S. Pat. No. 5,125,646 another aerobic step/bench exercise device which includes a base supported on a plurality of spaced legs and arranged such that the platform is capable of being disposed at a plurality of elevations. Aside from this adjustment of elevations, no provision is made for adjustments of related steps.
In U.S. Pat. No. 5,125,647, Robert Smith shows a jump platform exerciser in which a cantilever type platform is monitored electronically for the counting of pulses. By such means, a signal results representing a number of pulses emitted from a clock corresponding to a timing period. No adjustment of steps is provided by this patent.
W. Wilkinson shows furthermore in U.S. Pat. No. 5,118,096 an aerobic climbing step/bench in which a platform is supported by a plurality of detachable legs. This provides for adjusting the overall height of the platform but does not provide for adjusting of steps in the manner which will be described hereinbelow.
In U.S. Pat. No. 5,118,101, Raymond Belli shows a plyometric platform in which adjustment is provided to a plurality of positions thereby providing for the adjustment of steps, but this adjustment is wholly unlike the adjustment provided for in accordance with the present invention, as will be discussed in detail hereinbelow.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved exercising device and method.
It is another object of the invention to provide an improved exercising device having a plurality of adjustable width selections.
Still another object of the invention is to provide an improved exercising device which is compact and adjustable to a readily stored condition.
It is still another object of the invention to provide an improved means and method for the exercise of various muscles of the human physique.
To achieve the above and other objects of the invention, there is provided an exercise apparatus comprising a platform with extensible members being extendible in different directions from this platform. Furthermore, an arrangement is provided to control the extension of the extensible members from the aforesaid platform. Preferably, the aforementioned members are extensible in opposite directions from the platform and these members have substantial coplanar supporting surfaces adapted for respectively receiving the feet of an exercising individual. The platform moreover has a supporting surface which is located at a higher level than these coplanar supporting surfaces. Furthermore, the members are at least partly accommodated within the platform. In addition to the foregoing, the aforesaid arrangement includes a pivotal cam-like element interposed between the members to control the extension thereof. Furthermore, there may be provided a spring arrangement to spring load the members to bear against the cam-like elements to enable the control of these extensible members. These members and preferably the platform also include a shock absorbing skid proof material at the aforementioned surfaces. Moreover, the platform, which is preferably a central platform having generally quadrilateral profile, will be provided at its lower surface with a skid proof material.
The platform as noted above, which is preferably of quadrilateral shape, which is of preferably dimensions in the order of magnitude of 24 inches long by 16 inches wide. The platform is centrally located between the supporting surfaces of the aforementioned members. As a feature of the invention may be provided a calibrated turnkey coupled to the cam-like member for pivoting the same for purposes of controlling the extension of the extensible members.
In a preferred embodiment, the platform is in the order of magnitude of 6 inches in height. The members which provide the wings are for example, in the order of magnitude of 3 inches in height or, in other words, approximately about half the height of the entire device. The members may preferably be in the order of magnitude of 12 inches in length and 12 inches in width. The key is calibrated to extend the members in equal increments.
In accordance with the method provided in accordance with the invention, such method comprises controllably extending wings out of a platform to form steps above a supporting surface, standing on the platform with both feet, and moving the feet of the exercising individual respectively and selectively down and up the aforesaid steps.
The aforesaid wings may be extended according to the height of the exercising individual, and these wings are preferably extended in the order of magnitude of from 0 to 6 inches selectively.
The above and other objects, features, and advantages of the invention will be found in the following detailed description as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF DRAWING
In the drawing:
FIG. 1 diagrammatically illustrates an individual exercising on a device provided in accordance with the invention;
FIG. 2 illustrates the individual of FIG. 1 in various postures of utilization of the exercising device of the invention;
FIG. 3 is a diagrammatic top view of an embodiment of the invention illustrating the central platform with the wings extended;
FIG. 4 is a view corresponding to FIG. 3 with the wings retracted into the central platform; and
FIG. 5 is a front perspective view of an exercising device provided in accordance with the invention and corresponding to the illustrations of FIGS. 3 and 4.
DETAILED DESCRIPTION
The exercising device of the invention is an aerobic apparatus which is intended to provide for strengthening the legs and feet of a user. More specifically, there is provided in accordance with the invention a portable device for use in aerobic step climbing routines and programs. This device generally comprises a base or plateau otherwise known as a central platform which may, for example, have a dimension of 24 inches in length by 16 inches in width. It is preferably made of wood, plastic, fiber glass, plywood, metal, or other suitably durable materials and is covered with a skidproof material such as for example natural or synthetic rubber or a suitable plastic or paint. Between the wood and the skid proof material is a shock absorbent material which, for example, is a natural or synthetic material of sponge, compressible pads, vinyl or silicone foam, foam rubber, flexible foam, canvas, fabric, leather, foam carpet, polyurethane, or other similar materials. As will be shown, under the central platform, there are springs to assist in adjusting the extension of the wings. Also, there can be used rounded wooden, metal or plastic rods. Hardware such as bolts, clips, latches adjustable rods, or tracks or various other adjustable devices that can accommodate the shortening and lengthening of the right and left wings can also be used. A calibrated turnkey for adjusting the range of extension of the wings through a series of increments starting at zero and increasing in 1 inch magnitudes through a maximum extension as, for example, 6 inches is provided. The adjustments are made by the turnkey to suit the height of the individual exerciser and, therefore, in accordance with the leg lengths of the exerciser. Such adjustment is made before the device of the invention is used.
The central platform of the device may, for example, be in the order of magnitude of 6 inches above the supporting surface or floor. It is, as has been noted hereinabove, covered with a shock absorbing skid-resistant surface which is tapered with rounded edge on the right and left edge of the plateau. The central platform drops by, for example, 3 inches on the right and left sides of the same. The extension wings are, for example, 12 inches in length by 12 inches in width, and the supporting surfaces thereof are, for example, 3 inches in height, or approximately one-half the height of the entire device. The auxiliary wings are also covered with a shock absorbing and skid proof material.
In FIGS. 1 and 2 is shown an exercising individual E having legs L and feet F supported on a central platform 10. The central platform 10 has a height h which, as stated hereinabove, may be in the order of magnitude of about 6 inches. Also shown in FIGS. 1 and 2 are extensible wings or members 12 and 14 having useful widths w in the order of magnitude of 0 to 6 inches. Actually, these wings have a greater width because they extend into and are partially accommodated in the interior of the central platform 10, which consists of a wooden or plastic form covered by suitable material and provided with such bracing as to be able to support a wide range of weights which may be ascribable to exercising individuals using this apparatus. It is a simple, light weight, portable and a convenient device weighing between 15 lbs and 20 lbs for easy transportation and storage. It can be used by all age groups in all walks of life.
FIG. 2 illustrates that the legs of the exercising individual as indicated at L1 and L2 may be moved laterally so that the feet of the individual as shown at F1 and F2 descend down the steps constituted by the different supporting surfaces until coming to rest on the floor or supporting surface 16, whereupon the operation is reversed and the legs are so moved that the feet ascend the steps constituted by the supporting surfaces. The supporting surfaces of members 12 and 14 are preferably coplanar and below the height of the supporting surface provided by the central platform 10.
FIGS. 3 and 4 illustrate the members or wings 10 and 12 and furthermore show the supporting surfaces 16 and 18 thereof and the effective width w thereof. As will be seen, the portions 12' and 14' of the wing members extend internally into the interior of the central platform or plateau 10. Between the inner edges of these wings as indicated at 20 and 22 are accommodated springs 24 and 26. These springs diagrammatically illustrate that the wings are spring loaded in such a manner as to be drawn into the interior of the central platform 10.
Also illustrated in FIGS. 3 and 4 is a central cam-like member 30 pivotal on an axis 32 which represents a calibrated turnscrew adapted for adjusting the extension of the extendible members 16 and 18 according to a selected series such as, for example, 0-1-2-3-4-5-6 inches. Thus, the extension of the wings can be effected in equal increments although the magnitude and number of these increments may be selected as desired to accommodate ergonometrically the type of user who will purchase and use the exercising device of the invention.
FIG. 5 illustrates in perspective view the central platform 10 and extensible wings 12 and 14 of the exercise device of the invention. As the upper surface is covered by a shock absorbing and skid-resisting material, it will be apparent that access to the pivotable cam may be effected through the bottom of the device.
All muscles of the leg and foot are used. The main muscles includes the gluteus medius, the gluteus maximus, the adductor magnus, the biceps femoris, the semitendinosus, the semimembranosus, the gastrocnemius, the solsus, the peroneus, longus, the tensor fasciae latae, the pectineus, the adductor longus, the adductor magnus, the gracilis, the vastus medialis, the vastus lateralis, the peroneus longus, the extensor digitorum longus, the tibialis anterior, the achilles tendon, and the tendon of peroneus longus. For this exercise to be effective, an individual between 4 feet and 5 feet high should use the gauge range of 0-1-2 inches. Someone between 5 feet and 5 feet 6 inches should use the gauge range of 3 and 4 inches and then from 5 feet 7 inches to 6 feet 5 inches and above, one should use a gauge range of 5 and 6, which makes the right and left step 6 inches away from the initial position, which is set to zero.
From the above, it will be seen that there is provided an exercising method which comprises controllably extending wings out of a platform to form steps above a supporting surface such as a floor. The individual who is exercising stands on the platform with both feet and moves these feet respectively and selectively down and up the steps. The wings are extended according to the height of the individual and more particularly are extended in equal increments through a range of from 0 to 6 inches selectively by way of example. This range of extension may be varied according to need, but it should be noted that the extension is generally in accordance with the height of the exercising individual as well as the length of the individual's legs.
A person using the device of the invention operates by standing on the central platform with both feet and keeping the body in an upright neutral alignment or posture, then moving the feet from the central platform to the respective wings, and then onto the floor and then reversing the action from the floor to the wing and back to the central platform. One can also move the feet from the central platform to the floor missing the wing and return back to the central platform. The exercising party can also use the central platform by moving the feet from the platform to the floor in front of the platform and by then reversing the action. Such person can also use the central platform by moving the feet from the platform to the floor behind the platform and reversing the action. One can do, for example, 20 minutes of these repetitions for each of the legs to develop muscles, strength, balance, coordination, flexibility, endurance, and stamina. This type of workout can be used as a good leg extension exercise, a total aerobic workout and a cardio-vascular workout. One can also use the platform to elevate one's feet when doing situps and abdominal crunches and twist. The arms are either extended at the sides or placed on the waist for balance. To help in sculpturing the upper body, one can incorporate hand weights when doing the step exercise. The added strength may help prevent knee and bodily injuries and give one added stamina. This device is good for runners, dancers, walkers, swimmers, cyclists, and all ball playing athletes. The device can be used by a physical and physic therapists for strengthening bones, muscles, and tendons and overall toning of feet, ankles, knees, and legs.
There will now be obvious to those skilled in the art many modifications and variations of the structure and method set forth hereinabove. These modifications and variations will not depart from the scope of the invention if defined by the following claims.
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An exercise device is provided in the form of a central platform having two extensible wings which together with the supporting surface of floor on which the exercise device is supported forms along with the central platform a series of steps. The wings are spring loaded and controllable by a calibrated turnkey which enables the wings to be extended a determinable amount which correlates to the height of the individual using the device for purposes of exercise. To use the device, the exercising individual stands on the central platform and moves his feet from step to step, first down and then up, with the option of alternating between the user's two feet.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to and the benefit of Korean Patent Application No. 10-2007-0121456 filed in the Korean Intellectual Property Office on Nov. 27, 2007, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to an internal combustion engine. More particularly, the present invention relates to a method and apparatus for controlling an electronic variable valve apparatus of an internal combustion engine.
(b) Description of the Related Art
Performance of an internal combustion engine, especially a gasoline engine, substantially depends on how efficiently an air can be drawn into a combustion chamber.
For better intake efficiency, a variable valve apparatus for varying valve timing is employed such that optimal amount of air can be drawn into the combustion chamber for various engine speeds.
A hydraulic variable valve apparatus that is typically employed has a drawback in that, when the engine speed is low or engine oil is at a low temperature, a torque for operating the apparatus is increased. In addition, such a hydraulic variable valve apparatus does not usually provide sufficient variation of cam angle.
In order to solve such drawbacks, an electronic variable valve apparatus is widely studied as an alternative for such a hydraulic variable valve apparatus.
The electronic variable valve apparatus shows many merits. For example, it shows higher response speed that a conventional hydraulic variable valve apparatus. An oil pump of an engine may be downsized since the electronic variable valve apparatus does not require a hydraulic pressure. The electronic variable valve apparatus can be properly operated even if the engine speed is low or the engine oil is at a low temperature, which means that a load for starting the engine may be reduced. Furthermore, an exhaust gas may be reduced when the engine is at a low temperature.
In addition the electronic variable valve apparatus may be operated at a wider range of an angle, such that the merits of varying the valve timing may be maximized.
The electronic variable valve apparatus are typically driven by an electronic clutch or a motor.
The scheme employing the electronic clutch costs less but it is harder to control. The scheme employing the motor cost more but it is easier to control.
An example of the electronic variable valve apparatus can be found in Japanese Patent Laid-Open Publication No. 2002-276310.
In order to control an angle of a camshaft according to the conventional scheme, an engine control unit calculates an angular difference Δθ between a reference angle depending on an engine state and a current angle detected by a cam angle sensor, and determines whether the angular difference Δθ is above a predetermined error value.
When the angular difference Δθ is less than the predetermined error value, the current control is maintained, and a clutch release coil and a brake control coil is not applied with a current.
When the angular difference Δθ is above the predetermined error value, it is determined whether the angular difference Δθ is positive or negative. If the angular difference Δθ is positive, a current is applied to the clutch release coil and the brake control coil so as to perform an advance control. If the angular difference Δθ is negative, a current is applied to the clutch release coil and the brake control coil so as to perform a retardation control.
According to the above scheme where a current to be applied to the clutch release coil and the brake control coil is on/off controlled in order to control an angle of a camshaft, calibration maps should be provided depending on control responsiveness, angular error, and engine states.
According to such a scheme, huge amount of experimentation is required in order to prepare sufficiently precise calibration maps, which causes the cost for newly designing a vehicle to increase very high.
The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY OF THE INVENTION
The present invention has been made in an effort to provide a method and apparatus for controlling an electronic variable valve apparatus having advantages of a stable control with minimized usage of map tables by employing a sliding surface calculation.
An exemplary embodiment of the present invention provides an apparatus for controlling an electronic variable valve apparatus that includes: a cam angle sensor that detects a cam angle; a crank angle sensor that detects a crank angle; and a controller that determines a target cam angle and controls the electronic variable valve apparatus in order to achieve the target cam angle, based on a sliding surface calculation.
The controller may include: a synchronization unit that obtains a current cam angle by synchronizing a cam angle signal and a crank angle signal; a comparator that obtains a deviation between the target cam angle and the current cam angle; a control unit that outputs a control signal for adjusting the cam angle for advance and retardation based on the deviation received from the comparator; and an actuation unit that controls the electronic variable valve apparatus according to the control signal from the control unit.
An exemplary embodiment of the present invention provides a method of controlling a clutch type electronic variable valve apparatus that includes: setting a reference cam angle depending on an engine operation state; detecting a current cam angle, an engine speed, and an engine oil temperature; calculating a sliding surface; calculating a deviation of the current cam angle from the reference cam angle; determining whether the calculated deviation is above a reference value; calculating an estimated current for maintaining the sliding surface when the calculated deviation is above the reference value; calculating a application current using the calculated sliding surface and the estimated current; and adjusting the current cam angle by operating the electronic variable valve apparatus by a driving duty ratio that is converted from the application current.
According to an exemplary embodiment of the present invention, a clutch type electronic variable valve apparatus may be stably controlled regardless of variations of engine condition such as an engine oil temperature.
The above features and advantages of the present invention will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated in and form a part of this specification, and the following Detailed Description of the Invention, which together serve to explain by way of example the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention will now be described in detail with reference to certain exemplary embodiments thereof illustrated the accompanying drawings which are given hereinbelow by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a block diagram for an apparatus for controlling an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention;
FIG. 2 is a block diagram that shows a detailed configuration of an apparatus for controlling an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention;
FIG. 3 is an exploded view of an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention;
FIG. 4 is a flowchart for a method for controlling an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention;
FIG. 5 and FIG. 6 show graphs obtained by applying the scheme of controlling an electronic variable valve apparatus according to an exemplary embodiment of the present invention in conditions of different engine oil temperatures.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
<Description of Reference Numerals Indicating Primary Elements in the Drawings>
100 : cam angle sensor 200 : crank angle sensor 300 : controller 400 : electronic variable valve apparatus
DETAILED DESCRIPTION OF THE EMBODIMENTS
Hereinafter reference will now be made in detail to various embodiments of the present invention, examples of which are illustrated in the accompanying drawings and described below. While the invention will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention to those exemplary embodiments. On the contrary, the invention is 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.
FIG. 1 is a block diagram for an apparatus for controlling an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention.
As shown in FIG. 1 , an apparatus for controlling an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention includes a cam angle sensor 100 , a crank angle sensor 200 , a controller 300 , and an electronic variable valve apparatus 400 .
The cam angle sensor 100 detects an angular position of a camshaft (hereinafter called a cam angle) of an internal combustion engine, and provides information for the detected angular position of the camshaft to the controller 300 .
The crank angle sensor 200 detects an angular position of a crankshaft (hereinafter called a crank angle) of the internal combustion engine, and provides information for the detected crank angle to the controller 300 .
Based on the cam angle received from the cam angle sensor 100 and the crank angle received from the crank angle sensor 200 , the controller 300 determines a target cam angle, and controls the electronic variable valve apparatus 400 by a method involving a sliding surface calculation such that the cam angle may become the target cam angle.
The electronic variable valve apparatus 400 receives a control signal from the controller 300 , and controls the cam angle of the camshaft according to the control signal received from the controller 300 .
FIG. 2 is a block diagram that shows a detailed configuration of an apparatus for controlling an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention.
As shown in FIG. 2 , the controller 300 includes a synchronization unit 310 , a comparator 320 , a control unit 330 , and an actuation unit 340 .
The synchronization unit 310 obtains a current cam angle by synchronizing a square wave signal for the cam angle received from the cam angle sensor 100 and a square wave signal for the crank angle received from the crank angle sensor 200 .
The comparator 320 compares the current cam angle received from the synchronization unit 310 and a target cam angle depending on a driving condition, and outputs the comparison result.
The control unit 330 receives the comparison result form the comparator 320 , and outputs a control signal for adjusting the cam angle of the camshaft 600 for advance and retardation.
The actuation unit 340 controls an operation of the electronic variable valve apparatus 400 of an electronic clutch type according to the control signal received from the control unit 330 such that a cam angle of the camshaft 600 may become a target angle depending on the current engine state.
Spring torque may be regarded as disturbance element for the control system and thus element 500 is added to simulate the spring torque in this model.
FIG. 3 is an exploded view of an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention.
As shown in FIG. 3 , the electronic variable valve apparatus 400 includes an electronic clutch 410 , a damper disk 420 , an advance plate 430 , an exterior shaft 440 , an interior shaft 450 , and a chain sprocket 460 .
The electronic clutch 410 is mounted at a chain cover of an engine, and may be magnetized so as to make a contact with the damper disk 420 and generate a frictional force when a control signal is applied.
The interior shaft 450 is mounted at an end of the camshaft. The advance plate 430 is engaged with exterior circumference of the interior shaft 450 by helical gears. The exterior shaft 440 is engaged with an exterior circumference of the advance plate 430 by helical gears. Thus, a spline shaft unit is formed.
A chain sprocket 460 is placed behind the interior shaft 450 and the exterior shaft 440 of the spline shaft unit on the camshaft, and enables power delivery from a sprocket of a crankshaft by a timing chain.
The damper disk 420 is placed in front of the interior shaft 450 of the spline shaft unit. A rear side of the damper disk 420 is supported by the advance plate 430 , and a torsion coil spring is placed between the rear side of the damper disk 420 and the exterior shaft 440 . A friction surface is formed at a front side of the damper disk 420 such that a frictional force is generated by contacting the electronic clutch 410 .
Such an electronic variable valve apparatus 400 may be expressed as a second order differential equation of the following Equation 1.
Jd
×
ⅆ
θ
2
ⅆ
2
t
+
Dd
×
ⅆ
θ
ⅆ
t
+
(
Kn
×
θ
+
T
)
=
μ
×
r
d
×
kl
×
I
(
Equation
1
)
Here, T denotes a spring torque, Jd denotes a momentum inertia, θ denotes a cam angle, Dd denotes a viscosity coefficient, Kn denotes a spring constant, μ denotes a frictional coefficient of the clutch, rd denotes an effective radius of the clutch, Kl denotes an attractive force of the clutch, and I denotes an applied current.
The above Equation 1 may be changed to the following Equation 2.
ⅆ
θ
2
ⅆ
2
t
+
a
ⅆ
θ
ⅆ
t
+
b
×
θ
+
c
=
d
×
I
,
where
,
a
=
Dd
Jd
,
b
=
Kn
Jd
,
c
=
T
Jd
,
d
=
μ
×
r
d
×
kl
Jd
.
(
Equation
2
)
Next, the first step to derive the controller is to decide the expression of error. Therefore, in the Equation 2, an estimated error {tilde over (θ)} is defined as {tilde over (θ)}=θ−θd. The next step is to define a sliding surface S and thereby sliding surface S is defined as S=({tilde over (θ)}′+λ{tilde over (θ)}). S′ can be expressed as the following Equation 3.
S′=dI−aθ′−bθ−c+ 2{tilde over (θ)}″ (Equation 3)
From the Equation 3, an estimated current Î for maintaining the sliding surface may be obtained as the following Equation 4.
I
^
=
θ
″
d
+
a
θ
′
-
λ
θ
~
+
b
θ
+
c
d
(
Equation
4
)
From the Equation 4, an application current Ieq for a nonlinear control is obtained as the following Equation 5.
Ieq−Î+K sgn ( S ) (Equation 5)
Here, K is a control constant.
An operation of adjusting a cam angle according to an engine state is described hereinafter.
When the engine is running, the chain sprocket 460 is driven by the engine through a timing chain, and accordingly the camshaft connected thereto rotates.
The spline shaft unit having the advance plate 430 , the exterior shaft 440 , and the interior shaft 450 that are engaged with each other by helical gears also rotates with the rotation of the chain sprocket 460 . In addition, the damper disk 420 placed in front of the interior shaft 450 also rotates in the same way.
At this time, the controller 300 receives a cam angle signal from the cam angle sensor 100 and a crank angle signal from the crank angle sensor 200 , and determines a target cam angle according to a current engine state. Then, the controller 300 outputs a control signal for adjusting the cam angle to the electronic variable valve apparatus 400 .
Then, the electronic clutch 410 in the electronic variable valve apparatus 400 is magnetized and moves to the damper disk 420 in the rotational axis so as to make a contact therewith, such that a frictional torque is generated by the friction surface of the damper disk 420 .
Therefore, the damper disk 420 receives a force shown in an arrow.
Therefore, the interior shaft 450 engaged with the chain sprocket 460 varies an angle of the chain sprocket 460 that is connected with the camshaft.
Therefore, the cam angle is varied by the change of the angle of the chain sprocket 460 .
While such an operation is performed, the synchronization unit 310 in the controller 300 obtains a current cam angle by comparing signals from the cam angle sensor 100 and the crank angle sensor 200 .
The obtained current cam angle is compared with the target cam angle at the comparator 320 , and the comparison result is provided to the control unit 330 .
Depending on the comparison result, the control unit 330 varies a level of the current applied to the electronic clutch 410 of the electronic variable valve apparatus 400 through the actuation unit 340 until the current cam angle becomes the target cam angle.
FIG. 4 is a flowchart for a method for controlling an electronic variable valve apparatus of an internal combustion engine according to an exemplary embodiment of the present invention.
Firstly at step S 101 , the controller 300 calculates a reference cam angle θr depending on an engine operation state.
Then, at step S 102 , the controller 300 obtains a current cam angle θ and an engine speed based on signals from the cam angle sensor 100 and the crank angle sensor 200 .
In addition, the controller 300 may obtain an oil temperature of engine oil, and calculates a change rate of the cam angle.
A control responsiveness of the clutch type electronic variable valve apparatus depends on the condition of the engine speed and engine oil temperature. Therefore, at step S 103 , the controller 300 calculates a compensation current value corresponding to the engine speed and engine oil temperature.
Subsequently at step S 104 , the controller 300 sets the sliding surface S with the current cam angle θ, by calculating the estimated error and its derivative.
Then, at step S 105 , the controller 300 calculates a deviation of the cam angle as a difference between the current cam angle θ and the reference cam angle θr, and determines whether the deviation is above a reference value, i.e. a minimal permissible deviation.
When the cam angle deviation is less than the reference value, the process returns to the step of s 102 . When the cam angle deviation is above the reference value, the controller calculates the estimated current Î for maintaining the sliding surface at step S 106 .
Then at step S 107 , the controller 300 calculates the application current Ieq by the Equation 5 using the calculated sliding surface S and the estimated current Î.
Then, the controller 300 converts the application current Ieq to a driving duty ratio at step S 108 , and operates the electronic variable valve apparatus 400 by outputting the duty ratio at step S 109 such that the cam angle may become the target cam angle.
FIG. 5 shows a graph obtained by applying the scheme of controlling an electronic variable valve apparatus according to an exemplary embodiment of the present invention in a condition that an engine oil temperature is 60° C. and the engine speed 2,000 RPM.
As shown in FIG. 5 , it is experimentally confirmed that the cam angle precisely follows the reference cam angle.
FIG. 6 shows a graph obtained by applying the scheme of controlling an electronic variable valve apparatus according to an exemplary embodiment of the present invention in a condition that an engine oil temperature is 0° C. and the engine speed 2,000 RPM.
As shown in FIG. 6 , it is experimentally confirmed that the cam angle precisely follows the reference cam angle without tuning a specific parameter even if engine condition is changed.
While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
|
An electronic variable valve apparatus may be stably controlled regardless of variations of engine condition with minimized usage of map tables by employing a sliding surface calculation for controlling the electronic variable valve apparatus in order to achieve a target cam angle.
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|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 61/368,385, filed Jul. 28, 2010, the entire disclosure of which is incorporated by reference as if set forth fully herein.
FIELD OF INVENTION
[0002] The present invention relates to the use of siRNA.
BACKGROUND OF THE INVENTION
[0003] Angiogeneis is a physiological process that involves the growth of new blood vessels. An important part of this process is the production of vascular endothelial growth factor (“VEGF” or “VEGFA”), which is a chemical signal that is produced by cells and that stimulates the growth of new blood vessels.
[0004] The process is initiated when VEGFA is secreted by cells and binds to one or more cognate receptors such as the transmembrane protein kinase VEGFR1/FLT-1 and VEGFR2/FLK-1/KDR. After VEGFA binds to the transmembrane protein, a signal cascade is initiated that ultimately results in neovascularization.
[0005] Angiogeneis can be part of normal and vital body development and regulation. Unfortunately, it can also be associated with a number of undesirable conditions such as retinopathy, psoriasis, cancer, exudative age-related macular degeneration (ARMD), and rheumatoid arthritis. In these conditions, as well as in others, there are both high levels of VEGFA and concomitant increases in vascularization. Thus, the development of therapeutic strategies that focus on control of the production of VEGFA are being sought.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to compositions and methods for the suppression of VEGFA expression, as well as to the treatment of conditions that are associated with the overexpression of VEGFA. Accordingly, the present invention provides kits, siRNAs and methods for introducing siRNA that suppress, in whole or in part, the production of VEGFA.
[0007] According to a first embodiment, the present invention provides a method for suppressing the expression of VEGFA. The method comprises administering in vivo (e.g., in a human) an siRNA that comprises a sequence that is a selected from the group consisting of: SEQ ID NOs: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86, and 88 to an organism.
[0008] According to a second embodiment, the present invention provides a method for suppressing the expression of VEGFA. The method comprises administering in vitro an siRNA that comprises a sequence that is selected from the group consisting of: SEQ ID NOs: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86, and 88.
[0009] According to a third embodiment, the present invention provides a method for suppressing expression of VEGFA. The method comprises administering an siRNA according to either of the first two embodiments, wherein the siRNA has one or more of the following modifications: 2′-O-alkyl (e.g., 2′-O-methyl) modifications of all C and U nucleotides within the sense strand as well as on the first two 5′ nucleotides of the sense strand, 2′ Fluoro modifications of all of the C and U nucleotides within the antisense strand and a 5′ phosphorylation of the nucleotide at position one of the antisense strand. In some embodiments the siRNA has 2′-O-alkyl modifications on all C and U nucleotides within the sense strand and at least one 2′-O-alkyl modification on the antisense strand. In some embodiments the siRNA has one or more overhangs of one to six nucleotides. In some embodiments all of the aforementioned modifications are present, and only those modifications are present, thus, all G and A nucleotides, other than those located at positions 1 and 2 of the sense strand have 2′-OH groups.
[0010] According to a fourth embodiment, the present invention provides a method for suppressing expression of VEGFA. The method comprises administering an siRNA according to any of the first three embodiments, wherein the siRNA has one or more of the following modifications: a cholesterol moiety attached by a C5 linker, and mismatches at one or more of positions 6, 13 and 19 of the sense strand where the sense strand is 19 nucleotides long and the antisense strand is also 19 nucleotides in length (excluding overhangs). The positions on the sense strand are measured from the 5′ end of the sense strand wherein the first 5′ nucleotide of the sense strand is identified as the 5′-most nucleotide that is base-paired with a nucleotide on the antisense strand. As such, by this definition, 5′ sense strand overhang nucleotides are not included in the counting scheme. In some of these embodiments there are no 5′ overhangs. In some of the embodiments there are one or two 3′ overhangs of 1 to 6 bases or there are no overhangs. In some embodiments, except for at positions 6, 13 and 19, within the duplex region, there is 100% complementarity.
[0011] According to a fifth embodiment, the present invention provides a pool of at least two siRNA selected from the group consisting of SEQ ID NOs: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86 and 88.
[0012] According to a sixth embodiment, the present invention provides a pharmaceutical composition comprising a therapeutically effective amount of one or more of the siRNAs disclosed herein.
[0013] According to a seventh embodiment, the present invention provides a pharmaceutical composition comprising a therapeutically effective amount of an siRNA, wherein the siRNA consists of: (a) an antisense strand that is nineteen to thirty-six bases in length and that comprises a sequence selected from the group consisting of SEQ ID NOs: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86, and 88; and (b) a sense strand that is nineteen to thirty-six bases in length, wherein the antisense strand and the sense strand form a duplex region of seventeen to thirty base pairs and within the duplex region there is at least 75% complementary. In the event that the duplex region of the siRNA is longer than 19 base pairs in length, additional (sense and antisense) sequences are added to the 3′ end of the antisense strand and 5′ end of the sense strand.
[0014] Through the use of the methods, siRNAs and pharmaceutical compositions described herein, one may efficiently and effectively silence VEGFA.
BRIEF DESCRIPTION OF THE FIGURES
[0015] FIGS. 1A and B demonstrate the in vivo silencing activities of two VEGFA siRNAs modified as Accell molecules and delivered by intravitreal (IVT) injection in rats.
[0016] FIG. 2 is a representation of a dose response curve for an siRNA, VEGFA 3.2 (modified as an Accell molecule).
[0017] FIGS. 3A and 3B are representations of dose response curves for another siRNA, VEGFA 3.7 (modified as an Accell molecule).
[0018] FIGS. 4A and 4B demonstrate a duration of action of up to eight weeks for an siRNA, VEGFA 3.7, modified as an Accell molecule and delivered by IVT injection in rats.
[0019] FIGS. 5A and 5B demonstrate inhibition of VEGFA expression and preretinal neovascularization in the rat oxygen-induced retinopathy (OIR) model by siRNA, VEGFA 3.7, modified as an Accell molecule.
DETAILED DESCRIPTION
Definitions
[0020] Unless stated otherwise or apparent from context, the following terms and phrases have the meanings provided below:
2′ Modification
[0021] A 2′ modification refers to a substitution of the hydroxyl group that is typically located at the 2′ position of a ribose sugar within a ribonucleotide, with another moiety, e.g., an —O-alkyl group such as —O-methyl, —O-ethyl, —O-n-propyl, —O-isopropyl etc., or another group such as a fluoro group. Where —O-alkyl modifications are present, in some embodiments the same —O-alkyl group is present on all O-alkyl-modified nucleotides. Other types of 2′ modifications are halogen groups, e.g., 2′ Fluoro, or 2′ bromo.
[0000] “Accell” siRNA
[0022] The term “Accell” refers to a preferred siRNA structure comprising the following: the sense strand is 19 nucleotides long and has: (1) 2′-O-methyl modifications on positions 1 and 2 (counting from the 5′ terminus); (2) 2′-O-methyl modifications on all Cs and Us; and (3) cholesterol conjugated to the 3′ terminus via a C5 linker. The antisense strand is 21 nucleotides in length, has a 5′ phosphate modification, contains a 2′ F modification on all Cs and Us, forms a 2 nucleotide overhang when paired with the sense strand, and contains phosphorthioate modification between (1) the two nucleotides of the overhang, and (2) between the 3′ most nucleotide of the duplexed region and the first nucleotide of the overhang. In addition, Accell molecules contain mismatches at positions 6, 13, and 19 (counting from the 5′ end of the sense strand). In all cases, these mismatches are generated by replacing the sense nucleotide with an alternative base. In this way, the antisense strand retains complete complementarity with the target molecule. For additional details, see US 2009/0209626 A1, the disclosure of which is incorporated by reference.
Complementary
[0023] The term “complementary” refers to the ability of polynucleotides to form base pairs with one another. Base pairs are typically formed by hydrogen bonds between nucleotide units in antiparallel polynucleotide strands. Complementary polynucleotide strands can base pair in the Watson-Crick manner (e.g., A to T, A to U, C to G), or in any other manner that allows for the formation of duplexes. As persons skilled in the art are aware, when using RNA as opposed to DNA, uracil rather than thymine is the base that is considered to be complementary to adenosine. However, when a U is denoted in the context of the present invention, the ability to substitute a T is implied, unless otherwise stated.
[0024] Perfect complementarity or 100% complementarity refers to the situation in which each nucleotide unit of one polynucleotide strand can hydrogen bond with a nucleotide unit of a second polynucleotide strand. Less than perfect complementarity refers to the situation in which some, but not all, nucleotide units of two strands can hydrogen bond with each other. For example, for two 20-mers, if only two base pairs on each strand can hydrogen bond with each other, the polynucleotide strands exhibit 10% complementarity. In the same example, if 18 base pairs on each strand can hydrogen bond with each other, the polynucleotide strands exhibit 90% complementarity. In some embodiments, within a duplex region, there is at least 75% complementarity, at least 80% complementarity, at least 90% complementarity, at least 95% complementarity or 100% complementarity.
Conjugate Moiety
[0025] Conjugate moieties of the disclosure (also referred to simply as “conjugates”) are moieties that are connected either directly or indirectly to a nucleotide and can target entry into a cell by a variety of means. For instance, conjugate moieties can be lipid in nature. As such, lipid based conjugate moieties can include cationic lipids, neutral lipids, sphingolipids, and fatty acids including stearic, oleic, elaidic, linoleic, linoleaidic, linolenic, and myristic acids. Alternatively, the conjugate moieties can be proteinaceous in nature including peptides that are membrane translocating (e.g., TAT, penetratin, MAP) or cationic (e.g., poly(lys), poly(arg), poly(his), poly (lys/arg/his), or protamine).
[0026] Alternatively, the conjugate moiety can be a small molecule that, for instance, targets a particular receptor or is capable of inserting itself into the membrane and being absorbed by endocytic pathways. Thus, small molecules based on adamantanes, polyaromatic hydrocarbons (e.g., napthalenes, phenanthrenes, or pyrenes), macrocyles, steroids, or other chemical scaffolds, are all potential conjugates for the disclosure.
[0027] In yet another alternative, conjugate moieties can be based on cationic polymers, such as polyethyleneimine, dendrimers, poly(alkylpyridinium) salts, or cationic albumin.
[0028] In some cases, the conjugate moieties are ligands for receptors or can associate with molecules that in turn associate with receptors. Included in this class are bile acids, small molecule drug ligands, vitamins, aptamers, carbohydrates, peptides (including but not limited to hormones, proteins, protein fragments, antibodies or antibody fragments),viral proteins (e.g., capsids), toxins (e.g., bacterial toxins), and more. Also included are conjugates that are steroidal in nature e.g., cholesterol, cholestanol, cholanic acid, stigmasterol, pregnelone, progesterones, corticosterones, aldosterones, testosterones, estradiols, ergosterols, and more. Preferred conjugate moieties of the disclosure are cholesterol (CHOL), cholestanol (CHLN), cholanic acid (CHLA), stigmasterol (STIG), and ergosterol (ERGO).
[0029] In yet another embodiment, the molecules that target a particular receptor are modified to eliminate the possible loss of conjugated siRNAs to other sources. For instance, when cholesterol-conjugated siRNAs are placed in the presence of normal serum, a significant fraction of this material will associate with the albumin and/or other proteins in the serum, thus making the siRNA unavailable for e.g., interactions with LDLs. For this reason, the conjugate moieties of the disclosure can be modified in such a way that they continue to bind or associate with their intended target (e.g., LDLs) but have lesser affinities with unintended binding partners (e.g., serum albumin).
Duplex Region
[0030] The phrase “duplex region” refers to the region in two complementary or substantially complementary polynucleotides that form base pairs with one another, either by Watson-Crick base pairing or any other manner that allows for a stabilized duplex between polynucleotide strands that are complementary or substantially complementary.
[0031] Examples of sizes of duplex regions include but are not limited to 17-30 base pairs, 17-25 base pairs, 17-23 base pairs, 18-30 base pairs, 18-25 base pairs, 18-23 base pairs, 19-30 base pairs, 19-25 base pairs and 19-23 base pairs. A duplex region may be defined by the length of base pairs, as well as the degree of complementarity over that range.
[0032] Thus, when the duplex region is formed from two separate strands of nucleotides, the antisense strand and the sense strand, it is important to note that each strand may contain nucleotides that are part of the duplex and nucleotides that are not part of the duplex at either the 5′ end or the 3′ end. An siRNA may be designed such that on the antisense strand, all nucleotides that are complementary to a target are part of the duplex region, and thus have complementary nucleotides on the sense strand. However, the siRNA may be also be designed such that the antisense strand also contains nucleotides at either its 3′ end and/or its 5′ end that although not having complementary nucleotides on the sense strand, are part of a continuous stretch of nucleotides within the antisense strand that have complementary nucleotides on the target.
[0033] By way of example, a sense strand may contain 19 nucleotides and an antisense strand may contain 21 nucleotides. All but the two 3′ most nucleotides of the antisense strand may be complementary to the 19 nucleotides on the sense strand, while the entire stretch of 21 nucleotides of the antisense strand may be complementary to a stretch of 21 nucleotides of the target. Alternatively, the two 3′ most nucleotides of the antisense strand may be selected so as not to be complementary to a portion of the target, or selected randomly or to facilitate processing such that one or both might or might not be complementary to the two nucleotides of the target that are adjacent to the nucleotides to which the other 19 nucleotides of the antisense strand are complementary.
[0034] Additionally, in different embodiments, within a duplex region there may for example be no mismatches, one mismatch, two mismatches, three mismatches, four mismatches, or five mismatches.
Mismatch
[0035] The term “mismatch” includes a situation in which Watson-Crick base pairing does not take place between a nucleotide of a sense strand and a nucleotide of an antisense strand. Examples of mismatches include but are not limited to an A across from a G, a C across from an A, a U across from a C, a U across from a G, an A across from an A, a G across from a G, a C across from C, and a U across from a U.
Linker
[0036] A linker is a moiety that attaches two or more other moieties. Though not wishing to be limited by definitions or conventions, in this application the length of the linker is described by counting the number of atoms that represents the shortest distance between the atom that joins the conjugate moiety to the linker and the oxygen atom of the terminal phosphate moiety associated with the oligonucleotide through which the linker is attached to the oligonucleotide. For example, in embodiments where the conjugate moiety is joined to the linker via a carbamate linkage, the length of the linker is described as the number of atoms that represents the shortest distance between the nitrogen atom of the carbamate linkage and the oxygen atom of the phosphate linkage. In cases where ring structures are present, counting the atoms around the ring that represent the shortest path is preferred.
[0037] Non-limiting examples of structures of the conjugate-linker that may be used in the compositions and methods of the disclosure include but are not limited to linkers/linker chemistries that are based on β-amino-1,3-diols, β-amino-1,2-diols, hydroxyprolinols, ω-amino-alkanols, diethanolamines, β-hydroxy-1,3-diols, β-hydroxy-1,2-diols, β-thio-1,3-diols, β-thio-1,2-diols, β-carboxy-1,3-diols, β-carboxy-1,2-diols, ω-hydroxy-alkanols, ω-thio-alkanols, ω-carboxy-alkanols, functionalized oligoethylene glycols, allyl amine, acrylic acid, allyl alcohol, propargyl amine, and propargyl alcohol.
[0038] In some embodiments a linker not only provides a site of attachment to the conjugate moiety, but also provides functional sites for attachment to the support and for initiation of oligonucleotide synthesis. Preferably, these sites are hydroxyl groups; most preferably, they are a primary hydroxyl group and a secondary hydroxyl group, to allow them to be chemically distinguished during synthesis of the conjugate-modified solid support. One hydroxyl group, preferably the primary hydroxyl group, is protected with a protecting group that can be removed as the first step in the synthesis of the oligonucleotide, according to methods well understood by those of ordinary skill in the art. Preferably, this protecting group is chromophoric and can be used to estimate the amount of the conjugate moiety attached to the solid support; most preferably, the group is chosen from triphenylmethyl (Tr), monomethoxytriphenylmethyl (MMTr), dimethoxytriphenylmethyl (DMTr) and trimethoxytriphenylmethyl (TMTr). Another hydroxyl group, preferably a secondary hydroxyl group, is derivatized with a functionalized tether that can covalently react with a functional group on the solid synthesis support, according to methods well understood by those of ordinary skill in the art. Preferable tethers are, by way of example, dicarboxylic acids such as succinic, glutaric, terephthalic, oxalic, diglycolic, and hydroquinone-0,0′-diacetic. One of the carboxylic acid functionalities of the tether is reacted with the hydroxyl to provide an ester linkage that is cleavable using basic reagents (hydroxide, carbonate or amines), while the other carboxylic acid functionality is reacted with the synthesis support, usually through formation of an amide bond with an amine functionality on the support. The linker may also confer other desirable properties on the oligonucleotide conjugate: improved aqueous solubility, optimal distance of separation between the conjugate moiety and the oligonucleotide, flexibility (or lack thereof), specific orientation, branching, and others.
[0039] Preferably, the chemical bond between the linker and the conjugate moiety is a carbamate linkage; however, alternative chemistries are also within the scope of the disclosure. Examples of functional groups on linkers that form a chemical bond with a conjugate moiety include, but are not limited to, hydroxyl, amine, carboxylic acid, carboxylic acid halide, carboxylic acid active ester, carbonyl, chlorocarbonyl, imidazolylcarbonyl, thiol, maleimide, haloalkyl, sulfonyl, allyl and propargyl. Examples of chemical bonds that are formed between a linker and a conjugate include, but are not limited to, those based on carbamates, ethers, esters, amides, disulfides, thioethers, phosphodiesters, phosphorothioates, phorphorodithioate, sulfonamides, sulfonates, sulfones, sulfoxides, ureas, hydrazide, oxime, photolabile linkages, C—C bond forming groups such as Diels-Alder cyclo-addition pairs or ring-closing metathesis pairs, and Michael reaction pairs. In general, the conjugate moiety will have an appropriate functional group either naturally or chemically installed; the linker will then be synthesized with a functional group chosen to efficiently and stably react with the functional group on the conjugate moiety.
[0040] Linkers that have the same length, but are capable of associating with two or more conjugates, are also specifically contemplated.
[0041] In another embodiment, the linker may be a nucleoside derivative. The nucleoside may be, for example, a ribonucleoside, 2′-deoxyribonucleoside, or 2′-modified-2′-deoxyribonucleoside, such as 2′-O-methyl or 2′-fluoro. The nucleoside may be, for example, an arabinonucleoside or a 2′-modified arabinonucleoside. Using methods well known to those of ordinary skill in the art, purine and pyrimidine nucleosides may be modified at particular sites on the base to provide linkers and functional groups for attachment of conjugate moieties. For example, pyrimidine nucleosides, such as uridine and cytidine, may be modified at the 5-position of the uracil or cytosine base using mercuric acetate, a palladium catalyst, and an allylic reagent such as allylamine, allyl alcohol, or acrylic acid. Alternatively, 5-iodopyrimidines may be modified at the 5-position with a palladium catalyst and a propargylic reagent such as propargyl amine, propargyl alcohol or propargylic acid. Alternatively, uridine may be modified at the 4-position through activation with triazole or a sulfonyl chloride and subsequent reaction with a diamine, amino alcohol or amino acid. Cytidine may be similarly modified at the 4-position by treatment with bisulfite and subsequent reaction with a diamine, amino alcohol or amino acid. Purines may be likewise modified at the 7, 8 or 9 positions using similar types of reaction sequences.
[0042] In preferred embodiments, the linker is from about 3 to about 9 atoms in length. Thus, the linker may be 3, 4, 5, 6, 7, 8, or 9 atoms in length. Preferably, the linker is 5, 6, 7 or 8 atoms in length. More preferably, the linker is 5 or 8 atoms in length. Most preferably the linker is a straight chain C5 linker i.e., there are 5 carbon atoms between the atom that joins the conjugate moiety to the linker and the oxygen atom of the terminal phosphate moiety associated with the oligonucleotide through which the linker is attached to the oligonucleotide. Thus, where the conjugate moiety is joined to a C5 linker via a carbamate linkage, there are 5 carbon atoms between the nitrogen atom of the carbamate linkage and the oxygen atom of the phosphate linkage.
[0043] In one preferred embodiment, the conjugate moiety is cholesterol and the linker is a C5 linker (a 5 carbon linker) attached to the cholesterol via a carbamate group, thus forming a Chol-C5 conjugate-linker. When attached via a phosphodiester linkage to the 5′ and/or 3′ terminus of a sense and/or antisense oligonucleotide of a duplex, the resulting conjugate-linker-oligonucleotide can have the structure:
[0000]
[0044] In another preferred embodiment, the conjugate moiety is cholesterol and the linker is a C3 linker attached to the cholesterol via a carbamate group, thus forming a Chol-C3 conjugate-linker. When attached via a phosphodiester linkage to the 5′ and/or 3′ terminus of a sense and/or antisense oligonucleotide, the resulting conjugate linker-oligonucleotide can have the structure:
[0000]
[0045] In another preferred embodiment, the conjugate moiety is cholesterol and the linker is a C8 linker (a 8 carbon linker) attached to the cholesterol via a carbamate group, thus forming a Chol-C8 conjugate-linker. When attached via a phosphodiester linkage to the 5′ and/or 3′ terminus of a sense and/or antisense oligonucleotide, the resulting conjugate-linker oligonucleotide can have the structure:
[0000]
[0046] In another preferred embodiment, the conjugate moiety is cholesterol and the linker is a PRO linker (a 4 carbon linker) attached to the cholesterol via a carbamate group, thus forming a Chol-PRO conjugate-linker.
[0047] In another preferred embodiment, the conjugate moiety is cholesterol and the linker is a PIP linker (a 6 carbon linker) attached to the cholesterol via a carbamate group, thus forming a Chol-PIP conjugate-linker. When attached via a phosphodiester linkage to the 5′ and/or 3′ terminus of a sense and/or antisense oligonucleotide, the resulting conjugate-linker-oligonucleotide can have the structure:
[0048] In another preferred embodiment, the conjugate moiety is cholesterol and the linker is a C6-HP (also referred to as “HP6”) linker (a 9 carbon linker) attached to the cholesterol via a carbamate group, thus forming a Chol-C6-HP conjugate-linker. When attached via a phosphodiester linkage to the 5′ and/or 3′ terminus of a sense and/or antisense oligonucleotide, the resulting conjugatelinker-oligonucleotide can have the structure:
[0000]
Nucleotide
[0049] Unless otherwise specified, the term “nucleotide” refers to a ribonucleotide or a deoxyribonucleotide or modified form thereof, as well as an analog thereof. Nucleotides include species that comprise purines, e.g., adenine, hypoxanthine, guanine, and their derivatives and analogs, as well as pyrimidines, e.g., cytosine, uracil, thymine, and their derivatives and analogs. In some emobodiments, all nucleotides are selected from the group of modified or unmodified A, C, G or U.
[0050] Nucleotide analogs include nucleotides having modifications in the chemical structure of the base, sugar and/or phosphate, including, but not limited to, 5-position pyrimidine modifications, 8-position purine modifications, modifications at cytosine exocyclic amines, and substitution of 5-bromo-uracil; and 2′-position sugar modifications, including but not limited to, sugar-modified ribonucleotides in which the 2′-OH is replaced by a group such as an H, OR, R, halo, SH, SR, NH 2 , NHR, NR 2 , or CN, wherein R is an alkyl moiety. Nucleotide analogs are also meant to include nucleotides with bases such as inosine, queuosine, xanthine, sugars such as 2′-methyl ribose, non-natural phosphodiester linkages such as methylphosphonates, phosphorothioates and peptides.
[0051] Modified bases refer to nucleotide bases such as, for example, adenine, guanine, cytosine, thymine, uracil, xanthine, inosine, and queuosine that have been modified by the replacement or addition of one or more atoms or groups. Some examples of types of modifications that can comprise nucleotides that are modified with respect to the base moieties include but are not limited to, alkylated, halogenated, thiolated, aminated, amidated, or acetylated bases, individually or in combination. More specific examples include, for example, 5-propynyluridine, 5-propynylcytidine, 6-methyladenine, 6-methylguanine, N,N,-dimethyladenine, 2-propyladenine, 2-propylguanine, 2-aminoadenine, 1-methylinosine, 3-methyluridine, 5-methylcytidine, 5-methyluridine and other nucleotides having a modification at the 5 position, 5-(2-amino)propyl uridine, 5-halocytidine, 5-halouridine, 4-acetylcytidine, 1-methyladenosine, 2-methyladenosine, 3-methylcytidine, 6-methyluridine, 2-methylguanosine, 7-methylguanosine, 2,2-dimethylguanosine, 5-methylaminoethyluridine, 5-methyloxyuridine, deazanucleotides such as 7-deaza-adenosine, 6-azouridine, 6-azocytidine, 6-azothymidine, 5-methyl-2-thiouridine, other thio bases such as 2-thiouridine and 4-thiouridine and 2-thiocytidine, dihydrouridine, pseudouridine, queuosine, archaeosine, naphthyl and substituted naphthyl groups, any O- and N-alkylated purines and pyrimidines such as N6-methyladenosine, 5-methylcarbonylmethyluridine, uridine 5-oxyacetic acid, pyridine-4-one, pyridine-2-one, phenyl and modified phenyl groups such as aminophenol or 2,4,6-trimethoxy benzene, modified cytosines that act as G-clamp nucleotides, 8-substituted adenines and guanines, 5-substituted uracils and thymines, azapyrimidines, carboxyhydroxyalkyl nucleotides, carboxyalkylaminoalkyl nucleotides, and alkylcarbonylalkylated nucleotides. Modified nucleotides also include those nucleotides that are modified with respect to the sugar moiety, as well as nucleotides having sugars or analogs thereof that are not ribosyl. For example, the sugar moieties may be, or be based on, mannoses, arabinoses, glucopyranoses, galactopyranoses, 4′-thioribose, and other sugars, heterocycles, or carbocycles.
[0052] The term nucleotide is also meant to include what are known in the art as universal bases. By way of example, universal bases include but are not limited to 3-nitropyrrole, 5-nitroindole, or nebularine. The term “nucleotide” is also meant to include the N3′ to P5′ phosphoramidate, resulting from the substitution of a ribosyl 3′ oxygen with an amine group.
[0053] Further, the term nucleotide also includes those species that have a detectable label, such as for example a radioactive or fluorescent moiety, or mass label attached to the nucleotide.
Pharmaceutically Acceptable Carrier
[0054] The phrase “pharmaceutically acceptable carrier” means a pharmaceutically acceptable salt, solvent, suspending agent or vehicle for delivering a composition of the present disclosure to an organism such as an animal or human. The carrier may be liquid, semisolid or solid, and is often synonymously used with diluents, excipient, or salt. The phrase “pharmaceutically acceptable” means that any ingredient, excipient, carrier, diluent or component disclosed is one that is suitable for use with humans and/or animals without undue adverse side effects (such as toxicity, isolation and allergic response) commensurate with a reasonable benefit/risk ratio. See Remington's Pharmaceutical Science 16 th edition, Osol, A. Ed. (1980).
Ribonucleotide and Ribonucleic Acid
[0055] The term “ribonucleotide” and the phrase “ribonucleic acid” (RNA), refer to a modified or unmodified nucleotide or polynucleotide comprising at least one ribonucleotide unit. A ribonucleotide unit comprises an hydroxyl group attached to the 2′ position of a ribosyl moiety that has a nitrogenous base attached in N-glycosidic linkage at the 1′ position of a ribosyl moiety, and a moiety that either allows for linkage to another nucleotide or precludes linkage.
Sense Strand/Antisense Strand
[0056] The phrase “sense strand” refers to a polynucleotide that comprises a sequence that is in whole or in part, the same as a target nucleic acid sequence such as messenger RNA or a sequence of DNA. The phrase “antisense strand” refers to a polynucleotide that comprises a sequence that is in whole or in part, the complement of a target nucleic acid sequence such as messenger RNA or a sequence of DNA.
[0057] When a sequence of an siRNA is provided, by convention, unless otherwise indicated it is of the sense strand, and the complementary antisense strand is implicit. In a duplex siRNA (formed from two separate strands) one strand may be the sense strand, and the other strand may be the antisense strand. If overhangs are present, the phrase “sense region” may refer to the nucleotide sequence portion of the sense strand other than overhang regions. Similarly, the phrase “antisense region” may refer to the nucleotide sequence portion of the antisense strand other than overhang regions. If the siRNA is a shRNA, there are not two separate strands, and the “sense region” is the portion of the duplex region that has a sequence that is in whole or in part the same as the target sequence, and the “antisense region” is the sequence of nucleotides that is in whole or in part complementary to the target sequence and to the sense region.
[0058] Examples of lengths of sense strands and antisense strands are 19-36 bases, 19-30 bases, 19-25 bases and 19-23 bases. These strand lengths include possible overhang regions.
[0000] siRNA
[0059] The term “siRNA” refers to small inhibitory RNA duplexes that induce the RNA interference (RNAi) pathway. As used herein, these molecules can vary in length (generally 17-30 base pairs plus overhangs) and contain varying degrees of complementarity to their target mRNA in the antisense strand. Some, but not all, siRNA have unpaired overhanging bases on the 5′ or 3′ end of the sense strand and/or the antisense strand. The term “siRNA” includes duplexes of two separate strands, and unless otherwise specified as well as single strands that can form hairpin structures comprising a duplex region, which is referred to as a shRNA.
[0000] siStable
[0060] The term “siStable” refers to a chemical modification pattern that is associated with a particular duplex. Specifically, siStable siRNA comprise the following structures: the sense strand is 19 nucleotides long and has (1) 2′-O-methyl modifications on positions 1 and 2 (counting from the 5′ terminus), and (2) 2′-O-methyl modifications on all Cs and Us. The antisense strand is 21 nucleotides in length, has a 5′ phosphate modification, contains a 2′ F modification on all Cs and Us, forms a 2 nucleotide overhang when paired with the sense strand, and contains phosphorthioate modifications between (1) the two nucleotides of the overhang, and (2) between the 3′ most nucleotide of the duplexed region and the first nucleotide of the overhang. For details, see US 2007/0269889 A1.
Target
[0061] The term “target” is used in a variety of different forms throughout this document and is defined by the context in which it is used. “Target mRNA” refers to a messenger RNA to which a given siRNA can be directed against. “Target sequence” and “target site” refer to a sequence within the mRNA to which the sense strand of an siRNA shows varying degrees of identity and the antisense strand exhibits varying degrees of complementarity. The phrase “siRNA target” can refer to the gene, mRNA, or protein against which an siRNA is directed. Similarly, “target silencing” can refer to the state of a gene, or the corresponding mRNA or protein.
Therapeutically Effective Amount
[0062] A “therapeutically effective amount” of a composition containing a sequence that encodes a VEGFA-specific siRNA (i.e., an effective dosage), is an amount that inhibits expression of the polypeptide encoded by the VEGFA target gene by at least 10 percent. Higher percentages of inhibition, e.g., at least 15, at least 20, at least 30, at least 40, at least 50, at least 75, at least 85, at least 90 percent or higher may be preferred in certain embodiments. The skilled artisan will appreciate that certain factors may influence the dosage and timing required to effectively treat a subject, including but not limited to the severity of the disease or disorder, previous treatments, the general health and/or age of the subject, and other diseases present. Moreover, treatment of a subject with a therapeutically effective amount of a composition can include a single treatment or a series of treatments. In some cases transient expression of the siRNA may be desired. When an inducible promoter is included in the construct encoding an siRNA, expression is assayed upon delivery to the subject of an appropriate dose of the substance used to induce expression.
[0063] Appropriate doses of a composition depend upon the potency of the molecule (the sequence encoding the siRNA) with respect to the expression or activity to be modulated. One or more of these molecules can be administered to an animal (e.g., a mammal such as a human or other primate, e.g., a chimpanzee, orangutan, ape, monkey etc., or dog, cat, horse, cow, rat, sheep, or mouse) to modulate expression or activity of one or more target polypeptides. A physician may, for example, prescribe a relatively low dose at first, subsequently increasing the dose until an appropriate response is obtained. In addition, it is understood that the specific dose level for any particular subject will depend upon a variety of factors including the activity of the specific compound employed, the age, body weight, general health, gender, and diet of the subject, the time of administration, the route of administration, the rate of excretion, any drug combination, and the degree of expression or activity to be modulated.
[0064] A therapeutically effective amount of a VEGFA-specific siRNA is useful for treating a condition, disease, or disorder associated with elevated expression of VEGFA, including, but not limited to, psoriasis, cancer, rheumatoid arthritis, ocular neovascularization, abnormal angiogenesis, retinal vascular permeability, retinal edema, diabetic retinopathy (particularly proliferative diabetic retinopathy), diabetic macular edema, exudative age-related macular degeneration, sequela associated with retinal ischemia, and posterior segment neovascularization.
Preferred Embodiments
[0065] The present invention will now be described in connection with preferred embodiments. These embodiments are presented in order to aid in an understanding of the present invention and are not intended, and should not be construed, to limit the invention in any way. All alternatives, modifications and equivalents that may become apparent to those of ordinary skill upon reading this disclosure are included within the spirit and scope of the present invention.
[0066] Furthermore, this disclosure is not a primer on compositions or methods for performing RNA interference. Basic concepts known to persons skilled in the art have not been set forth in detail.
[0067] According to a first embodiment, the present invention provides a method for decreasing expression of VEGFA, in vivo, comprising administering an siRNA to an organism, wherein the siRNA comprises a sequence selected from SEQ ID NO: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86, and 88.
[0068] The subject may be any organism that possesses an RNAi pathway, including, but not limited to a mammal, bird or reptile. Examples of mammals include, but are not limited to humans, monkeys, apes, chimpanzees, dogs, cats, mice and rats.
[0069] In addition, the duplex formed by the sense strand and the antisense strand can comprise at least one overhang, each overhang comprising at least one nucleotide. The overhang(s) can for example be located:
[0070] at the 5′ end of the sense strand;
[0071] at the 3′ end of the sense strand;
[0072] at the 5′ and 3′ end of the sense strand;
[0073] at the 5′ end of the antisense strand;
[0074] at the 3′ end of the antisense strand;
[0075] at the 5′ and 3′ end of the antisense strand;
[0076] at the 5′ end of the sense strand and the 5′ end of the antisense strand; or
[0077] at the 3′ end of the sense strand and the 3′ end of the antisense strand.
[0078] In some embodiments, the overhang is six or fewer nucleotides in length, in preferred embodiments, an overhang is present at the 3′ end of the antisense strand, i.e., attached to the 3′ most nucleotides of the antisense regions. More preferably, the overhang on the 3′ end of the antisense strand is two nucleotides in length. The selection of the bases for nucleotides in the overhang may be made in an arbitrary manner i.e., the overhang nucleotides may or may not base pair with a target mRNA. For convenience and simplicity, a two nucleotide overhang is usually a UU overhang (although AA, GG, CC, AC, CA, AG, GA, GC, and CG di-nucleotide overhangs, and others, are also contemplated, see Vermeulen et al. (2005) RNA 11 (5): 674-682). Preferably, the linkage between the nucleotides of the overhang as well as the linkage between the terminal nucleotide of the duplex and the first nucleotide of the overhang are phosphorothioate linkages. In one particularly preferred embodiment, the antisense strand comprises a UU overhang located at the 3′ end of the antisense strand with a phosphorothioate linkage linking the 3′ terminal U to the second U nucleotide, and with a phosphorothioate linkage linking the second U nucleotide to the next nucleotide (in the 5′ direction) in the antisense strand.
[0079] In some embodiments, the 5′ end of the sense strand and/or the 3′ end of the sense strand and/or the 5′ end of the antisense strand and/or the 3′ end of the antisense strand comprises a terminal phosphate. Preferably, a terminal phosphate is located at the 5′ end of the antisense strand.
[0080] In some embodiments there are no modified nucleotides (i.e., the 2′ position of each of the ribose sugars has an OH moiety). In other embodiments there are one or more than one chemical modifications. For example, there may be one or more or all of:
(1) 2′-O-alkyl modifications of positions 1 and 2 and all C nucleotides, and all U nucleotides of the sense strand (e.g., O-methyl, O-ethyl, O-n-propyl, O-isopropyl, etc.); (2) a conjugate moiety wherein the conjugate moiety is comprised of, consists essentially of or consists of a linker and a conjugate moiety such as a cholesterol moiety and the linker is attached to the 3′ position of the last nucleotide of the sense strand; (3) 2′ Fluoro modifications of all C and U nucleotides of the antisense strand or at least one 2′-O-alkyl modification on the antisense strand; (4) phosphorylation at the 5′ position of the first nucleotide of the antisense strand and all other nucleotides may in some embodiments be unmodified; (5) one or more overhangs; and (6) one or more phosphorothioate modifications associated with the nucleotides of any overhang on either strand.
[0087] In some embodiments, where overhangs are present, 2′-O modifications may appear in the Cs and Us of the overhangs on the sense strand and 2′-fluoro modifications may appear in the Cs and Us of on the antisense strand. In other embodiments the 2′-O modifications and 2′-fluoro only appear within nucleotides in the duplex region. Additionally, in some embodiments it may be desirable to have all of the aforementioned 2′ Cs and Us modified in each strand (either including or excluding in any overhang regions if present). However, in other embodiments it may be desirable to have fewer than all of the C and Us on each or either strand contain the aforementioned modifications. When fewer than all Cs and Us are modified, the total number of C and U modifications may be chosen by for example, an absolute number, for example 1-8 or 2-7 or 3-6 are modified or it may for example be defined in terms of the number that are not modified, e.g., all but 1, all but 2, all but 3, all but 4, all but 5, all but 6, all but 7, all but 8 of the Cs or Us are unmodified. In other embodiments, it may be preferable to omit a 2′ modification at one or more specific positions, e.g., at one or more of positions 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, and if present, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 or 30. As a person of ordinary skill in the art will recognize preferably each strand contains at least one C or U nucleotide. Additionally, in some embodiments on the antisense strand it may be preferable to have 2′ fluoro groups on 0-30 or 0-25 or 0-23 or 0-19 or 1-30 or 1-25 or 1-23 or 1-19 or 3-30 or 3-25 or 3-23 or 3-19 or 5-30 or 5-25 or 5-23 or 5-19 or 7-30 or 7-25 or 7-23 or 7-19 or 10-30 or 10-25 or 10-23 or 10-19 or 8-15 or 10-12 nucleotides. The modified nucleotides may all be pyrimidines, all be purines or be a combination of purines and pyrimidines. In some embodiments all nucleotides on the antisense strand have 2′fluoro groups and this strand may have at least one pyrimidine, at least one purine, all pyrimidines, all purines or a combination of purines and pyrimidines. Further in some embodiments the 2′fluoro groups are on any overhang nucleotides if present while in other embodiments, the overhang nucleotides do not include these modifications. Similarly, in some embodiments on the sense strand it may be preferable to have 2′-O-alkyl (e.g., 2′-O-methyl) groups on 0-30 or 0-25 or 0-23 or 0-19 or 1-30 or 1-25 or 1-23 or 1-19 or 3-30 or 3-25 or 3-23 or 3-19 or 5-30 or 5-25 or 5-23 or 5-19 or 7-30 or 7-25 or 7-23 or 7-19 or 10-30 or 10-25 or 10-23 or 10-19 or 8-15 or 10-12 nucleotides. The modified nucleotides may all be pyrimidines, all be purines or be a combination of purines and pyrimidines. In some embodiments all nucleotides on the sense strand have 2′-O-alkyl groups and this strand may have at least one pyrimidine, at least one purine, all pyrimidines, all purines or a combination of purines and pyrimidines. Further in some embodiments the 2′-O-alkyl groups are on any overhang nucleotides if present while in other embodiments, the overhang nucleotides do not include these modifications.
[0088] In embodiments that have at least one 2′-O-alkyl modification on the antisense strand, there may for example be, from one to ten, one to eight, one to six, one to five, one to four, one to three, or one to two modifications. In other embodiments, there may be exactly one, two, three, four, five, six, seven, eight, nine or ten such modifications. These at least one modifications may for example be located in a 3′ antisense overhang region and/or at one or more of positions one to eight, one to seven, one to six, one to five, one to four, one to three, or one to two of the antisense strand as measured from the 5′ end of that strand and within the duplex region.
[0089] By way of non-limiting examples, there may be a single 2′-O-alkyl modification (e.g., methyl) at any of positions 1, 2, 3, 4, 5, 6, 7 or 8 of the antisense strand. Alternatively, there may be a single 2′-O-alkyl modification in one of the two nucleotides in a UU overhang or in both of those nucleotides. Other combinations of 2′-O-alkyl modifications include but are not limited to at positions 1 and 2, 1 and 3, 1 and 4, 1 and 5, 1 and 6, 1 and 7, 1 and 8, 2 and 3, 2 and 4, 2 and 5, 2 and 6, 2 and 7, 2 and 8, 3 and 4, 3 and 5, 3 and 6, 3 and 7, 3 and 8, 4 and 5, 4 and 6, 4 and 7, 4 and 8, 5 and 6, 5 and 7, 5 and 8, 6 and 7, 6 and 8, 7 and 8, 1 and one of the two nucleotides in a UU overhang or in both of those nucleotides, 2 and one of the two nucleotides in a UU overhang or in both of those nucleotides, 3 and one of the two nucleotides in a UU overhang or in both of those nucleotides, 4 and one of the two nucleotides in a UU overhang or in both of those nucleotides, 5 and one of the two nucleotides in a UU overhang or in both of those nucleotides, 6 and one of the two nucleotides in a UU overhang or in both of those nucleotides, 7 and one of the two nucleotides in a UU overhang or in both of those nucleotides, or 8 and one of the two nucleotides in a UU overhang or in both of those nucleotides.
[0090] Furthermore, in some embodiments in which there is at least one 2′-O-alkyl modification present on the antisense strand the position is selected such that only A or G bases contain the modification, thereby allowing for all C and U bases to be modified with fluoro groups. In other embodiments, one or more C or U bases contain the 2′-O-alkyl modification. In those cases, the siRNA may be designed such that any C and U base that does not have a 2′-O-alkyl modification has a 2′fluoro modification.
[0091] In some embodiments, the siRNA contains a duplex region that is 17-30 base pairs long or 18-30 base pairs long or 19-30 base pairs long or 19-23 base pairs long or 19-21 base pairs long or 18-23 base pairs long. When a duplex region is 17 base pairs long and a 19-mer antisense sequence is provided, it may be that two bases at the 3′ end of the antisense 19-mer form an overhang.
[0092] Within the duplex region there may be 100% complementarity or less than 100% complementarity, e.g., at least 80% complementarity, at least 85% complementarity, at least 90% complementarity, or at least 95% complementarity. In one embodiment, there is 100% complementarity except at sense strand position 6 or at position 13, or at position 19, or at positions 6 and 13 or at positions 13 and 19 or positions 6 and 19, or at positions 6, 13 and 19. In this example, at the designated position(s) there is a mismatch. Mismatches are introduced into the duplex by altering the identity of a nucleotide in the sense strand. In this way, the antisense strand retains 100% complementarity with the region of the target mRNA. Furthermore, as used herein, a position number within a strand refers to the location of that nucleotide relative to the first, i.e., 5′ most, nucleotide of the duplex region. Thus, position 1 of the sense strand is the 5′ most position of the sense strand, while position 1 of the antisense strand is the 5′ most position of the antisense strand. Position 2 is the position immediately downstream (or 3′) of position 1 of the respective strand.
[0093] As stated above, in some embodiments, a mismatch is introduced into the sense strand. In some cases, the nucleotides introduced at the positions of mismatch have the same identity or chemical nature as the nucleotide in the antisense strand that normally binds to that particular sense strand nucleotide. Thus, for example, if one has a double stranded molecule containing 19 nucleotides in the sense strand and 19 nucleotides in the antisense strand with no overhangs on either strand, if a mismatch is introduced at position 6 of the sense strand (counting from the 5′ end of the strand), the nucleotide at that position of the sense strand does not pair in a Watson-Crick fashion with the nucleotide at position 14 of the antisense strand. Furthermore, if the nucleotide at position 14 of the antisense strand is e.g., a “C”, then the mismatch would be achieved by introducing a “C” at position 6 of the sense strand. As a result of these changes, the nucleotide at position 6 of the sense strand no longer has identity with the corresponding nucleotide in the target region of e.g., the mRNA. However, the antisense nucleotide at e.g., position 14 would retain complementarity to the nucleotide on the target region.
[0094] The position of the conjugate-linker on the duplex oligonucleotide complex can vary with respect to the strand or strands that are conjugated (e.g., the sense strand, the antisense strand, or both the sense and antisense strands), the position or positions within the strand that are modified (i.e., the nucleotide positions within the strand or strands), and the position on the nucleotide(s) that are modified (e.g., the sugar, the base). Conjugate-linkers can be placed on the 5′ and/or 3′ terminus of one or more of the strands. For example, a conjugate-linker can be placed on the 5′ end of the sense strand and/or the 3′ end of the sense strand and/or the 3′ end of the antisense strand. A conjugate-linker can be attached at the 5′ and/or 3′ end of a strand via a phosphodiester bond. In preferred embodiments, a conjugate-linker is attached to the one or both ends of the sense strand via a phosphodiester bond, more preferably to the 3′ end of the sense strand.
[0095] A conjugate-linker can also be attached to internal positions of the sense strand and/or antisense strand. In addition, multiple positions on the nucleotides including the 5-position of uridine, 5-position of cytidine, 4-position of cytidine, 7-position of guanosine, 7-position of adenosine, 8-position of guanosine, 8-position of adenosine, 6-position of adenosine, 2′-position of ribose, 5′-position of ribose, and 3′-position of ribose, can be employed for attachment of the conjugate to the nucleic acid.
[0096] In another embodiment, the present invention provides a method of gene silencing, comprising introducing into a cell in vitro at least one siRNA that comprises a sequence that is selected from SEQ ID NOs: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86, and 88. The siRNA can be introduced by allowing passive uptake of siRNA, or through the use of a vector.
[0097] Any of the methods and kits disclosed herein can employ either unimolecular siRNAs, siRNAs comprised of two separate polynucleotide strands, or combinations thereof. Furthermore, any of the methods disclosed herein can be used in gene silencing using a variety of different protocols. In one non-limiting example, two or more siRNAs targeting the same gene can be administered simultaneously. As is the case with individual siRNAs, the two or more siRNA can be administered in a single dose or single transfection, in multiple doses, or as the case may be.
[0098] In one embodiment the invention provides the use of a compound that inhibits the expression and/or activity of a VEGFA gene for the manufacture of a medicament for treatment of a disorder associated with over-expression of VEGFA. The medicaments may, for example, be administered orally, parenterally (including subcutaneously, intramuscularly, or intravenously), rectally, transdermally, buccally, or nasally. The medicaments may comprise any one or more of the compounds described herein.
[0099] Interfering RNA may be delivered directly to the eye by ocular tissue injection such as periocular, conjunctival, subtenon, intracameral, intravitreal, intraocular, subretinal, subconjunctival, retrobulbar, or intracanalicular injections; by direct application to the eye using a catheter or other placement device such as a retinal pellet, intraocular insert, suppository or an implant comprising a porous, non-porous, or gelatinous material; by topical ocular drops or ointments; or by a slow release device in the cul-de-sac or implanted adjacent to the sclera (transscleral) or in the sclera (intrascleral) or within the eye. Intracameral injection may be through the cornea into the anterior chamber to allow the agent to reach the trabecular meshwork. Intracanalicular injection may be into the venous collector channels draining Schlemm's canal or into Schlemm's canal.
[0100] For ophthalmic delivery, an interfering RNA may be combined with ophthalmologically acceptable preservatives, co-solvents, surfactants, viscosity enhancers, penetration enhancers, buffers, sodium chloride, or water to form an aqueous, sterile ophthalmic suspension or solution. Solution formulations may be prepared by dissolving the interfering RNA in a physiologically acceptable isotonic aqueous buffer. Further, the solution may include an acceptable surfactant to assist in dissolving the interfering RNA. Viscosity building agents, such as hydroxymethyl cellulose, hydroxyethyl cellulose, methylcellulose, polyvinylpyrrolidone, or the like may be added to the compositions of the present invention to improve the retention of the compound.
[0101] In order to prepare a sterile ophthalmic ointment formulation, the interfering RNA is combined with a preservative in an appropriate vehicle, such as mineral oil, liquid lanolin, or white petrolatum. Sterile ophthalmic gel formulations may be prepared by suspending the interfering RNA in a hydrophilic base prepared from the combination of, for example, CARBOPOL®-940 (BF Goodrich, Charlotte, N.C.), or the like, according to methods known in the art. VISCOAT® (Alcon Laboratories, Inc., Fort Worth, Tex.) may be used for intraocular injection, for example. Other compositions of the present invention may contain penetration enhancing agents such as cremephor and TWEEN® 80 (polyoxyethylene sorbitan monolaureate, Sigma Aldrich, St. Louis, Mo.), in the event the interfering RNA is less penetrating in the eye.
[0102] The present invention also provides pharmaceutical compositions that comprise an siRNA of the present invention in a pharmaceutically acceptable carrier. Thus, in another embodiment, the present invention is directed to a pharmaceutical composition comprising a therapeutically effective amount of an siRNA, wherein the siRNA consists of: (a) a sense strand and an antisense strand that form a duplex region, wherein the duplex region is 17-30 base pairs in length and comprises an antisense region that has a sequence selected from the group consisting of SEQ ID NOs: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86 and 88; and (b) a sense region that is 100% complementary to the antisense region or has mismatches at one or more positions. In one example, the molecule consists of a sense strand and an antisense strand that form a 19 base double stranded complex and mismatches that are located at positions 6, 13 or 19 of the sense region, wherein said positions are defined relative to the 5′ most nucleotide of the sense strand that is part of the duplex region. For all of the descriptions relayed above, the following modifications can be adopted: sense region positions 1 and 2 and all Cs and Us have 2′-O-Me modifications, and all other 2′ positions of the sense region have 2′-OH groups, and wherein all Cs and Us of the antisense region are 2′-F modified, all other nucleotides of the antisense region have 2′-OH groups, and the nucleotide at position 1 of the antisense region is phosphorylated and there is a UU overhang attached to the 3′ end of the antisense region, wherein the internucleotide bond between the two nucleotides of the overhang as well as the first nucleotide of the overhang and the 3′ most antisense nucleotide of the duplexed region of the antisense strand is a phosphorothioate linkage; and a cholesterol moiety is attached to the 3′ end of the sense region by a C5 linker. In yet another embodiment, the siRNA has the same features as the aforementioned but the antisense strand has at least one 2′-O-Me modification instead of a 2′-F modification.
[0103] The pharmaceutically acceptable carrier may comprise one or more of excipients, such as vehicles adjuvants, pH adjusting and buffering agents, tonicity adjusting agents, stabilizers and wetting agents. Furthermore, in some embodiments, the siRNA is delivered in microcapsules, for example by coacervation techniques or by interfacial polymerization (e.g., hydroxymethylcellulose or gelatin-microcapsules and poly-(methylmethasylate) microcapsules, respectively) in colloidal drug delivery systems (for example, liposomes, microspheres, microemulsions, nano-particles, and nanocapsules or microemulsions).
[0104] The siRNA may be introduced into a cell or organism by any method that is now known or that comes to be known and that from reading this disclosure, persons skilled in the art would determine would be useful in connection with the present invention in enabling siRNA to cross the cellular membrane. These methods include, but are not limited to, any manner of transfection, such as, for example, transfection employing DEAE-Dextran, calcium phosphate, cationic lipids/liposomes, micelles, manipulation of pressure, microinjection, electroporation, immunoporation, use of vectors such as viruses, plasmids, cosmids, bacteriophages, cell fusions, and coupling of the polynucleotides to specific conjugates or ligands such as antibodies, antigens, or receptors, passive introduction, adding moieties to the siRNA that facilitate its uptake, and the like.
[0105] In another embodiment, the present invention features use of an siRNA that targets VEGFA in the manufacture of a medicament for treating, inhibiting or ameliorating one or more of the following conditions: psoriasis, cancer, rheumatoid arthritis, ocular neovascularization, abnormal angiogenesis, retinal vascular permeability, retinal edema, diabetic retinopathy (particularly proliferative diabetic retinopathy), diabetic macular edema, exudative age-related macular degeneration, sequela associated with retinal ischemia, and posterior segment neovascularization. Recipients of the siRNAs of the present invention may for example, be persons who are afflicted with one or more of the aforementioned disorders.
[0106] The dosage of the siRNA is preferably a therapeutically effective amount. A therapeutically effective amount will be determined at least in part by the age, weight and condition or severity of the affliction o the organism to be treated.
[0107] Examples of the siRNAs of the present invention may comprise an antisense sequence selected from SEQ ID NOs: 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86, and 88, and the corresponding sense strand in Table I.
[0108] Table 1 shows the silencing activities of 42 unmodified siRNAs tested in vitro as described in the Examples Section.
[0000]
% VEGFA
% VEGFA
SEQ ID
Top: Sense Strand, 5′→3′
RNA
Protein
Seq. Ref.
NO:
Bottom: Antisense strand, 5′→3′
remaining
remaining
vegfa 2.1
1
UACUAAAUCUCUCUCCUUU
41.6
50.0
2
AAAGGAGAGAGAUUUAGUA
vegfa 2.2
3
ACAGAACGAUCGAUACAGA
22.5
20.6
4
UCUGUAUCGAUCGUUCUGU
vegfa 2.3
5
CGACAGAACAGUCCUUAAU
19.9
21.2
6
AUUAAGGACUGUUCUGUCG
vegfa 2.4
7
GAAGAGACACAUUGUUGGA
22.3
21.4
8
UCCAACAAUGUGUCUCUUC
vegfa 2.5
9
GUCACUAGCUUAUCUUGAA
13.6
31.6
10
UUCAAGAUAAGCUAGUGAC
vegfa 2.6
11
CAGCACACAUUCCUUUGAA
57.3
44.4
12
UUCAAAGGAAUGUGUGCUG
vegfa 2.9
13
GGAGACCACUGGCAGAUGU
24.1
37.5
14
ACAUCUGCCAGUGGUCUCC
VEGFA 2.11
15
GCUCGGUGCUGGAAUUUGA
51.0
35.1
16
UCAAAUUCCAGCACCGAGC
vegfa 2.12
17
GAAAGACAGAUCACAGGUA
20.8
27.8
18
UACCUGUGAUCUGUCUUUC
vegfa 2.14
19
CCAGAAACCUGAAAUGAAG
31
22.5
20
CUUCAUUUCAGGUUUCUGG
vegfa 2.15
21
GAGAAGAGACACAUUGUUG
36.6
20.5
22
CAACAAUGUGUCUCUUCUC
vegfa 2.17
23
CGACAAAGAAAUACAGAUA
40.8
40.0
24
UAUCUGUAUUUCUUUGUCG
vegfa 2.18
25
GGGCAAAUAUGACCCAGUU
12.2
39.8
26
AACUGGGUCAUAUUUGCCC
vegfa 2.19
27
GAAGAGAAGAGACACAUUG
43.3
21
28
CAAUGUGUCUCUUCUCUUC
vegfa 2.20
29
GAAACCAGCAGAAAGAGGA
47.6
44
30
UCCUCUUUCUGCUGGUUUC
vegfa 2.21
31
GAUCACAGGUACAGGGAUG
44.8
33.1
32
CAUCCCUGUACCUGUGAUC
vegfa 2.22
33
GGAAAGAGGUAGCAAGAGC
52
53.3
34
GCUCUUGCUACCUCUUUCC
vegfa 2.23
35
GAGAUGAGCUUCCUACAGC
88.5
14.7
36
GCUGUAGGAAGCUCAUCUC
vegfa 2.24
37
GAUCAAACCUCACCAAGGC
30.8
11.3
38
GCCUUGGUGAGGUUUGAUC
Vegfa 2.25
39
CAACAAAUGUGAAUGCAGA
22.0
5.52
40
UCUGCAUUCACAUUUGUUG
vegfa 3.1
41
AAAUGAAGGAAGAGGAGAC
16.2
9
42
GUCUCCUCUUCCUUCAUUU
vegfa 3.2
43
AAUGCAGACCAAAGAAAGA
25.3
11.5
44
UCUUUCUUUGGUCUGCAUU
vegfa 3.3
45
ACAUAGGAGAGAUGAGCUU
16.3
14.3
46
AAGCUCAUCUCUCCUAUGU
vegfa 3.4
47
ACGACAAAGAAAUACAGAU
32.6
52.4
48
AUCUGUAUUUCUUUGUCGU
vegfa 3.5
49
AGACACACCCACCCACAUA
17.6
26.1
50
UAUGUGGGUGGGUGUGUCU
vegfa 3.6
51
AGACAUUGCUAUUCUGUUU
31.4
25.7
52
AAACAGAAUAGCAAUGUCU
vegfa 3.7
53
AGAGAAAAGAGAAAGUGUU
23.4
9.8
54
AACACUUUCUCUUUUCUCU
vegfa 3.8
55
AGCACACAUUCCUUUGAAA
26.6
42
56
UUUCAAAGGAAUGUGUGCU
vegfa 3.9
57
CAAAUGUGAAUGCAGACCA
45.8
35.4
58
UGGUCUGCAUUCACAUUUG
vegfa 3.10
59
CACACAUUCCUUUGAAAUA
39.3
28.3
60
UAUUUCAAAGGAAUGUGUG
vegfa 3.11
61
CAGAACAGUCCUUAAUCCA
22.9
34.4
62
UGGAUUAAGGACUGUUCUG
vegfa 3.12
63
CAGAGAAAAGAGAAAGUGU
30.1
30.7
64
ACACUUUCUCUUUUCUCUG
vegfa 3.13
65
CCAGCACAUAGGAGAGAUG
34.7
22.3
66
CAUCUCUCCUAUGUGCUGG
vegfa 3.16
67
CGAGAUAUUCCGUAGUACA
32.8
61
68
UGUACUACGGAAUAUCUCG
vegfa 3.17
69
CUACUGUUUAUCCGUAAUA
40.9
55.2
70
UAUUACGGAUAAACAGUAG
vegfa 3.18
71
CUGAAAUGAAGGAAGAGGA
43.5
43
72
UCCUCUUCCUUCAUUUCAG
vegfa 3.19
73
GAAAUGAAGGAAGAGGAGA
42.7
48.3
74
UCUCCUCUUCCUUCAUUUC
vegfa 3.20
75
GAACAGUCCUUAAUCCAGA
25.9
30.9
76
UCUGGAUUAAGGACUGUUC
vegfa 3.21
77
GAGAGAUGAGCUUCCUACA
64.6
33
78
UGUAGGAAGCUCAUCUCUC
vegfa 3.22
79
GAGAUAUUCCGUAGUACAU
60.5
61.3
80
AUGUACUACGGAAUAUCUC
vegfa 3.23
81
GAGGCAGAGAAAAGAGAAA
26.9
32.4
82
UUUCUCUUUUCUCUGCCUC
vegfa 3.24
83
GAUAUUAACAUCACGUCUU
37.8
73.5
84
AAGACGUGAUGUUAAUAUC
vegfa 3.25
85
GCACACAUUCCUUUGAAAU
18.8
38.1
86
AUUUCAAAGGAAUGUGUGC
vegfa 3.26
87
GCGGAUCAAACCUCACCAA
30
33.5
88
UUGGUGAGGUUUGAUCCGC
[0109] Table 2 shows the silencing activity of a selection of siRNAs in unmodified and siStable modified formats. Specifically, data in columns D and E are derived from unmodified molecules at 24 hours. Data in columns F, G, H, and I are derived from siStable modified molecules at 72 hours. Data in columns F and G were derived when siRNA were transfected into cells at 100 nM concentrations.
[0000]
B
D
E
F
G
H
I
A
SEQ
C
RNA
protein
siStable
siStable
RNA
protein
Seq.
ID
Top: Sense Strand, 5′→3′
IC 50
IC 50
% RNA
% protein
IC 50
IC 50
Ref.
NO:
Bottom: Antisense strand, 5′→3′
(nM)
(nM)
remaining
remaining
(nM)
(nM)
vegfa
1
UACUAAAUCUCUCUCCUUU
0.31
0.51
17
41
4.78
2.35
2.1
2
AAAGGAGAGAGAUUUAGUA
vegfa
41
AAAUGAAGGAAGAGGAGAC
5.2
0.82
18
12
0.36
0.15
3.1
42
GUCUCCUCUUCCUUCAUUU
vegfa
43
AAUGCAGACCAAAGAAAGA
0.93
0.17
10
9
0.4
0.37
3.2
44
UCUUUCUUUGGUCUGCAUU
vegfa
45
ACAUAGGAGAGAUGAGCUU
0.43
0.59
11
10
0.82
0.77
3.3
46
AAGCUCAUCUCUCCUAUGU
vegfa
51
AGACAUUGCUAUUCUGUUU
0.81
0.94
28
31
23
3.17
3.6
52
AAACAGAAUAGCAAUGUCU
vegfa
53
AGAGAAAAGAGAAAGUGUU
1.3
0.46
10
10
0.26
0.46
3.7
54
AACACUUUCUCUUUUCUCU
vegfa
59
CACACAUUCCUUUGAAAUA
1.05
0.97
13
20
0.26
0.17
3.10
60
UAUUUCAAAGGAAUGUGUG
vegfa
63
CAGAGAAAAGAGAAAGUGU
4.6
1
10
15
0.11
0.21
3.12
64
ACACUUUCUCUUUUCUCUG
vegfa
75
GAACAGUCCUUAAUCCAGA
2
0.62
9
28
0.31
0.53
3.20
76
UCUGGAUUAAGGACUGUUC
vegfa
81
GAGGCAGAGAAAAGAGAAA
1.4
1.2
14
45
2.2
2.7
3.23
82
UUUCUCUUUUCUCUGCCUC
[0110] It is noted that the above recited duplexes do not contain mismatches. The present invention includes the specifically recited siRNAs as well as pharmaceutical compositions that contain them and methods for using them. The present invention also includes siRNAs that are similar to them but have a different base at position 6 or position 13 or position 19 of the sense strand or at both positions 6 and 13 or both of positions 13 and 19 or at both of positions 6 and 19 of the sense strand or at all three of positions, 6, 13 and 19 of the sense strand. Thus at any of those three positions, wherein in tables 1 or 2 there is an A complementary to a U, a U, C or G may be inserted, wherein in tables 1 or 2 there is an U complementary to an A, an A, C or G may be inserted, wherein in tables 1 or 2 there is a C complementary to a G, a U, A or G may be inserted, wherein in tables 1 or 2 there is a G complementary to a C, a U, C or A may be inserted. Still further, any of these siRNAs may contain overhang regions, e.g., a UU 3′ antisense overhang and/or a UU 3′ sense overhang.
[0111] By way of further example, in one embodiment, the present invention is directed to an siRNA from Table 2, or to an siRNA that differs from that of table 2 in that the sense strand has three mismatched nucleotides that are located at positions, 6, 13, and 19 with the opposite nucleotides on the antisense e.g., an siRNA that contains the sense and antisense sequences of vegfa 3.7, except that the sense strand has three mismatched nucleotides that are located at positions, 6, 13, and 19. In some embodiments the mismatches are selected such that one or more, for example, two or three of the mismatched bases are the same as the bases on the opposite strand and no other mismatched bases are present in the duplex. By way of a non-limiting example, for vegfa 3.7 a duplex may be
[0000]
SS-
5′ AGAGAUAAGAGAUAGUGUA 3′
(SEQ ID No: 91)
AS-
3′ UCUCUUUUCUCUUUCACAA 5′
(SEQ ID No: 54)
[0112] This duplex, as well as any other duplex disclosed herein, may contain 3′ overhangs on either the sense strand or the antisense strand. By way of a non-limiting example, there may be a dinucleotide overhangs, e.g., UU. This overhang may exist on the sense strand, but not the antisense strand; on the antisense strand but not the sense strand; on both strands or on neither strand. Each overhang may be constructed to have a standard internucleotide linkage between nucleotides of the overhang and a standard linkage to the 3′ end of the appropriate strand of the duplex, or in the overhang, the bond between the two nucleotides of the overhang as well as the first nucleotide of the overhang and the 3′ most antisense nucleotide of the duplexed region of the strand is a phosphorothioate linkage. Thus, e.g., in the vegfa 3.7 duplex of the preceding paragraph, SEQ ID No: 54 may contain a UU 3′ antisense overhang that does not contain a phosphorothioate linkage between the nucleotides of the overhang or between the overhang and the 3′ of SEQ ID No: 54, or there may be phosphorothioate linkages at one or both of those positions.
[0113] Unless otherwise specified, each of the features of each of the aforementioned embodiments may be used in connection with any of the other embodiments, unless such use is incompatible or inconsistent with that embodiment.
[0114] Having described the invention with a degree of particularity, examples will now be provided. These examples are not intended to and should not be construed to limit the scope of the claims in any way.
EXAMPLES
Example 1
General Techniques for in Vitro Studies
[0115] siRNA Selection for Study
[0116] A collection of siRNAs capable of targeting all the variants of VEGFA were identified (NM — 001025366, NM — 003376, NM — 001025367, NM — 001025368, NM — 001033756, NM — 001025369, NM — 001025370). Table 1 provides a list of the siRNAs along with the sense and antisense strand sequences (5′→3′).
[0117] To assess the relative functionality of each siRNA, sequences were synthesized using 2′ ACE chemistry (U.S. Pat. No. 6,008,400; U.S. Pat. No. 6,111,086; U.S. Pat. No. 6,590,093; Scaringe (2000) Methods in Enzymology 317:3-18; Scaringe (2001) Methods 23(3):206-217) and then transfected into HeLa cells (ATCC, #CCL-2) by lipid mediated transfection using the manufacturer's protocols (10,000 cells per well in a 96 well format, 100 nM siRNA, 0.2 μl DharmaFECT 1/well). Seventy-two hours post-transfection, overall cell viability and target knockdown at the mRNA and protein level was determined. All assays were performed in triplicate and for a select group of siRNAs, a dose curve (0.001, 0.01, 0.1, 1.0, 10.0, and 100 nM) was performed to ascertain the IC 50 for the siRNA/target mRNA pair. Positive and negative controls were included in all experiments and consisted of a non-targeting control (NTC #5 sense strand sequence: 5′-UGGUUUACAUGUCGACUAAUU-3′ (SEQ ID NO: 89)) and a positive control targeting PPIB (sense strand sequence: 5′-ACAGCAAAUUCCAUCGUGU-3′ (SEQ ID NO: 90)). Note: the positive control molecule used in these studies contains the following modifications: sense strand contains a 2′-O-methyl modification on the first two nucleotides counting from the 5′ end of the strand; antisense strand contains a 5′ phosphate group; both sense and antisense strands contain a 2 nucleotide UU overhang on the 3′ end.
[0118] Target mRNA and Protein Knockdown Analysis
[0119] Target mRNA knockdown was determined at 72 hour post-transfection using the branched DNA assay (QuantiGene Screen Kit, Panomics). The expression of PPIB was used as a reference mRNA and the targeted mRNA knockdown was further normalized to the corresponding non-targeting control (NTC). Protein expression was assessed by performing a VEGFA ELISA assay on supernatants from transfected cells at 72 hours post-transfection. The ELISA was performed according to the manufacturer's instructions using 50 μL of supernatant (Human VEGFA ELISA kit, Thermo Scientific). Absorbance was read on a spectrophotometer at 450 nM. Data was normalized to the corresponding NTC control.
[0120] Cell Viability Assay
[0121] Cell viability was assessed by a resazurin assay at 72 hours post-transfection. Resazurin was added directly into the culture media and the plates were incubated for 1-1.5 hours prior to measuring the fluorescence on a Wallac VICTOR 2 (Perkin Elmer Life Sciences) plate reader (Excitation 530 nm, Emission — 590 nm and 1 second exposure). Data was normalized to the corresponding NTC control.
[0122] siRNA Designs for Study
[0123] siRNA configurations tested in the in vitro studies include (1) the standard unmodified design (19 base pairs duplex, UU overhangs on the 3′ end of both sense and antisense strands), and (2) the stabilized design (a 19 base pair duplex; sense strand modifications: 2′-O-methyl modifications on nucleotides 1 and 2 (counting from the 5′ end of the strand) plus 2′-O-methyl modifications on all Cs and Us; antisense strand modifications: a phosphate on the 5′ terminal nucleotide, 2′ F modifications on all Cs and Us, a 2 nucleotide (UU) overhang on the 3′ terminus, and a phosphorothioate internucleotide modification between the two nucleotides of the overhang and between the first (3′ most) nucleotide of the duplex and the first nucleotide of the overhang).
[0124] For in vivo studies, siRNAs included the following design:
a 19 bp duplex sense strand modifications
2′-O-methyl modifications on nucleotides 1 and 2 (counting from the 5′ end of the strand) 2′-O-methyl modifications on all Cs and Us cholesterol conjugated to the 3′ terminus using a C5 linker (see U.S. Pat. Pub. 2009/0209626, published Aug. 20, 2009 the disclosure of which is incorporated by reference as if set forth fully herein)
antisense strand modifications
5′ phosphate 2′ F on all Cs and Us a two nucleotide (UU) overhang on the 3′ terminus phosphorothioate internucleotide modifications between the two nucleotides of the overhang and between the first (3′ most) nucleotide of the duplex and the first nucleotide of the overhang.
[0135] In addition, mismatches at positions 6, 13, and 19 have been incorporated into molecules used in in vivo studies. In all cases, mismatches between the two strands of the siRNA are achieved by changing the nucleotide of the sense strand to have identity with the base (on the antisense strand) that typically pairs with that position. Thus, for instance, if the sense-antisense pair at sense strand position 6 is normally U-A, then the mismatch will be introduced by converting the pair to A-A. Similarly, if the sense-antisense pair at sense strand position 6 is G-C, then the mismatch will be C-C. In this way, a mismatch is incorporated into the duplex, but the antisense strand remains the reverse complement of the intended target.
Example 2
Results of In Vitro and In Vivo Studies
[0136] The performance of all the sequences tested in vitro is shown in Table 1. Multiple sequences were observed to provide greater than 70% gene knockdown at both the RNA and protein level including, for instance, Vegfa 2.2, 2.3, 2.4, 2.12, 3.1, 3.2, 3.3, 3.5, and 3.7. In addition, when a subset of the collection was tested with the stabilized design, overall performance was found to be equivalent or better than that observed in the unmodified state (see, for instance, vegfa 2.1, 3.2, 3.3). As Table 2 shows, in both the unmodified and modified states, IC 50 for RNA knockdown ranged from approximately 0.11→23 nM while IC 50 for protein knockdown ranged from ˜0.17→3.17 nM. Based on these results, two sequences, Vegfa 3.2 and 3.7, were re-synthesized using the in vivo design (referred to as “Accell”) described previously. The results of these experiments may be further demonstrated by reference to the accompanying figures.
[0137] FIGS. 1A and 1B illustrate the effect of intravitreal (IVT) injection of Accell VEGFA siRNAs on expression of VEGFA mRNA and protein, respectively, in the rat retina at 72 h post-injection. Lewis rats received 10 μg IVT injections (OD) of Accell VEGFA 3.2, Accell VEGFA 3.7 or Accell non-targeting control #1 (NTC1) siRNAs resuspended in 1× siRNA buffer (Dharmacon). The Accell NTC1 siRNA sense strand sequence is 5′-UGGUUAACAUGUCGACUAA-3′ (SEQ ID NO: 92); the Accell NTC1 siRNA antisense strand sequence is 5′-UUAGUCGACAUGUAAACCAUU-3′ (SEQ ID NO: 93). Contralateral eyes (OS) were not treated. Eyes were harvested at 72 h post-injection, and retinas were isolated by dissection. ( 1 A) Total RNA was extracted using Trizol (Invitrogen), and VEGFA and β-actin (ACTB) mRNA levels were determined by Taqman qRT-PCR assay (Applied Biosystems). VEGFA mRNA expression was normalized to β-actin expression. ( 1 B) Protein was extracted using RIPA buffer (Pierce), and rat VEGFA protein level was determined by ELISA (R&D Systems). VEGFA protein expression was normalized to total protein determined by BCA assay (Pierce). Data are presented as the mean (n=6)±standard deviation (error bars). *, P<0.001 versus NTC1. Both of the VEGFA siRNAs significantly reduced the expression of VEGFA mRNA; VEGFA 3.7 also significantly reduced VEGFA and protein. The NTC1 control siRNA had little, if any, effect on VEGFA expression.
[0138] FIG. 2 shows a comparison between the dose response curves for Accell VEGFA 3.2 siRNA and a control siRNA in the rat retina. Lewis rats received 1-25 μg IVT injections (OD) of Accell VEGFA 3.2 or Accell NTC1 control siRNAs resuspended in 1× siRNA buffer (Dharmacon). Contralateral eyes (OS) were not treated. Eyes were harvested at 72 h post-injection, and retinas were isolated by dissection. Total RNA was extracted using Trizol Plus (Invitrogen), and VEGFA and β-actin mRNA levels were determined by Taqman qRT-PCR assay (Applied Biosystems). VEGFA mRNA expression was normalized to β-actin mRNA. Data are presented as the mean OD:OS ratio (ratio of VEGFA level in the treated eye versus the non-treated eye) for normalized VEGFA mRNA expression (n=6)±standard deviation (error bars). *, P<0.05; **, P<0.01 versus Accell NTC1. Intravitreal injection of increasing amounts of Accell VEGFA siRNA 3.2 resulted in a dose response that reached essentially complete silencing of VEGFA mRNA expression at 25 μg.
[0139] FIGS. 3A and 3B shows a comparison between the dose response curves for Accell VEGFA 3.7 siRNA and a control siRNA in the rat retina. Lewis rats received 1-50 μg IVT injections (OD) of Accell VEGFA 3.7 siRNA or Accell VEGFA 3.7 cleavage site mismatch (CS MM) control siRNAs resuspended in 1× siRNA buffer (Dharmacon). The Accell VEGFA 3.7 CS MM control siRNA has the same sequence as Accell VEGFA 3.7 siRNA except for a 3-nucleotide mismatch to the VEGFA mRNA target sequence. The Accell VEGFA 3.7 CS MM siRNA sense strand sequence is 5′-AGAGAUAACUCAUAGUGUA-3′ (SEQ ID NO: 94); the Accell VEGFA 3.7 CS MM siRNA antisense strand sequence is 5′-AACACUUUGAGUUUUCUCUUU-3′ (SEQ ID NO: 95). Contralateral eyes (OS) were not treated. Eyes were harvested at 72 h post-injection, and retinas were isolated by dissection. ( 3 A) Total RNA was extracted using Trizol (Invitrogen), and VEGFA and β-actin mRNA levels were determined by Taqman qRT-PCR assay (Applied Biosystems). VEGFA mRNA expression was normalized to β-actin mRNA expression. ( 3 B) Protein was extracted using RIPA buffer (Pierce), and rat VEGF-A level was determined by ELISA (R&D Systems). VEGFA protein expression was normalized to total protein level determined by BCA assay (Pierce). Data are presented as the mean OD:OS ratio for normalized VEGFA mRNA or protein expression (n=6)±standard deviation (error bars). *, P<0.03; **, P<0.0002; #, P<0.005. Intravitreal injection Accell VEGFA 3.7 siRNA at doses as low as 5 μg caused a significant reduction in VEGFA expression at both the mRNA and protein levels. The Accell VEGFA 3.7 siRNA exhibited a dose response that reached >70% inhibition of VEGFA mRNA expression and approximately 80% inhibition of VEGFA protein expression at 25 μg siRNA. Non-RNAi-mediated inhibition of VEGFA expression was also observed with the control siRNA. This effect was less pronounced for VEGFA protein than for VEGFA mRNA.
[0140] FIGS. 4A and 4B show the time duration of action for the Accell VEGFA 3.7 siRNA. Lewis rats received 25 μg IVT injections (OD) of Accell VEGFA 3.7 siRNA or Accell NTC1 control siRNAs resuspended in 1× siRNA buffer (Dharmacon). Contralateral eyes (OS) were not treated. Eyes were harvested at 1, 3, 7, 14, 28, 42, and 56 d post-injection, and retinas were isolated by dissection. Expression of VEGFA mRNA ( 4 A) and VEGFA protein ( 4 B) was evaluated as described in the previous examples. Data are presented as the mean OD:OS ratio for normalized VEGFA mRNA or protein expression (n=6)±standard deviation (error bars). *, P<0.001; #, P<0.002 versus NTC1. Intravitreal injection of Accell VEGFA 3.7 siRNA caused significant inhibition of VEGFA mRNA and protein expression within 24 h. Inhibition persisted for several weeks.
[0141] FIGS. 5A and 5B show inhibition of VEGFA protein expression and preretinal neovascularization, respectively, in the rat oxygen-induced retinopathy (OIR) model (modified from Penn et al., Pediatr. Res. 36:724-731, 1994). Following 14 d of cycling between 50% and 10% O 2 , neonatal Sprague Dawley rats were exposed to room air (21% O 2 ) for 7 d (postpartum days 15-21, P15-P21). On days P15 and P18, animals received 25 μg IVT injections (OS) of Accell VEGFA siRNA 3.7 or Accell VEGFA 3.7 CS MM control siRNA resuspended in 1× siRNA buffer (Dharmacon). Contralateral eyes (OD) were treated with vehicle (1× siRNA buffer). Injection volume was 1 μl. Eyes were harvested on day P21, and retinas were isolated by dissection. ( 5 A) Protein was extracted using RIPA buffer (Pierce), and VEGFA protein level was determined by ELISA (R&D Systems). VEGFA protein expression was normalized to total protein level determined by BCA assay (Pierce). Data are presented as mean normalized VEGFA protein expression (n=7)±standard deviation (error bars). *, P<0.03. ( 5 B) Retinas were fixed in 10% neutral buffered formalin for 24 h, subjected to ADPase staining, and fixed onto slides as whole mounts. Images were acquired using a Nikon Coolscope®, and each of 12 sectors per retina was assessed for the presence or absence of neovascularization to obtain a clockhour score (n=6-8). #, P<0.05. The Accell VEGFA 3.7 siRNA caused a significant reduction in VEGFA protein expression (˜40%), resulting in an approximately 88% inhibition of preretinal neovascularization. The Accell VEGFA 3.7 CS MM control siRNA did not have a significant effect on either VEGFA expression or neovascularization.
[0142] As persons of ordinary skill in the art are aware, extrapolating to humans, observations made in rats is well-known.
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Vascular endothelial growth factor A (VEGFA) is a chemical signal produced by cells that stimulates the growth of new blood vessels, and overexpression of VEGFA can lead to undesirable physiological conditions. Through the identification of new siRNA and modifications that improve the silencing ability of these siRNA in vivo, therapeutic compositions and methods have been invented to address the problems associated with this overexpression.
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PRIOR PROVISIONAL PATENT APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 61/135,148 filed Jul. 17, 2008, the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention is directed to a method and apparatus for the designing, producing, manufacturing and delivering of personalized living environments, and, more particularly, to a method and apparatus utilizing proprietary unitized assemblies joined together by various proprietary assembly joineries by which the creating, selecting, ordering, shipping and constructing of personalized living environments can be customized in almost unlimited configurations and effectively performs as a shelter, meeting or exceeding requirements for a code compliant weather resistant living environment.
BACKGROUND OF THE INVENTION
[0003] Historically, the design, production, manufacture, and delivery of residential dwellings (i.e., homes) has marginally evolved over time. One of the more familiar paths has been design and construction of “site-built” homes. Site-built homes are extremely popular and are the mainstay of home building.
[0004] However, site-built homes necessitate many inefficiencies in the design and construction process to complete and, as they become more complex, they are disproportionately expensive, time-consuming and environmentally inefficient to deliver. For instance, steps to complete the construction of such a home require the organization and sequencing of unrelated labor and material demands to coalesce around a construction system and configuration largely unfamiliar to the work force. These components need to be ordered, shipped, organized, and sequenced through a critical path of construction. The shell for instance cannot proceed until the entire excavation, foundation and sill plates are complete, and the interior finishing cannot start until all the interior mechanical systems are fully installed. And so on and so on. These various steps are necessarily timed in a linear sequence and cannot be “fast tracked” without significant premiums and risk of error. The process is time consuming, variable in quality because of the varying work conditions and labor over the job, subject to weather and labor delays, and highly unpredictable in terms of costs and time. The job conditions are also environmentally taxing because of the extensive transportation of workers and machinery to and from a remote job sight, construction material waste on site, inconsistent waste material disposal, etc. . . . Accordingly, site-built custom homes can take as long as two or three years (or even longer) before the home is ready for occupancy and over that period of development contribute significant greenhouse gasses (GHG) and material waste into the environment.
[0005] Beginning in the 1950's, however, a type of housing construction in which the home was largely assembled elsewhere and then transported to the building site began to emerge. Such home building process was known as manufactured, or “pre-fabricated”, housing. Pre-fabricated homes can either be constructed through a panelized means of construction (“pre-fab panelized”) or a modular means of construction (“pre-fab modular”) but the means and methods of construction remained largely conventional.
[0006] Prefab modular is an interior finished floor, wall and ceiling assembly making a module “box” that is designed to be stacked or set next to another, joined with a site installed exterior skin to create a living space. Because it is fabricated in its final room dimensions, and conceived to be paired with other modules, the interior size and configurations are limited to road and bridge clearance on the transportation route from the factory to the site. This results in a system that is very rigid dimensionally, inefficient for transportation and shipping, fully integrated but limited in architectural expression and by complexity of site conditions.
[0007] Prefab panelized is a panel based system that joins precut panels to make an enclosure. Usually the panels are only a component of the structure and need to be combined with other site assembled structural systems to stand. The product most often does not integrate multiple trades in the manufacturing process. Because the system is panelized it ships very efficiently but it requires the same trades and basically the same time frame that a site-built custom home would take to fully finish. It is best applied as a single trade, structural and exterior skin solution with limited expectations for a factory finished interior. Because the panels are structurally limited and generally dependant on secondary systems such as column frames for joining they are also limited in dimension and result in great complexity in creating a weatherproof, code compliant exteriors.
[0008] As a result both panelized and modular means of construction have had limited applicability to complex or custom projects. Their application has most widely been applied to ubiquitous structures, temporary building where speed and low cost, but not quality, customization or durability, are primary. Because of this demand they are generally made of materials that are inexpensive and that allow for quick and easy assembly of the structure.
[0009] While pre-fabricated homes require much less site labor, they are targeted to be cheaper to build and buy as compared to the conventional site-built homes, and, as such, pre-fabricated homes are not widely applicable to the custom housing marketplace. Indeed, pre-fabricated homes are generally considered to be very basic “box” style buildings with little ability to vary character within a system. Within the parameters of a given methodology or system, the pre-fabricated homes tend to have very limited design options that significantly alter both the form and character of a product. Building sites that are most suitable for pre-fabricated homes tend to be limited to those that are easily accessible and with simple, flat or very gentle topography. In other words, home sites that can only be accessed via narrow roads, gates, under low overpasses, or that are on sloped sites are very challenged for the current methodologies for pre-fabricated homes.
[0010] Accordingly, it is clear that while existing technology in pre-fabricated modular or panelized homes do have certain advantages, there are still also many unsolved problems and execution difficulties associated with such homes. Thus, if pre-fabricated homes were able to have significant improvement of quality and features, these homes would have greater acceptance by a growing segment of the residential marketplace and realize a significant efficiency both economically and environmentally.
SUMMARY OF THE INVENTION
[0011] Accordingly, the present invention creates a fully finished manufactured unit and assembly where all the trades are integrated (structural, mechanical, plumbing, electrical and finish) in the manufacturing process, so that the design, production, manufacture and delivery of personalized living environments that are highly customized to a specific site and client. The present invention accomplishes this by utilizing a unitized assembly and various assembly joineries to form a unique environment that is created by and for the homeowner. The system and process together create a dimensionally flexible custom home that is weather tight, universally code applicable, and transportable to the most challenging of site conditions and locations.
[0012] The unitized assemblies are both fixed and flexible in dimension depending on the graining of the unit. They are trade-integrated modules in unitized, shippable configurations. The module dimension where units are connected to each other are fixed, and the alternating grain or dimension is flexible. The unitized assembly is designed to achieve a high-craft finished quality and unmatched dimensional flexibility in both the vertical and horizontal planes. The unitized ceiling wall and floor assemblies are able to be joined and sealed effectively with the combination of a universal split column, drop column insert and rigid stacking stud integrally incorporated within their construction. The drop column inserts are rotating connection pins that allow for the simple assembly of the units and columns with other unitized assemblies and/or assembly joineries. This construction, manufacturing, and assembly system solves the above-mentioned building issues by creating fully integrated, fully finished “units” that are shippable. As a result, the ultimate building expression and enclosure is no longer limited to the size of road clearance less a flat bed or a shipping container, it is only limited by the imagination and aspirations of the homeowner.
[0013] The assembly joineries and connection methods permit fully integrated and fully finished modules to be transported cost effectively and allow for virtually unlimited interior height (up to 40′ clear). The current prefabricated modular systems are limited to approximately 10′-0″ finished ceiling height in a single module. The assembly joineries provide dimensional freedom, efficient strength to weight ratios, and expressed or stylized configurations in a variety of hybrid materials.
[0014] The unitized assemblies, assembly joineries and connection methods allow for proper architectural proportion to be the determining factor of exact room dimension. This is expressed through the use of a proprietary proportional algorithm. The proportional algorithm is a three dimensional fixed snap system that is generated by the specific conditions found in each of a number of various collections and ensures a proportion of length, to width, to height that configures a volume of a space elegantly.
[0015] The architecture of the overall system and complimentary passion profile process allows for the customization and personalization of the living environment. The process architecture (or integrated, comprehensive system) includes a detailed human factors behavioral analysis, as well as the design and construction of the physical unitized assembly. Taken together, these two process steps feed into an experience blueprint for the consumer. The experience blueprint comprises three foundational aspects that specifically map out a consumer's journey and service therein from introduction through execution of a branded and customized lifestyle environment. The experience blueprint structures a process that creates a specific visualization that is equally part of a proprietary system and part of the individual in the form of a passion-inspired product collection. Through the experience blueprint, the homeowner selects specific elements from a series of finished collections, that are assembled by the proprietary assembly joinery system.
[0016] Thus, the combination of a process for personalization and a fully trade integrated fixed and flexible “unit” with flexible aesthetics and dimensions solves the long standing limitations associated with traditional house execution models, panelized or modular systems.
[0017] The present invention, including its features and advantages, will become more apparent from the following detailed description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a relationship chart of the methodology for implementation of the process architecture, demonstrating the important interrelationships between the physical systems and the emotions, behaviors, and experiences that consumers identify with themselves to create a personalized environment, according to an embodiment of the present invention.
[0019] FIGS. 2( a - f ) illustrates the primary physical features of the unitized assembly, according to an embodiment of the present invention.
[0020] FIG. 3 illustrates a chart featuring examples of behavior mapping within the human factors behavioral analysis, demonstrating the three aspects of the structured analysis: segmentation, characteristics and profiling, according to an embodiment of the present invention.
[0021] FIG. 4 illustrates a chart linking behavior analysis with physical expressions in categories of personal interests and passions, and as such demonstrates the connections between passion and product as they fit within the various collections and within the framework of the human factors behavioral analysis, according to an embodiment of the present invention.
[0022] FIG. 5 illustrates a flow chart of a methodology for the implementation of the . behavior segmentation and mapping process within the experience blueprint, according to an embodiment of the present invention.
[0023] FIG. 6 illustrates a chart of the experience principles within the experience blueprint that structures and identifies the moments that most matter in the process creating a personalized environment, according to an embodiment of the present invention.
[0024] FIG. 7 illustrates a chart of a methodology for patterning a customer journey model within the experience blueprint, according to an embodiment of the present invention.
[0025] FIG. 8 illustrates a view of the universal column assembly joinery, comprising a four piece column where each leg attaches or is integrated into an adjacent unit; and as such it provides sufficient rigidity in its singular form to transport and erect and provides full capacity to resist gravity, wind and earthquake loads in its fully assembled, 4-sided configuration, according to an embodiment of the present invention.
[0026] FIG. 9 illustrates a view of a drop column insert assembly joinery that creates a structural pin connection to the universal column and “drops” away to minimize shipping dimensions, and reinforce the edge of the unitized ceiling sandwich during transportation and erection, according to an embodiment of the present invention.
[0027] FIG. 10 illustrates a view of a rigid stacking stud assembly joinery, wherein the stud locks into the seat of the drop column insert to secure two unitized ceiling units during transportation and, along with the drop column insert, creates a rigid moment frame connection with the floor and ceiling units, according to an embodiment of the present invention.
[0028] FIGS. 11( a - e ) illustrate the mechanical operation of the drop column insert and rigid stacking stud assembly joineries and their integration with the universal ceiling sandwich, wherein the rigid stacking stud maintains a protective dimension between finished surfaces during shipping and erection, according to an embodiment of the present invention.
[0029] FIG. 12 illustrates a view of a universal split beam assembly joinery that marries to the universal column and joins two adjacent unitized ceiling sandwiches, according to an embodiment of the present invention.
[0030] FIG. 13 illustrates a view of the composite column unit assembly joinery, it being such that the 4-piece universal column uniquely permits the integration of both wood and steel structural systems while maintaining the integrity of the system assembly and fabrication, according to an embodiment of the present invention.
[0031] FIG. 14 illustrates a view of a universal split partition interior finish assembly, where the split partition permits the field connection of units and inspection of all required infrastructure in the wall partition, according to an embodiment of the present invention.
[0032] FIG. 15 illustrates a view of a unitized ceiling and wall sandwich assembly, where the assembly is an open system that permits any and all infrastructure to be factory installed and routed through the interior, according to an embodiment of the present invention.
[0033] FIG. 16 illustrates a profile view of a MEP flex-joint assembly joinery (connector) for use between unitized assemblies permitting the movement associated with installation and external forces (e.g., earthquake and hurricane) to not effect the integrity of the installed and inspected systems, according to an embodiment of the present invention.
[0034] FIG. 17 illustrates a “green-bundled” system and a “wet-module” system with associated MEP assembly joineries, according to an embodiment of the present invention.
[0035] FIGS. 18 and 19 illustrate an exploded view and an architectural drawing, respectively, of the construction of an assembly unit with both fixed and flex assemblies, and wherein the diagram emphasizes the dimensional flexibility of both interior and exterior expression, according to an embodiment of the present invention.
[0036] FIGS. 20 through 28 illustrate various universal column Signature Collections, a representative set of passion inspired forms that demonstrate the influence of the behavioral analysis not only on the overall form of the structure but also integral to the details of the system, according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0037] FIGS. 1-28 illustrate a method and apparatus for designing, producing, manufacturing, and delivering a personalized living environment. FIG. 1 illustrates the methodology and process architecture involved in creating the customized structure. FIGS. 2( a - f ) illustrate the unitized assembly and its associated assembly joineries as they are utilized in the configuration and construction process. FIGS. 3 and 4 show the human factors behavioral analysis and the mapping of particular human emotions (i.e., profile), associating those passions (i.e., behaviors and desires) to the products (i.e., forms, textures and surfaces) as they are organized within the various collections. FIGS. 5-7 illustrate the customer experience principles and how they tie into the experience blueprint to describe and structure the customer journey from the beginning of the process to the end with a lifestyle portrait (or “Canvas”). FIGS. 8-15 illustrate the various proprietary unitized assemblies and assembly joineries, utilized in forming the finished expression (i.e., size, volume, shape) of a personalized living environment. FIGS. 16 and 17 illustrate critical methods by which the assembly systems join complex conditions where extensive infrastructure (i.e., plumbing, mechanical, electrical) or multiple trades (i.e., interior and exterior) are resolved to ensure a fully trade-integrated manufactured product that is weather resistive. FIGS. 18 and 19 illustrate construction of an assembly unit with both fixed and flexible assemblies. The combination of these two diagrams demonstrate the range in expression and configuration of: the floor plan, the architectural section, the interior space, the exterior wall, the roof line and their individual proportions. Lastly, FIGS. 20-28 illustrate various universal columns and their signature collections that may be selected from. Each of these collections are specifically related to behavior characteristic profiles and segmentations. They demonstratively make a concrete connection between design and desire, by literally and figuratively embodying a set of aesthetic principles that will connect a form, texture, material and color, to a certain behavior and emotion.
[0038] Referring now to FIG. 1 , a chart of the methodology for implementation of the process architecture for designing, producing, manufacturing and delivering “personalized living environments” relates five interdependent parts of the journey: Unitized Assemblies, Behavior Analysis (Passion Profile), Experience Blueprint, Signature Collections, and Assembly Joinery. The process essentially begins with two co-dependant steps that initiate and then reinforce connections between personal interests, emotions and their associated visual expression. Although these parts make up a journey that is described in a general sequence, it is important to know that the process works with a person entering it at any point, just as long as every part of the exercise is eventually completed. The consistencies with which connections are made between “passions and place” allow the process to be open and interactive while still achieving a defined and personalized result. In Step 10 , the unitized assembly is studied, selected, prioritized and configured to test large scale form making decisions according to and in combination with the conclusions of the behavioral analysis in step 20 . The behavioral analysis is conducted to discover and profile the inner passions and/or desires of the eventual homeowner. It is a matrix organization associating active passions and behavior in profiles such as: being precise, technical and analytical, with characteristics of that profile such as: detail and team orientation, with segment categories: such as “A planner”. This matrix overlays with the second step (shown in FIG. 4 ) that defines forms that correspond to the profiles and analysis, thereby weaving passion and place very early in the process.
[0039] The identification of the unitized assemblies occurring in Step 10 and the conducting of the human factors behavioral analysis in Step 20 interrelate with the “experience blueprint” in Step 30 . The experience blueprint has three (3) foundational aspects, which are: 1) behavior segmentation and mapping; 2) experience principles; and 3) patterning of a customer journey model. Each will be described in further detail below. The experience blueprint structures a future homeowner's physical, emotional and behavioral journey through this process.
[0040] In Step 40 of the personalized living environments process architecture, various Signature Collections may be chosen from. This demonstrative set of detailed designs effectively associate visual expressions with personal interests at a detailed scale. By interrelating the large scale forms and gestures embodied in the Unitized Assemblies with behaviors, and then showing consistently powerful emotional connections at the detail level of joinery (column design) the strength of the process architecture is revealed. A person can work from the details to the emotions to the large forms; or a person can work from the emotions to details to the large forms; or a person can work from the large forms to the details to the emotions. As is shown in the Figure, there may be one or more Collections, depending upon various factors. For example, Collection I may be called “America's Cup”, which is a sailing inspired living environment. Collection II may be the “Cabernet” collection, which is based upon a vineyard inspired living environment. Further examples may be Collection III which is a “Tour” collection, which is a City inspired living environment. Various other examples of the living environment collections may be a ritual inspired living environment named “Tea”, or a theater art inspired living environment named “Biennalle”. Various other collections may be based upon: speed inspired living environments, sportsman inspired living environments, country inspired living environments, or yoga inspired living environments. The collections presented are a representative set that addresses many behavior profiles, but others will be introduced over time as “hybrid” profiles are defined. Regardless of the individual types or variations of the multitude of collections, in Step 40 the homeowner through the experience blueprint of Step 30 is able to select, prioritize and personalize on the basis of the combination of the human factors behavioral analysis in Step 20 and in the flexibility of the unitized assembly investigated in Step 10 , to customize to his or her own passions in a “personalized” living environment. As such, the various representative collections validate the ability of the present invention to support virtually unlimited, fully personalized visual expressions. The various Signature Collections will be discussed in further detail below.
[0041] In Step 50 , assembly joineries are utilized to structurally join, seal, and finish the unitized assemblies identified in Step 10 . These components and details maximize the flexibility and economy of the system as a whole. The assembly joineries will be discussed in further detail below.
[0042] Referring now to FIGS. 2( a - f ), a unitized assembly 10 is shown. The unitized assembly is a module system that is both fixed and flexible, and is manufactured in configurations that are easily transported. The unitized assembly enables a fully finished, weather tight product for a highly customized home which is produced in a quality controlled factory environment. It allows for an extremely consistent, high touch, well engineered, and refined craft in the final installed product. The assembly creates a fully finished environment unmatched in dimensional flexibility in both the vertical and horizontal planes that is economically transported. Resultantly, it is able to be viably applied to and installed in the most challenging site conditions and location.
[0043] Specifically then, as is shown by the figures, the unitized assembly is a trade-integrated sandwich or unit in which all of the structural, electrical, plumbing, HVAC, low voltage, and all other internal home mechanicals and interior finish trades are incorporated in the unitized-factory built assembly system. Additionally, the exterior of the unitized assembly is such that it is finished, insulated, and code compliant. Construction of the unitized assembly incorporates both internal and external assemblies. The internal assemblies, applied to an interior floor and ceiling condition are completed with finished trades, such as carpentry, tile, carpeting, wood, or stone. The substrate is constructed of concrete and can provide code compliant fire resistance between floors. The external (i.e., wall and roof) assemblies can have ceiling finishes to the interior and roofing or thermal and moisture resistive surfaces to the exterior. In the vertical wall application the interior would again be the selected interior finish and the exterior would be the selected exterior material such as wood, stucco, stone, metal, or glass
[0044] The unitized assemblies, as exemplified in the FIG. 2( a ), are constructed as concrete substrates on a steel frame 10 that are preferably 1′-4″ to 8′-0″ in width, 12′-0″ to 42′-0″ in height, and 8′ to 42′ in length and that incorporate both interior mechanicals and exterior finishes in final form. As shown in FIGS. 2( a ) and 2 ( b ), each unitized assembly 10 is fitted together by means of an interlocking seal 16 when exposed to the exterior as to create a weather tight enclosure. For example, if a unitized assembly 10 were designated as a roof-ceiling sandwich piece 11 , it would be sealed to the wall unit 12 via interlocking seals 16 . Ceiling piece 13 would be supported on the one side by the wall piece 12 and on the other side by columns 14 and 15 . The columns would be fitted and secured onto the unitized assemblies 11 and 13 via drop column inserts. Drop column inserts would be fixed to the unitized assembly and capable of being rotated into a slot of the unitized assembly for shipping purposes, while rotated out for assembly. The drop column inserts, one of a number of assembly joineries 50 , are described in detail further below. It is to be understood, of course, that while this is a preferred embodiment, it is not the only embodiment.
[0045] As shown in FIGS. 2( c ) and 2 ( d ), the unitized assemblies are universal which allows the graining of the unitized assemblies to be placed in vertical or horizontal direction. Structural Angle 1 acts as the basic element of the Unitized Assembly 10 . When two or more of the Angles 1 are brought together they create a physical place 2 for the human factors behavioral analysis (described in detail further below) to be expressed. When the units are joined a 4 piece column is formed as a universal and fully resolved visual intersection of parts (the joining of the unit modules when completed are not apparent versus conventional modular construction that results in double columns or double walls where modules join). The combination of the Unitized Assembly 10 and the human factors behavioral analysis act together to define a volumetric space 3 a and a dimension of the vertical or horizontal building component system 3 b. The column/unit assembly defines a space “within” which the emotions and desires defined in the behavioral analysis can live. Additionally, such combination allows for significant flexibility as shown by the various sizing of Unitized Assemblies acting as a wall 6 a, a floor/ceiling 6 b and a ceiling 6 c, with resultant space volume 6 d. The assembled combinations, structured around universal column 4 a, create an underlying geometry 4 b that translates into a Proportional Algorithm. Two examples of such are shown as 4 c 1 and 4 c 2 .
[0046] As shown in FIG. 2( e ), the Proportional Algorithm is integral to the unitized assembly design and is generative for the architectural volume of the finished living environment. The algorithm determines an idealized height, width and depth of a space or form. The algorithm avoids mistakes in determining the height of a room given its footprint. It ensures an architectural and spatial quality for a personalized lifestyle. The dimensions of the Unitized Assemblies 10 is based upon the Proportional Algorithm being a three dimensional fixed “snap” system. The base fixed “snap” system 5 a shows the three dimensional aspect, that is, length “x”, height “z” and width “y”. A preset “small” snap 5 b, a preset “medium” snap 5 c and a preset “large” snap 5 d are available at the various dimensions and can be generated based upon conditions required by the various Signature Collections.
[0047] Accordingly, the unitized assembly can be fabricated or constructed anywhere in the industrialized world, and transported via rail or shipping container to anywhere else in the world. As shown in FIG. 2( f ), each Unitized Assembly 10 can be easily transfigured from shipment-ready form 111 to construction-ready form 112 . This flexibility is allowed by the configuration of the drop column insert assembly joinery and the rigid stacking studs assembly joinery (each of which will be described in detail below). Unitized Assemblies 10 placed together in a trucking configuration 113 allows for easy placement in shipping or rail containers 114 and indicate a protective space between the units made by the rigid stacking studs.
[0048] Referring now to FIGS. 3 and 4 , the human factors behavioral analysis of Step 20 of the methodology of the process Architecture 1 , is a process and experience designed to allow a homeowner to create “lifestyle portrait” for him or herself. The behavioral analysis is about connecting the homeowner's passion(s) to the environment in which they live. In so doing it creates personalized living experiences that are inspired by the desires and/or aspirations of the customer's interests. Those interests are essentially dimensionalized into aesthetic, lifestyle themes.
[0049] Referring now specifically to FIG. 3 , a chart is illustrated that features examples of behavioral mapping within the human factors behavioral analysis context, to describe, refine and profile the homeowner's active passions. Varying active passions are listed under Column 1 . Likewise, under Columns 2 and 3 the behavioral profile and behavior characteristics of the homeowner, respectively, are categorized as they relate to the active passion listed in Column 1 . The organization of this matrix permits an efficient analysis of likes and dislikes in and around the behaviors. For example, if a homeowner tends to be a more focused, intense, unrelenting person, as described under the behavior profile Column 2 , or has the behavior characteristics of being performance oriented, urban, and patterned, as described under the behavior characteristics Column 3 , then the homeowner is more likely to connect with (from a perspective of associating that person's emotions and desires to a living environment) a “cycling” inspired form. Also for example, if the person has the behavior profile of that seen in Column 2 as being a caring, nurturing, caring or patient person, or has the behavior characteristics associated of Column 3 of an organic, seasonal or timely person, then he or she will be considered as best suited to the emotions evoked by a “country living” inspired forms. It is to be understood, of course, that the listed active passions and the behavior profile and characteristics that describe the passion can evolve and change as experience and time dictates.
[0050] Further, in Column 4 , the behavior characteristics and profiles are segmented into behavior categories into which the homeowner may fit. For example, from the figure such categories are: “planner”, “explorer”, “down-sizer”, “up-scaler”, “early adopter”, etc. By way of further explanation: the “explorer” is a person who seeks to discover new places, styles, and cultures; the “ex-urbanite” is a person who is urban at their soul but left to find solace elsewhere; the “down-sizer” is suburbanite who wants to reconnect and be more flexible in their lifestyle; the “up-sizer” is a upwardly mobile aspirational person who seeks to define an expanded lifestyle adding dimension to their current pursuits; the behavior segmentation category of the “early adopter” is the discontent, performance oriented person who needs the latest and greatest on the cutting edge; while the “planner” is the purposeful groomer of lifestyle features and intent. Likewise to Columns 2 and 3 , the behavior segmentation of Column 4 is categorized to the active passion of Column 1 . However, these behavior segmentation categories can be independent in and of themselves or can be linked to the various behavior profiles seen in Column 2 and/or the behavior characteristics seen in Column 3 . Thus it is to be understood that the matrix organization demonstrates cross associations of passions, behavior patterns, profiles, and categories.
[0051] Referring now specifically to FIG. 4 , as the purpose behind the human factors behavioral analysis of Step 20 of the methodology of the process Architecture 1 is to map (i.e., categorize and accept) the homeowner's behavior(s) to the homeowner's passion(s) and thus connect them into a lifestyle Signature Collections, demonstrative connections of the consumer's mapped desires to that of the passion of the product in place (i.e., home) to be built can be reviewed and discovered with the consumer. A homeowner who maps into an active passion of “sailing” motif of Column 1 in FIG. 3 would be initially connected to the “America's Cup” Collection as shown in Column 1 of FIG. 4 . The dynamic of such Collection can then be reviewed with the homeowner to confirm their understanding and compatibility. Columns 3 , 4 and 5 show, respectively, the Collection's mood, construction elements and materials. For instance, as can be seen from the figure, the “America's Cup” Collection espouses the mood of a crisp, fresh, refined, light, movement, and thus is composed of the elements of a mast, sail, turnbuckle, and staywire, and will have the materials of canvas, shingles, teak, polished steel and cable. Likewise the “Hunt” Collection will evoke a more traditional mood and will have the elements of expressed frame, tiebacks, and tube steel, and have the materials of natural wood, planks and saddle leather. This combined structure between FIG. 3 and FIG. 4 illustrates how this particular method of analysis uniquely connects a person's profile with a set of environmental characteristics and ultimately architectural form. The “spirit” of the form is embodied not in the adaptation of a given style typically seen in housing (i.e., French Colonial), but rather in the details, textures and forms of the assembly and enclosure system as well as the ultimate expression of a fully composed, personalized home. The details and inspirations become integral to the design and construction process based on this unique connection of emotion to environment.
[0052] Referring now to FIGS. 5 , 6 and 7 , the personalization as defined through the experience blueprint of Step 30 and the methodology of the process architecture 1 is described. As mentioned above, the experience blueprint has as its basis three foundational steps. The first is the behavior segmentation and mapping, that codifies who the personalized living environment product is being created for. The second is the experience principles and criteria, that both define and enhance the consumer's emotional connections to the product. The third is a patterning of a customer journey to structure moments in the project delivery process that reinforce a connection from the person's passion(s) to a place and a product to be constructed specifically for him or her.
[0053] Referring now to specifically to FIG. 5 , the behavior segmentation and mapping process within the experience blueprint 30 is shown. The experience blueprint 30 has two parallel tracks which answer complimentary questions that in combination craft the customer's process through the customer journey model. The first question that is answered through the experience blueprint is: who is the product designed for? The second question that is answered through the experience blueprint is: what moments connect them to it? With regard to the first question, “who is the product designed for?”, the experience blueprint details in step 31 to observe the customer's behavior pattern in both the virtual and physical environment. In step 32 to find commonality between desires and actions in the profiling process, in step 33 to profile the customer's personality by comparing both to visual and written analysis, in step 34 to graph the customer's passion(s) across the matrix to determine rules and expectations in their responses, and in step 35 to reconcile with the segmentation of the behavioral analysis 20 . With regard to the second question, “what moments connect them to it?”, the experience blueprint details in step 36 that the steps in the project are identified for a particular person depending on where they chose to enter the system. In step 37 it is sequenced and organized to ensure that the entire process is completed, in step 38 captures the associated thoughts as someone goes through their personal journey, in step 39 the associated feelings are defined and confirmed with visual cues of materials, lifestyles and collections, and in step 391 the formative moments are affirmed for a particular homeowner.
[0054] Accordingly, the experience blueprint 30 structures a process that creates specific visualizations that are equally part of the system and part of an individual, in a form of a passion inspired product and collection. In such manner then the experience blueprint specifically maps a consumer's journey and service model from introduction through execution of a branded and personalized lifestyle environment.
[0055] Referring now to FIG. 6 , the experience principles and six moments of emotion that matter in the experience blueprint 30 within the context of the methodology of the process Architecture 1 is shown. Within the illustrated chart the questions: “steps: What to do?”, and “Feelings: What to I feel?”, are defined by six moments that matter. For each person the description of what happened at the moments that matter will change but the structure and sequence of the moments themselves do not. The moments that matter are: 1) expanding expectations; 2) creating possibilities in your passions; 3) structuring commitment; 4) preparing for success; 5) realizing your desire; and 6) sharing experiences. The six moments that matter are each individually correlated to the “what to do?” steps and the “what do I feel?” emotions. What to do? similar to The Collection is a form or expression of what I feel at the moment. This consistent association of form and feeling gives the system its underlying structure.
[0056] The process experience principles and six moments of emotion that matter shown by the figure help identify important steps and feelings associated with those steps to complete the experience blueprint and emotionally bind the customer/homeowner to the finished product. For instance, in the first moment that matters within the experience blueprint of Step 30 , the moment of “expanding expectations”, the steps that occur are the entry by the customer into the experience blueprint of the process that codifies the “design for desire” methodology of the process architecture and the corresponding customer feeling of anxiousness associated with such entry. This important step attempts to remove the preconceptions of previous projects that the consumer may have experienced and what now was possible. The second step that corresponds to the first moment that matters of “expanding expectations” is the introduction and the corresponding feeling of needed preparation. Such allows for recognition and identification of solutions or things that need to be done to assist the customer/homeowner along the journey disposing of specific concerns that may distract or hamper the strength of the analysis. As another example, the fourth moment that matters is the “preparing for success”. Within this moment the corresponding steps thereof are the collection, segregation, and integration/synthesis. The emotions of confirmation and revelation are experienced through those steps. With the segregation of the collection comes the corresponding emotion of confirmation in the decision making process, while with the step of integrating and synthesizing the collection into the overall development comes the feeling of revelation of seeing the process falling into place and the result of your journey. The constant reinforcing of the interrelationship of emotions to forms, of desires and interest to the physical environment and vise versa comprise the unique and special experience that is personalization. In this case we create a system of personalization that brings speed, accuracy, flexibility and consistency to what is normally a process filed with anecdote and unpredictability.
[0057] Referring specifically now to FIG. 7 , the customer journey model 70 , of the integrated and branded experience blueprint of Step 30 of the methodology of the process Architecture 1 , is shown. The customer journey model 70 has four experience principals 71 that lead into the six moments that matter 72 (as described with reference to FIG. 6 ) and eight process fingerprints 73 . The four experience principals 71 are referred to as: “tell a story of unity” 74 , “expose expertise” 75 , “celebrate the details” 76 , and “cross fertilize” 77 . As can be seen from the figure of the customer journey model 70 , the experience principals 71 may lead into more than one of the six moments that matter 72 . For example, the experience principal of telling a story of unity “passion in craft” 74 is integral to the “expanding expectations” moment that matters, the “creating possibilities” moment that matters, and the “structuring commitment” moment that matters.
[0058] Likewise, the six moments that matter 72 then lead into the eight process fingerprints 73 . The process fingerprints 73 detail various “points” in the product completion process and correlate to the particular one or more of the six moments that matter. For instance, with regard to the “expanding expectations” moment that matters the service packaging allows for a providing insight and education to the customer. Also for instance, with regard to both the “expanding expectations” and “creating possibilities” moments that matters the lifestyle gallery allows for curetting the various collections such that the customer may view the various possibilities checking, review and validating their reactions. Accordingly, the various process fingerprints 73 are specific implementable actions that assist in defining and realizing the six moments that matter for the customer/homeowner as he/she completes the customer journey model towards a personalized living environment.
[0059] Referring now to FIGS. 8 , 9 , 10 , 11 and 12 , the various assembly joineries 50 are illustrated. The assembly joineries 50 are utilized to support the various unitized assemblies and act as structural and finishing components. The use of the assembly joineries acts to provide efficient support strength to weight of the unitized assembly components and acts to further express the tailored configurations of the collections. The columns can be constructed of varying hybrid materials, such as wood/steel, stone/steel, chrome/black steel, or pre-cast concrete/steel. In such a manner the assembly joineries 50 provide for unique and personalized expressions of the various Signature Collections 40 within the methodology of the process Architecture 1 and maintain the integrity of the system as a whole.
[0060] Referring now specifically to FIG. 8 , a universal column 80 is shown. The universal column is a two-to-four piece column that when assembled comprises two to four adjoining structural “L-shaped” angles. The universal column 80 can be made in 4 parts for shipping stability of the fully assembled unit. Each of the quarter columns are rigid enough to fully support the shipping and erection processes. For construction purposes and when combined in a four sided configuration it creates a column that fully resists for dead load and/or live loads, and is compliant with earthquake and hurricane design criteria. The structural design of the universal column 80 allows for plumb and true mating with a drop column insert and/or rigid stacking stud (each described in more detail below).
[0061] Referring now specifically to FIG. 9 , a drop column insert 90 is shown. The drop column insert 90 is a column attachment bracket that rotates around a hinge point 91 on the unitized assembly 10 . In a fully rotated “out” position the drop column insert 90 inserts into the universal column 80 and creates a structurally sound pin connection. In the fully rotated “in” position, the drop column insert 90 is locked open by stud 92 . The two rotated positions of the drop column insert allow for connection to a universal column in one position and efficient shipping in the other. It is also to be understood that rather than a hinged connection point, the drop column can be slide actuated in and out of the unitized assembly. Either connection method when joined with the column results in a virtually unlimited height (within expected standards of the proportional algorithm), dimensionally true and nearly perfectly level erecting, and an efficient field assembly. Additionally, the stud 92 allows for fit to a rigid stacking stud (described in further detail below) in the shipping position.
[0062] Referring now specifically to FIG. 10 , the rigid stacking stud 100 is shown. The rigid stacking stud 100 is a fixed column connection integral with the unitized assembly 10 . The fixed positioning of the rigid stacking stud allows for connection to a universal column 80 . The connection may be by welding, bolting, or other means of fixing the rigid stacking stud to the unitized assembly. In combination with the drop column insert 90 , as show in FIG. 9 , the rigid stacking stud 100 enables a rigid column-slab connection making a moment frame capable of resisting hurricane and earthquake loads, ensures a plumb and true column installation, and permits a fully assembled and fully finished unit I the factory to be broken down into a fully protected shipping container format. In the shipping format the drop column insert is seated into the stacking studs 92 . This stabilizes one unit to another for shipping and protects the finished floor, wall, or ceiling by leaving a 4″ airspace between unitized assemblies
[0063] Additionally, referring now specifically to FIGS. 11( a - e ), the mechanical operation of the drop column insert 90 and the rigid stacking stud 100 on the unitized assembly 10 , and then in combination with the universal column 80 is shown. Specifically in FIGS. 11( a ) and ( b ), the rotatable operation of the drop column insert 90 in it's fully rotated “in” and “out” positions is respectively shown. Further, specifically in FIGS. 11( c - e ), side, top and perspective views of the mechanical operation of the connection of a universal column 80 to either the drop column insert 90 or rigid stacking stud 100 are shown. As can be in these views, the universal column 80 , in either it's two or four adjoining “L-angle” configuration slides onto the drop column insert 90 or rigid stacking stud 100 , as the case may be. The combination of the unitize ceiling/wall assembly, universal column, drop column insert, and rigid stacking stud give the system great flexibility in terms of the physical expression (volume, texture, form) and great efficiency in transporting and erecting and fully finished trade integrated product.
[0064] Referring now to FIG. 12 , a universal split beam 120 is shown. The universal split beam 120 is a two piece composite beam/joist that translates the universal column to a horizontal assembly and permits fully finished floor/ceiling/wall unitized assembly 10 “sandwiches” to be joined. The split beam marries with the universal split column for a rigid connection while allowing the ceiling and wall assemblies to oriented in either direction vertically or horizontally prior to assembly.
[0065] Referring now to FIG. 13 , a composite column unit 130 is shown. The composite unit 130 is a two piece column that is a composite construction of wood, heavy timber and/or fully finished exposed steel section in either stainless steel, chrome, or riveted finishes to deliver double story height. This is demonstrative of the flexibility within the system to integrate multiple building systems and materials. In this figure it is contemplated that a heavy timber wood column would be comprise one side of the universal column configuration and rise two stories.
[0066] Referring now to FIG. 14 , a universal split partition 140 is shown. The universal split partition 140 is a fully finished open-back interior partition that acts as an interior finish and decorative assembly. The construction of such allows for connection to a universal column 80 as shown.
[0067] Referring now to FIG. 15 , an internal “sandwich” aspect of a floor/ceiling/wall unitized assembly 10 is shown. The sandwich aspect is a completely trade-integrated unitized assembly 10 containing various systems needed to support the living environment: electrical, plumbing, air-conditioning and heating, and/or insulation components. The sandwich is an open plenum, prefabricated interstitial space that uses the open web of the structure to affix and distribute the MEP infrastructure. Thus each “sandwich” may be support different demands from other sandwiches based on where the particular unitized assembly is to be utilized in construction. For instance, a unitized assembly that is designated for use in a kitchen area will have dense electrical and plumbing components already installed. Alternative, for instance, a unitized assembly designated for use as a ceiling and/or floor will have air-conditioning and heating ducts, lighting, and insulation already installed. Similar sandwich configurations apply directly to multi-family and/or multi-story installation and construction. Further, the open construction of the unitized assembly itself as such permits local re-inspection and further trade installation if necessary. Accordingly, the finished “sandwiches” (with the flip column detail) apply all the benefits of controlled manufacturing without sacrificing interior ceiling height or limiting exterior expression, and overcome the constraints of transportation/geographic limitations, project delivery speed, and allow for consistent execution quality.
[0068] Referring now to FIG. 16 , a profile view of a MEP (mechanical, electrical and plumbing) flex joint connector 160 is shown. The flex-joint connector 160 is a proprietary mechanical, electrical and plumbing joinery that allows for connection of the various pre-installed trades upon connection and assembly of the various “sandwiches” of unitized assemblies 10 . For instance, the design of the connector 160 permits the flexibility of joining of plumbing mechanicals or HVAC system mechanicals during connection of unitized assemblies. Further, the connector 160 permits inspection and testing of systems prior to such unitized assemblies connection, and also allows for the movement introduced in an earthquake and hurricane condition.
[0069] Referring now to FIG. 17 , a “green-bundled” system 170 and a “wet module” system 171 are shown in conjunction. The “green-bundled” system 170 is a proprietary composite of green technology that controls the systems for lighting, HVAC and plumbing (i.e., light, water and air) purification and performance. The system 170 can be incorporated into the “sandwich” of a unitized assembly 10 or set apart as its own module system and connected where needed through appropriate joineries to next to or below a unitized assembly 10 . The “wet module” system 171 is a proprietary composite of plumbing fixtures contained and fixed in a pre-fabricated module of assembled unitized assemblies 10 . Such plumbing fixtures in the system can include, for example, a fully installed tub, shower, sink or toilet. The system 171 Like the ceiling sandwich is a fully finished, shippable wet module. Unlike the wall or ceiling sandwich, it is a box unit defined by a unitized ceiling sandwich below and a rigid frame at the door head height above. This rigid frame is designed to support the water and air units in the ceiling and continuous louvers on the perimeter. Such construction and pre-assembly allows for an ability to “plug” the system 171 into various locations based the floor plan configuration.
[0070] Referring now to FIGS. 18 and 19 , the utilization of fixed/flexible assembly units describes the system flexibility in form and dimension. Such fixed/flexible assembly units come in two types, that is, a fixed and flexible exterior assembly unit 180 and a fixed/flexible interior assembly unit 190 . At a large scale, the form, proportion, and shape of the spaces, exterior and roof can be equally personalized to address the specific needs of the customer or conditions of the site by the flexibility provided by the assembly joineries. At a detailed level, the discussion of the collection column designs (as shown in FIGS. 20-28 ) demonstrate the specific relationship of emotions to features of the physical environment. The assembly units have grains that are fixed to marry to another module and grains that are flexible to address the visual or programmatic needs of a design. The pattern of fixed and flexible dimensions yields great dimensional flexibility in a shippable format.
[0071] Referring now specifically to FIG. 18 , an example of fixed/flexible exterior assembly units utilized in such construction is shown. For example, the exterior assembly unit 180 forms the exterior profile of the living environment, such as outer walls or rooftops. Also, for example the interior assembly unit 190 is utilized in the interior aspects of the living environment, such as inside walls. Referring now specifically to FIG. 19 , each type has both fixed and flexible portions and in this case they are stacked in section. The configuration demonstrates the ability to easily create double story interior heights and roof forms. The fixed portion relates to that aspect of the assembly unit which is fixed in dimension, while the flexible portion relates to that aspect of the assembly unit which is flexible in dimension. Such combination of fixed and flexible portions allows for greater use of geometry and “sizing” of the living environments. The flexible portions of the assembly units is created through the use of supporting elements within the unit.
[0072] Referring now to FIGS. 20-28 , various universal column Signature Collections 40 are shown. The collections each have a “signature” that relates to the active passion(s) of the customer/homeowner as described above. The “signature” connects to the universal column 80 by various means, which column is acting as a support column between the various unitized assemblies 10 . For instance, FIG. 20 shows the “America's Cup” signature 20 , FIG. 21 shows the “Cabernet” signature 21 , FIG. 22 shows the “The Tour” signature 22 , FIG. 23 shows the “Tea” signature 23 , FIG. 24 shows the “Triannale” signature 24 , FIG. 25 shows the “Autobahn” signature 25 , FIG. 26 shows the “The Hunt” signature 26 , FIG. 27 shows the “Gentleman Farmer” signature 27 , and FIG. 28 shows the “Vinyasa” signature 28 . It is to be understood that many other variations of Signature Collections may be created based upon a customer/homeowner's passions, and thus such signature list is not to be considered exhaustive or complete by any means. The grouping does demonstrate the range of expressions and in category show how any number of future combinations can be created within the integrity of the system.
[0073] Accordingly, as can be seen from the above detailed description with accompaniment of the various figures, the construction and architectural system of the present invention enable a hybrid manufacturing. That is, components may be manufactured in idela manufacturing regions, shipped anywhere in the world, and effectively assembled at the site that has been selected for the home. Additionally, the construction and architectural system in combination with the human factors based analysis and the various themed Signature Collections, allows for efficient access and development of a personalized living environment.
[0074] Additionally, the open system of construction as it is set forth by the present invention, allows for branded and bundled technology to be integrated with the unitized assembly and assembly joineries. This open system allows for universal construction and energy code compliance. The one infrastructure design is designed to be capable of meeting all applicable code standards for all contingencies—hurricane, earthquake, energy, etc. The constructed components also allow meet all international certifications: UL, MEA, etc., and in so doing allow for a national execution network of licensed exclusive professionals.
[0075] In the foregoing description, the method and apparatus of the present invention have been described with reference to specific examples. It is to be understood and expected that variations in the principles of the method and apparatus herein disclosed may be made by one skilled in the art and it is intended that such modifications, changes, and substitutions are to be included within the scope of the present invention as set forth in the appended claims. The specification and the drawings are accordingly to be regarded in an illustrative rather than in a restrictive sense.
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A method and apparatus for the creation, selection, ordering, shipping and constructing of personalized living environments that can be customized in almost unlimited configurations through the use of an architectural process, unitized assemblies, and assembly joineries is presented. The architectural process allows for the initial creation, design and selection of the unitized assembly collections based upon human factors behavioral based criteria. The unitized assemblies are fixed and/or flexible, trade-integrated modules in unitized, shippable configurations designed and incorporated with high touch finished crafts, allowing for dimensional flexibility in both the vertical and horizontal planes. The combination of the unitized assembly and human factors behavioral analysis combine for an experience blueprint of a homeowner's lifestyle portrait. The assembly joineries, based upon the desired collections selection, provide finishing touches to the unitized assembly, efficient strength to weight ratios, and expressed, stylized configurations in hybrid materials. The combination of the physical constructs with the behavioral process (together the experience blueprint) allows for “mass customization” in the design, production, manufacturing and delivering of personalized living environments.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 62/038,860 filed Aug. 19, 2014. The content of the above application is incorporated by reference in its entirety.
FIELD OF THE DISCLOSURE
This disclosure relates generally to the field of lighting systems used for plant growth, particularly indoor horticulture.
BACKGROUND
Photoperiodism is a quality of most plants that controls a plant's response to changes in light. Diurnal, or day and night, changes in light are cues to the plant to undertake certain responses, and in many plants the length of day or night is itself a cue. These responses include germination of seeds, start of flowering, and smaller, more granular changes like nighttime processes that plants undertake when not actively photosynthesizing.
Indoor horticulture has been able to reproduce and in some cases enhance natural processes to permit plants to be grown without natural sunlight, or, in some cases, with supplemental light in addition to natural sunlight. Current methods of providing horticultural lighting are similar to those used in other lighting applications, usually involving a single incandescent bulb or multiple LED chips to provide a varying spectrum of light and employing a simple analog on-off switch. None of the current methods include offset timing for different spectra. Such methods do not adequately simulate natural sunrise and sunset conditions that some plants require to switch between daytime and nighttime activities. Such methods also do not allow enhanced photoperiodic responses that can be obtained by offset timing for specific spectra.
Plants use a photosensitive pigment to detect light. One of these, phytochrome detects light in the red and far red spectrum and affects plant signals to “wake” or “sleep.” Different important biological processes occur in plants during these times. In addition to the time of day, many plants track the length of days with phytochrome and related systems; this allows, for example, a plant to know when the days are getting shorter in the fall, signaling the best time to convert from producing vegetative tissues to producing flowering tissues.
Reference to, and discussion of, the foregoing background is not presented as prior art and is respectfully submitted that none of the above-indicated patents and patent applications disclose, teach, suggest, show, or otherwise render obvious, either singly or when considered in combination, the invention described and claimed herein.
For the foregoing reasons, there is a need for a lighting system that provides offset timing for different light sources and spectra.
SUMMARY
The disclosure presented herein relates to lighting for plant growth; particularly lighting used for indoor horticulture. The apparatus, system and method described herein uses a combination of different types of lighting devices connected to a system that when performed per a specific method, replicates the effects of sunrise and sunset by providing certain wavelengths of light at certain times. In some embodiments, the sunrise/sunset response of the plants is actually sped up or enhanced by providing measured doses of spectra that affect plant photoperiodism.
Preceding and following embodiments and descriptions are for illustrative purposes only and are not intended to limit the scope of this disclosure. Other aspects and advantages of this disclosure will become apparent from the following detailed description.
Certain terminology and derivations thereof may be used in the following description for convenience in reference only, and will not be limiting. For example, words such as “upward,” “downward,” “left,” and “right” would refer to directions in the drawings to which reference is made unless otherwise stated. Similarly, words such as “inward” and “outward” would refer to directions toward and away from, respectively, the geometric center of a device or area and designated parts thereof. References in the singular tense include the plural, and vice versa, unless otherwise noted.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present disclosure are described in detail below with reference to the following drawings. These and other features, aspects, and advantages of the present disclosure will become better understood with regard to the following description, appended claims, and accompanying drawings. The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure. Also, the drawings included herein are considered by the applicant to be informal.
FIG. 1 is a top view of an embodiment of a grow light device.
FIG. 2 is a side view of an embodiment of one lens of a grow light device.
FIG. 3 is a cut-away view of a grow light device and connection to systems.
FIG. 4 is a section view of an embodiment of a grow light device.
FIG. 5 . is a detailed side view of a LED light and attachment.
FIG. 6 . is an isometric view of an embodiment of a grow light device assembly.
FIG. 7 . is a graphical representation of one method over time.
FIG. 8 . is a bottom view of an embodiment of the grow light device assembly.
FIG. 9A . is a process flow for a computer-controlled system of one or more grow light devices.
FIG. 9B . is a process flow for a wireless computer-controlled system of one or more grow light devices.
DEFINITIONS
Grow Light Device: An elongated apparatus which contains, powers and arranges at least one LEDs; is mountable and designed to dissipate heat.
High Intensity Discharge Lamp or “HID Lamp”: one of several common types of light-emitting bulbs; the most common of which are high pressure sodium, induction, ceramic metal halide, metal halide, digital, plasma, and fluorescent.
Photoperiodism: the response of a plant to changes in the length of daylight. A plant that responds to length of daylight is called “photoperiodic”.
LEDs: a plurality (2 or more) of LED lights embedded onto a printed circuit board, including all electronic elements commonly used on such an array.
Hood: a generally convex unit in which the bulb or other lighting devices are placed, and which causes light from the bulb to be directed by reflection off the internal surface.
Far Red: the wavelength electromagnetic radiation in the 700-760 nm range, preferably 730 nm.
Red: the wavelength of electromagnetic radiation in the 630-690 nm range, preferably 660 nm.
DETAILED DESCRIPTION
In the Summary above and in this Detailed Description, and the claims below, and in the accompanying drawings, reference is made to particular features (including method steps) of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.
The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, among others, are optionally present. For example, an article “comprising” (or “which comprises”) components A, B and C can consist of (i.e., contain only) components A, B and C, or can contain not only components A, B, and C but also contain one or more other components.
Where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility).
The term “at least” followed by a number is used herein to denote the start of a range beginning with that number (which may be a range having an upper limit or no upper limit, depending on the variable being defined). For example, “at least 1” means 1 or more than 1. The term “at most” followed by a number (which may be a range having 1 or 0 as its lower limit, or a range having no lower limit, depending upon the variable being defined). For example, “at most 4” means 4 or less than 4, and “at most 40%” means 40% or less than 40%. When, in this specification, a range is given as “(a first number) to (a second number)” or “(a first number)-(a second number),” this means a range whose limit is the second number. For example, 25 to 100 mm means a range whose lower limit is 25 mm and upper limit is 100 mm.
FIG. 1 shows a preferred version of the grow light device 1 together with two separate power supplies 3 . Alternate embodiments may be constructed and powered using just a single power supply. As for the grow light device itself, the shape, size, proportions, and number of components are generally scalable such that any number of lights could be support in such a way so long as the power source(s) can supply enough power. In the preferred embodiment shown in FIG. 1 , is a single row of 14 (fourteen) light bulbs 40 are configured along the centerline of the housing 42 of the grow light device. The bulbs are lit by light emitting diodes (LEDs) which are located in the center of the bulbs. In this preferred embodiment, two alternating types of LEDs are used, as shown in FIG. 1 where a red wavelength LED 2 is positioned adjacent to a far red wavelength LED 6 where the next bulb in the row would be a red LED 2 followed by a far-red LED 6 and so on. An alternative embodiment is accomplished by configuring two or more rows of bulbs and LEDs, may be accomplished by having a larger housing, more power and more bulbs. On either side of the bulbs 40 in the preferred embodiment shown in FIG. 1 are length-wise fins 5 which protrude from the center of and run the length of the housing 42 . The fins 5 are preferably metallic and are integral with the housing 42 . The fins 5 are a method of providing an air path to cool the housing 42 (also shown well on FIG. 4 ) and are configured such that they are relatively thin when compared to the body of the housing. As shown in FIG. 4 there can be many fins (in the embodiment shown in FIG. 4 there are 12 fins). The thickness of each fin is no more than 25% the thickness of the housing height. Other methods for cooling may be used instead of these metallic fins such as fan-cooled. Attached to each end of the grow light device 1 is an end cap 4 . Each end cap secures wiring, and provides support for power cords 45 .
As used herein for purposes of the present disclosure, the term “LED” should be understood to include any electroluminescent diode or other type of carrier injection/junction-based system that is capable of generating radiation in response to an electric signal. Thus, the term LED includes, but is not limited to, various semiconductor-based structures that emit light in response to current, light emitting polymers, organic light emitting diodes (OLEDs), electroluminescent strips, and the like. In particular, the term LED refers to light emitting diodes of all types (including semi-conductor and organic light emitting diodes) that may be configured to generate radiation in one or more of the infrared spectrum, ultraviolet spectrum, and various portions of the visible spectrum (generally including radiation wavelengths from approximately 400 nanometers to approximately 800 nanometers). Some examples of LEDs include, but are not limited to, various types of infrared LEDs, ultraviolet LEDs, red LEDs, blue LEDs, green LEDs, yellow LEDs, amber LEDs, orange LEDs, and white LEDs (discussed further below). It also should be appreciated that LEDs may be configured and/or controlled to generate radiation having various bandwidths (e.g., full widths at half maximum, or FWHM) for a given spectrum (e.g., narrow bandwidth, broad bandwidth), and a variety of dominant wavelengths within a given general color categorization.
As used herein for purposes of the present disclosure, the term “HID lamp” should be understood to include, but not be limited to, any non-LED based lamp that has performance characteristics similar to the group of lamps known as mercury, metal halide, and high pressure sodium. The term HID lamp specifically includes, but is not limited to, inductive discharge lamps that operate using the principal of induction.
An alternative embodiment of the LED grow light device would have all of the LEDs be of either red (630-690 nm) or of all far red (700-760 nm). Yet another embodiment as opposed to a linear grow light device, but for the housing to be in the shape of a circle where the LEDs alternate red then far red, red then far red, etc. Also, with the circular grow light device embodiment, another embodiment where all LEDs in the circular embodiment are all far red or are all red.
FIG. 2 shows a top view and side view of the lens which covers each LED bulb in the grow light device. As shown, there is a base 47 which is made up of preferably metallic materials, but could be made of composite, plastic polymer or other common materials for electrical attachment. Attached to the base 47 is the clear plastic lens 9 . The lens 9 is parabolic in shape. Other embodiments of the lens 9 are full 180 degree hemispheres to allow maximum light exposure. Having a parabolic shape as in the preferred embodiment allows for more directed light while allowing for an appropriately wide bath of light. The lens 9 is secured to the base 47 by two simple screw fasteners. The base 47 is fixed to the grow light device circuit board 301 , as shown in FIG. 3 . Also shown in FIG. 2 and FIG. 3 is the LED bulb 49 which is positioned directly in the center of the base 47 .
A preferred embodiment of the power distribution of the grow light device is shown in FIG. 3 . Two independent sources 311 A and 311 B may be used to power two or more separate LED bulbs 49 . The power for both LED lights, 311 may be controlled by a wireless controller 312 . The wireless controller receives basic signals such as power on or power off for each grow light power source 311 A or 311 B and then transmits power from one of two power sources 3 to one or more of the grow light device power sources.
An important embodiment of having two or more power distributions is that each power source may power one specific type of LED independently. In this embodiment, the power source 311 A powers only those LEDs which are far red wavelengths and require a specific amps, wattage and voltage. Whereas the power source 311 B in the same embodiment powers only the red wavelengths which require a different amperage, wattage and voltage. Other embodiments may have three or more power sources for three or more independent LEDs.
FIG. 4 shows a side profile of the grow light device. There are at least two adjustable hanging mounts 421 which are positioned within the housing of the grow light device and on the opposite side as the bulbs. The mounts are adjustable because the housing 42 allows for sliding translation along the length of the grow light device. The adjustable hanging mounts 421 , as discussed below are preferably configured to receive a fastener of an angled arm as part of a grow light assembly (See FIG. 6 ). The grow light device housing 42 is made of highly conductive metallic material, preferably aluminum, titanium or a composite of similar quality. However, other embodiments may be made from ceramic, composite, carbon fiber, among other fibrous plant-based materials. The design of the fins 5 of the grow light device are directed away from the source of energy, the LEDs 49 , so that the path of heat energy flows along the ribs and away from the sensitive components of the LEDs 49 and the wiring, circuit board 301 and grow light device generally. Alternative embodiments of the grow light device use other light sources than LEDs which may also be used in the grow light device including but not limited to digital, plasma, high pressure sodium, induction, ceramic metal halide, metal halide, and fluorescent lighting. Also shown is a generally parabolic (alternatively semi-circular/hemispherical) lens 9 that covers at least one LED 49 . The lens 9 is secured onto the base 47 which provides magnification and amplification of the light. Each lens 9 in the grow light device magnifies the range of LED coming from the grow light device and provides a wide swath of light (preferably 180 degrees of light) to the plant. The base 47 is made up of reflective material or in some embodiments has a reflective or metallic surface or adhesive. The reflective surface 47 A is on the side of the base 47 that the LED 49 protrudes from.
FIG. 6 shows the structure and attachment of the grow light device to the larger, grow light assembly 600 . The overall assembly is made up of at least two grow light devices 1 positioned around two opposite ends of a main HID light structure 626 . There are horizontal members 601 and angled members 603 which suspend the grow light device 1 beyond the edge of the main HID light structure 626 . A preferred embodiment allows the grow light devices 1 on either side to tilt, rotate or swivel about a lower attachment end 628 and upper attachment end 630 of each of at least four angled arms. The lower attachment points 628 are located on at least two locations along the back of the grow light device where two angled members 603 per grow light device are connected on one end to at least two grow light device adjustable hanging mounts 421 and the other side to one of the horizontal members 601 by conventional means of connection such as pin, screw, or joint. Each of the horizontal members 601 are held in place to the HID light structure 626 preferably by non-permanent connection, as shown in FIG. 6 , at least one large magnet 625 per horizontal member 601 holds it in place. Other embodiments have permanent fastening means common in the art such as screws, pins, weld, or joints. The horizontal members 601 span across the HID light structure 626 for growing the horticulture. The main HID light structure 626 secures and provides power to at least one HID bulb in a manner consistent with the prior art. However, the preferred embodiment requires separate power sources for at least each of the two grow light devices 1 and the main HID light 626 .
FIG. 7 shows the grow light assembly 600 and the method 770 of adjusting the height and position of the grow light assembly relative to the height and size of the plant. As shown on the left, the grow light assembly may be hung within a specified distance 701 from the plant 750 so that the plant receives an optimal amount of all three lights (HID light and at least two grow lights). While the entire grow light assembly 600 travels predominately along a cable 701 along the z-axis, the two or more grow light devices 1 are each adjustable about both the z-axis through their connection to the main HID light structure but also are rotatable about the y-axis at their connection points with the angled arms. As the plant 752 grows, in the center picture, the grow light assembly translates upward along the z-axis with a smaller cable 703 . Alternatively, the cable 701 could simply be shortened or partially used. On the far right, the plant 754 is still growing and the assembly 600 continues to translate upward along the z-axis and a shorter still cable 705 is used. Alternative embodiments would use either longer cables 701 or 703 . it can be shown the cables and the grow light assembly are adaptable and preferably move with the plant's growth while maintaining a specified or desirable height above the plant. Similarly, the opposing grow light devices may be adjusted in the y-axis to assure precision exposure relative to the plant's height.
FIG. 8 shows a bottom-up view of one embodiment of the grow light device assembly. The outermost structure is the Hood 808 , with a single HID Bulb 814 in the middle flanked by two grow light devices 810 with LEDs. All three are affixed to a Hood so that the light from each is generally directed the same way. The embodiment shown in FIG. 8 has two rows of nine LED lights. The LED lights are alternating in the kind of spectrum they put out. One of the LEDs provides far red spectrum light preferably 660 nm (alternative embodiments may range from 630 nm-690 nm); the other provides red spectrum light preferably 730 nm (alternative embodiments may range from 700 nm-760 nm). Looking at FIG. 8 , LED lights 820 and 822 would have the same spectrum of light (either red or far red) and LED lights 821 and 823 would have the opposite spectrum of light as 820 and 822 (either red or far red).
One embodiment of the hood 808 is a generally square or rectangular shape when viewed from the top and trapezoidal from the side, with the larger end towards the bottom. The HID Bulb 814 and LEDs are attached within the interior portion of the hood, which is open on the bottom and closed on the top. The interior of the hood is exposed metal or it is coated or covered with a reflective substance common in the art. The hood 808 is preferably constructed of a lightweight conducting metal which will dissipate heat into the environment, however other materials such as carbon fiber, or fiberglass, plastic, ceramic, or other materials might be possible in other embodiments.
In another embodiment, the hood 808 may be a different shape, such as hyperboloid or paraboloid. In another embodiment, the LEDs are attached to the Grow Light Device, but are not inside the convexity of the hood, or are themselves placed in separate hoods.
In another embodiment, The LEDs will be of two varieties, producing either red or far red light. Beyond the color distinction, the LEDs may be substantially similar, though there is no requirement that the two be identical. In this preferred embodiment, however, the LEDs are almost indistinguishable from one another until they are turned on. Embodiments described herein may apply to either color LEDs.
One embodiment of the LEDs has at least one row of LED lights which are embedded in a circuit board. The LED lights are arranged approximately centrally in the housing protruding from one face of the housing. The LED lights used in the preferred embodiment are generally “high powered” at preferably 3-watts each, though in some embodiments the lights may be of lower wattage, but should be more than 1-watt and may be more than 3 watts, but would be unnecessary. In the preferred embodiment, the circuit board is attached on one side to an amount of lightweight conducting metal which will dissipate heat into the environment, however other materials such as carbon fiber, or fiberglass, plastic, ceramic, or other materials might be possible in other embodiments.
In a preferred embodiment, this side of the grow light device includes the back side of the attachment point of the HID bulb, and is the attachment point for wiring, including control and power supply wiring. In another embodiment, wiring is directed to another part of the hood, such as the middle. In another embodiment power for the separate lights (HID and LED) may attach at different points on the hood.
The electrical and power systems which control the LED and HID lights is shown in FIG. 3 . There are two separate sources of power, one to the Red light LED and one to the Far Red LED. Other embodiments can have more than two power sources, depending on the size and requirements for the bulbs being used. The preferred embodiment allows multiple independent power sources, varying degrees of lumens, watts and overall power to each set of LED bulbs. Other embodiments, as are shown in FIGS. 9A and 9B , show a computerized timing device which controls the power and duration of each of the independent power sources.
A computerized wireless communication system 950 (see FIG. 9B ) communicates wirelessly to more than one computerized control system 957 which controls all grow lights (including HID light and LED grow lights) in a grow light assembly 600 . The computer 951 , using a common wireless host module 953 and wireless repeater 955 sends software signals to each computerized control system 957 found in FIG. 9A . A wireless slave module 901 or a training device 903 sends at least one signal to a microcontroller 905 which controls all the lights within the assembly 600 . The wireless slave module 901 receives wireless signals from a computer 951 according to a specific software program which is programmed to a specific timing method described later. As shown in FIG. 9A , the microprocessor sends signals to both a ballast controller 907 and at least one LED controller (LED controller A 925 and LED controller B 913 in FIG. 9A ). The ballast controller 907 allows variability to the current and voltage flowing through from the microprocessor to the HID light 911 because these lights are such high wattage (typically over 1000 W), a ballast 909 is common. The LED Controllers A and B control the timing and voltage to at least two LED bars 921 and 915 , like the grow light device 1 . In other embodiments, three or more LED bars per LED controllers are set up, such that the third LED bars ( 923 and 917 as shown in FIG. 9A ) may be positioned and wired in parallel to the other two. The LED Controller 925 or 913 will receive the signals and dispense power from the microcontroller 905 based on specific timing per the software provided wirelessly to the wireless slave module 901 .
The term “controller” or “microcontroller” is used herein generally to describe various apparatus relating to the operation of one or more light sources. A controller can be implemented in numerous ways (e.g., such as with dedicated hardware) to perform various functions discussed herein. A “processor” is one example of a controller which employs one or more microprocessors that may be programmed using software (e.g., microcode) to perform various functions discussed herein. A controller may be implemented with or without employing a processor, and also may be implemented as a combination of dedicated hardware to perform some functions and a processor (e.g., one or more programmed microprocessors and associated circuitry) to perform other functions. Examples of controller components that may be employed in various embodiments of the present disclosure include, but are not limited to, conventional microprocessors, application specific integrated circuits (ASICs), and field-programmable gate arrays (FPGAs).
In various implementations, a processor or controller may be associated with one or more storage media (generically referred to herein as “memory,” e.g., volatile and non-volatile computer memory such as RAM, PROM, EPROM, and EEPROM, floppy disks, compact disks, optical disks, magnetic tape, etc.). In some implementations, the storage media may be encoded with one or more programs that, when executed on one or more processors and/or controllers, perform at least some of the functions discussed herein. Various storage media may be fixed within a processor or controller or may be transportable, such that the one or more programs stored thereon can be loaded into a processor or controller so as to implement various aspects of the present invention discussed herein. The terms “program” or “computer program” are used herein in a generic sense to refer to any type of computer code (e.g., software or microcode) that can be employed to program one or more processors or controllers.
The preferred method of use for the grow light assembly 600 involves careful timing and input into either a manual (physically turning a power switch on or off, or plugging or unplugging power) or computerized system 900 and 957 (as described above). The specific nanometer ranges used for the lullaby method are critical, and are as follows: Sunrise (red light) LEDs give off light that is preferably exactly 660 nanometers (nm) but other embodiments may use a range of anywhere between 630 nm to 690 nm; Sunset (far red light) LEDs give off light that is preferably exactly 730 nm, but other embodiments may use a range of anywhere between 700 nm to 760 nm.
The timing of turning lights on is what makes up the preferred method for using the grow light assembly 600 . The steps are:
1) Preferably 15 minutes before HID light, turn on Sunrise (red light) LEDs; As little as 8 minutes and as many as 20 minutes may be given. 2) Preferably 5 minutes of overlap where both Sunrise LEDs and HID (main light) are both on; as little as one minute and as many as 30 minutes may be given for overlap. 3) HID (main) Grow light may remain on to the user's desired length based upon specific grow cycle, but preferably 12 hours. 4) Preferably 5 minutes of overlap where both Sunrise LEDs and HID (main light) are both on; as little as one minute and as many as 30 minutes may be given for overlap. 5) Preferably 15 minutes before HID light, turn on Sunset (far-red light) LEDs; As little as 8 minutes and as many as 20 minutes may be given.
Timing; most growers induce the flowering cycle with a 12 hours on/12 off lighting pattern. Using the aforementioned method however, allows a grower to light plants up to 14 hours because the plants sleep very quickly after the second light effect (sunset/far-red) is completed. Without the second light effect, a plant would take up to 2 hours to sleep. This is because when a plant goes from total light (HID “on”) to complete darkness (HID “off”) it enters a state of shock and the pores of the plant are not able to close very well. Conversely, in the morning, if the plant is gently awakened by a natural sunrise (red light) it will more completely and quickly be prepared to begin photosynthesis from full sun (HID light).
Computerized Timing; the computer timed embodiment (See FIG. 9A-9B ) will control different growing cycles based on the type or strain of plant being grown. This allows the grower to emulate the most favorable growing conditions from anywhere in the world based on what plant or strain of plant they are growing. Meaning, if the grower knew the precise environmental lighting conditions for that grow season based on a farmer's almanac resource, then a grower could theoretically create a very similar lighting environment to a specific location in Afghanistan in 1978 and create a strain of plant that would emulate that of the plant from the past. The computerized aspect of this exists in the embodiment portrayed in FIGS. 9A and 9B . For example, one embodiment of the computer system, in order to simulate the season of Afghanistan 1978, the lighting would be programmed into a software or other readable medium such that the computer/device 951 could read and transmit at least daily light/night durations and wavelengths to the wireless host module 953 and wireless repeater 955 in order to communicate to the computer control system 957 to receive signals into the wireless slave module 901 and finally to the microcontroller 905 which controls how much of which type of light gets applied to the plant. In addition, the moisture and soil environment would also be simulated, but soil and moisture simulation that is well known in the art may be used effectively in combination with the true lighting conditions for simulations like Afghanistan 1978.
While preferred and alternate embodiments have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the LIGHTING DEVICE, SYSTEM AND METHOD FOR GROWING HORTICULTURE INDOORS. Accordingly, the scope of the LIGHTING DEVICE, SYSTEM AND METHOD FOR GROWING HORTICULTURE INDOORS is not limited by the disclosure of these preferred and alternate embodiments. Instead, the scope of the LIGHTING DEVICE, SYSTEM AND METHOD FOR GROWING HORTICULTURE INDOORS should be determined entirely by reference to the claims. Insofar as the description above and the accompanying drawings (if any) disclose any additional subject matter that is not within the scope of the claims below, the inventions are not dedicated to the public and Applicant hereby reserves the right to file one or more applications to claim such additional inventions.
The reader's attention is directed to all papers and documents which are filed concurrently with this specification and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
All the features disclosed in this specification (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example of a generic series of equivalent or similar features.
Any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function is not to be interpreted as a “means” or “step” clause as specified in 35. U.S.C. §112 ¶6. In particular, the use of “step of” in the claims herein is not intended to invoke the provisions of U.S.C. §112 ¶6.
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A lighting device and assembly which incorporating an independently powered array of at least two types of LED lights that each give off specific wavelengths of light for growing plants. The assembly includes at least two of the lighting devices in conjunction with at least one high intensity bulb commonly used for indoor horticulture, where the assembly is adjustable for dimensional changes in the subject plants as they grow. A timing method for applying specific durations of each type of light which effectively simulate sunrise, daylight and sunset by allowing the plant to awaken naturally, absorb more light during the day and prepare for sleep at night, giving the plant more rest—all leading to more healthy plant growth.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of electrophotographic printing.
An electric copying machine by way of electrophotography has been widely known in the field of copying technology in which an optical image of an original (a manuscript) of a document or drawing for example, is restored by means of energy of an electro-magnetic radiation beam and a sensitized member.
In the copying machine, a charge latent image corresponding to an optical image of the original is formed on the sensitized member to which a charged photoconductive member is applied and is developed by toner to get a hard copy.
A laser printer also has been widely used in recent years. The laser printer uses a charged photoconductive member as a sensitized member which is scanned by a spot of a laser beam whose intensity is modulated by means of information signals to be recorded to form a charge latent image corresponding to the information signals on the sensitized member. The charge image is developed to obtain a hard copy.
There is further an electrophotographic apparatus to which the copying machine as well as the laser printer are applied.
As is well known, the copying process of an electric copying machine by way of electrophotography is as follows: Firstly, an original optical image is exposed on a sensitized member of a pre-charged photoconductive member to form a charge latent image corresponding to the original optical image thereon.
The charge latent image is then developed by toner and the developed image is transferred onto a transfer paper and is fixed thereon to obtain a hard copy. (The paper needs not be a transfer paper if the paper itself is a sensitized member.)
It is therefore required to two-dimensionally expose an original optical image on a sensitized member of a pre-charged photoconductive material each time in order to obtain a duplicate. Consequently, it is difficult to speed up the copying rate.
It is thus general to obtain many duplicates by means of not a copying machine but a printing machine. In order to solve such a problem, there is an apparatus as a copying machine by way of electrophotography but also doubles as a printing machine disclosed in U.S. Pat. No. 2,576,047.
The apparatus disclosed in the US patent employs zinc oxide as a pre-charged photoconductive material as a sensitized member. When the apparatus operates in printing mode, an original optical image is exposed on a sensitized member to form a charge latent image corresponding to the original optical image thereon.
The charge latent image is then developed by toner to .obtain a fixed image as a master. The master is charged and exposed entirely and is further developed by toner. The developed image is transferred onto a transfer paper and is fixed thereon to obtain a duplicate.
It is essential for companies active in an information-oriented society to document information selected from much information and to deliver the documents to sections in the companies which need that information as soon as possible.
It is therefore required for the documenting mentioned above to duplicate an original by a copying machine, to document the original by a word processor and to obtain many duplicates by copying operation of a copying machine or printing operation of a printing machine.
With an improvement of functions of an electric copying machine, particularly its copying rate, companies have not ordered a printing office but have duplicated documents by themselves with their copying machines if the number of copies is not great.
However, as already mentioned, it is difficult to speed up the copying rate so that a printing machine must be used instead of a copying machine if so many documents.
An apparatus which operates as a copying machine but also doubles as a printing machine by way of electrophotography is useful under such circumastances.
However, the apparatus disclosed in U.S. Pat. No. 2,576,047 already mentioned needs troublesome operation to detach a master used in the printing mode from the apparatus and to install a new sensitized member therein when the printing mode is switched to the copying mode. The apparatus also cannot operate as a laser printer.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method of electrophotographic printing in which many duplicates can be obtained at a high copying rate.
According to the present invention, there is provided a method of electrophotographic printing in which firstly a recording medium comprising a photoconductive member and photo-modulation member laminated to each other, both exhibitng photoelectric effect and a sensitized member made of a chargeable photoconductive member are arranged so as to face each other.
Next, a first electro-magnetic radiation beam which is intensity-modulated with data to be recorded is radiated to the recording medium at the photoconductive member side thereof to record the data to the photo-modulation member with the photoelectric effect.
A second electro-magnetic radiation beam of constant intensity is further radiated to the recording medium to emit therefrom a third electro-magnetic radiation beam exhibiting intensity variation subjected to the recorded data.
The sensitized member is exposed with the third electro-magnetic radiation beam to form thereon a charge image corresponding to the recorded data and toner is stacked onto the sensitized member formed with the charge image to form thereon a toner image.
The toner image is then transferred onto a printing paper, to thus perform repeated printing utilizing the data once recorded to the recording medium.
Accordingly, the present invention is advantageous in that many duplicates can be obtained at a high copying rate.
The other objects and features of the present invention will become understood from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a perspective diagrammatic configuration of a recording apparatus applied with electrophotographic printing according to the present invention, particularly the component parts thereof used in production of a master for printing;
FIG. 2 shows a perspective diagrammatic configuration the component parts of the apparatus shown in FIG. 1 used in production of a duplicate by means of the master produced in FIG. 1 and also the operational principle thereof according to the present invention;
FIG. 3 shows an example of a recording medium used in the recording apparatus shown in FIGS. 1 and 2 according to the present invention; and
FIGS. 4 to 7 are other examples of the recording medium used in the recording apparatus shown in FIGS. 1 and 2 according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with reference to the accompanying drawings. Throughout the drawings, like reference numerals and letters are used to designate like or equivalent elements for the sake of simplicity of explanation.
FIG. 1 shows a diagrammatic configuration of a recording apparatus applied with electrophotographic printing according to the present invention, particularly the component parts thereof used in production of a master for printing.
FIG. 2 shows the component parts of the apparatus shown in FIG. 1 used in production of a duplicate by means of the master produced in FIG. 1 and also the operational principle thereof.
The recording apparatus shown in both FIGS. 1 and 2 comprises a belt like sensitized member 1 which is wound arround a drive roller 2 and passive roller 3. The drive roller 2 is rotated by a rotation shaft 4 which is further rotated by a drive power supply (not shown). The sensitized member 1 is coated with a sensitized layer and needs not be belt-like.
An optical system for focussing an optical image on the sensitized member 1 as well as mechanism related thereto are omitted from FIGS. 1 and 2. Further omitted therefrom are a charging section developing section, transfer section, fixing section, cleaning section, paper feed section, paper deliver section, etc. which might be provided arround the sensitized member 1.
The recording apparatus shown in FIG. 1 comprises a motor 5 with a rotary shaft 6 and a polygon mirror 12 with a rotary shaft 10. A drive pulley 7 fixed to the rotary shaft 6 and a pulley 9 fixed to the rotary shaft 10 via a bearing 11 are linked together by a belt 8. The polygon mirror 12 is rotated by the motor 5 via the component parts mentioned above.
The recording apparatus further comprises a semiconductor laser source 13 which emits a laser beam. There are also provided a collimator lens 14 and cylindrical lens 15 through which the laser beam passes.
When the laser beam which passed therethrough is sequentially incident to mirriors of the polygon mirror 12, the laser beam is reflected there and is then deflected in the surface including the cylindrical axis of the cylindrical lens 15 and optical axis of the laser beam.
There are further provided a troidal lens 16, doublet spatial lens 17 and recording medium 50 in FIG. 1. The deflected laser beam is incident to the recording medium 50 via the lenses 16 and 17 to conduct main scanning on the recording medium 50 in the direction X.
Subsidiary scanning is conducted in the recording medium 50 in the direction Y in FIG. by a transfer mechanism (not shown). The recording medium 50 is recorded with data if the laser beam is modulated in its intensity with the data.
FlG. 3 is an example of configuration of a recording medium. A recording medium 50a comprises substrates 51 and 56 of macromolecular material, transparent electrodes 52 and 55 made of such as Indium-Tin Oxide membrane, a photoconductive layer (abbreviated in a HCL hereinafter) member 53 and a macromolecular-liquid crystal memory (abbreviated in a HLM hereinafter) membrane 54 as a photo-modulation layer.
The HLM membrane 54 is composed such that nematic or smectic liquid crystals which have the cnaracteristics as the liquid crystal at a room temperature and have high volume resistivity are dispersed in the macromolecular material such as methacrylic resin, polyester resin, polycarbonate resin, vinyl chloride resin, poly amide resin, polyethylene resin, polypropylene resin, polystyrene resin and silicone resin, having volume resistivity of 10 14 Ωcm or more.
The HLM membrane 54 further may be laminated thereon with a dielectric layer of thin membrane composed of such as methacrylic resin, polyester resin, polycarbonate resin, vinyl chloride resin, poly amide resin, polyethylene resin, polypropylene resin, polystyrene resin and silicone resin, having volume resistivity of 10 14 cm or more.
The liquid crystals in the HLM membrane 54 are enclosed in numerable pores 18 randomly distributed in the macromolecular material.
Employment of the liquid crystals having higher volume resistivity and viscosty results in the reproduction of data with higher contrast ratio or higher recording performance.
Furthermore, employment of the liquid crystals having a lower melting point than that of the macromolecular material is advantageous to compose a recording medium in which recorded data can be erased.
Recording operation of data to the recording medium 50a, reproduction operation of the data therefrom and erasing operation of the data therefrom will be explained as follows with reference to FIG. 3.
First in the recording operation, an electro-magnetic radiation beam source (abbreviated in a light source hereinafter) 57 radiates an electro-magnetic radiation beam (abbreviated in a beam hereinafter) whose intensity is modulated with data to be recorded to the recording medium 50a. The beam may be focused on the recording medium 50a via an imaging lens (not shown).
In FIG. 3, between the transparent electrodes 52 and 55, a series circuit of a power supply 19 and switch 20 is connected. The switch 20 is turned on to apply a voltage from the power supply 19 across the electrodes 52 and 55 for the recording operation.
The electric resistance of the PCL member 53 varies accordingly with the intensity of the beam incident thereto from the light source 57 via the substrate 51.
The field distribution induced across the PCL member 53 and transparent electrode 55 by the voltage applied thereacross further varies accordingly with the intensity of the beam incident thereto.
An electric field with intensity distribution corresponding to the intensity of the beam is thus applied to the HLM membrane 54.
Consequently, the nematic or smectic liquid crystals enclosed in the pores 18 in the HLM membrane 54 are reoriented accordingly with the magnitude of the intensity of the electric field applied thereto so as to increase transparency of the HLM membrane 54 as the electric field applied to the liquid crystals increases beyond a threshold level.
Orientation direction of the liquid crystals thus changed is not changed any more even if the electric field is removed.
The HLM membrane 54 is composed such that the liquid crystals are enclosed in the numerable pores 18 randomly distributed in the macromolecular material. The liquid crystals thus cannot freely change their orientation direction.
When the electric field is applied thereto to give enough energy to liquid crystals larger than that of the macromolecular material, the liquid crystals are reoriented but subjected to the macromolecular material to maintain the state.
Therefore, the orientation direction remembers the state to which the liquid crystals have had an electric field applied. The larger the pores 18 in which the liquid crystals are enclosed, the more difference in orientation among the liquid crystals. This results in a degradation of the memory function. Accordingly, it is desirable to have pores 18 with a diameter of 0.5 μm or less, and which are uniformely dispersed.
Next, the reproduction operation can be performed by radiating a beam for reproduction onto the prerecorded recording medium 50a. The beam for reproduction passing through the recording medium 50a or reflected therefrom may be used as output data.
Furthermore, the data recorded in the recording medium 50a is erased by heating the liquid crystals to the temperature over the melting point of the liquid crystals and under that of the macromolecular materials so as to make the liquid crystals exhibit isotropy. The liquid crystals thus heated are cooled down to be nematic or smectic.
When the liquid crystals are heated to a temperature disclosed as above, molecules of the liquid crystals exhibit isotropy due to thermal motion overcoming the wall energy of the pores 18. The liquid crystals are then cooled down to be nematic or smectic and the HLM membrane 54 becomes opaque.
Again in the recording apparatus in FIG. 1 and if the recoding medium 50a in FIG.3 is used, the switch 19 is turned on to make the power supply 20 apply a voltage across the transparent electrodes 52 and 55 of the recording medium 50a.
Under such a state, the semiconductor laser source 13 radiates a laser beam whose intensity is modulated with data to be recorded onto the mirrors of the polygon mirror 12 via the collimator lens 14 and cylindrical lens 15. The laser beam is deflected thereon and scans the recording medium 50a in the direction X via the toroidal lens 16 and doublet spatial lens 17.
The data is then memorized in the HLM membrane 54 of the recording medium 50a as the orientation state of the moleculars of the liquid crystals in the HLM membrane 54.
When a beam is radiated to the recording medium 50a which has been recorded with the data, a beam whose intensity is modulated with the data is emitted out from the recording medium 50a.
Next in FIG. 2, the recording medium 50 is already recorded with data. A light source 21 is provided to radiate a beam thereto. A beam whose intensity is modulated with the data memorized in the HLM membrane 54 is emitted out from the recording medium 50 to expose the sensitized member 1.
As is already mentioned, there are provided the charging section , developing section, transfer section, fixing section, cleaning section, paper feed section and paper deliver section, etc. (not shown) around the sensitized member 1.
When the beam so modulated with the memorized data is radiated to the sensitized member composed of photoconductive material exhibiting photosensitivity due to colona discharge, a charge image (a charge latent image) corresponding to the data is formed thereon.
The charge image thus formed is developed in the developing section by means of toner. The developed toner image is transferred onto a printing paper in the transfer section and then is fixed thereon in the fixing section. The printed paper is delievered from the paper deliever section.
Excess toner remained on the sensitized member 1 is removed in the cleaning section. The printing paper is fed by the paper feeding section.
The data recorded in the recording medium 50 is printed on the printing papers one after another by means of electrophotography with repeating the process of charging, exposing, paper feeding, developing, transferring, fixing, cleaning and paper delivering.
Other preferred embodiments according to the present invention will be explained with reference to FIGS. 4 and 5.
In the figures, a recording emdium 50b is composed such that a transparent electrode 58, the HLM membrane 54 and PCL member 53 are laminated on a substrate 59 in order. A protection layer may be further laminated on the PCL member 53.
FIG. 4 shows a diagrammatic configuration of a recording system for recording data to be printed to the recording medium 50b. The recording system is provided with a writing head 60 composed of a transparent substrate 61 and transparent electrode 62.
The power supply 19 shown in FIGS. 1 to 3 is to be connected across the substrate 61 and electrode 62 when recording operation is performed.
A light for data-writing (abbreviated in a writing light hereinafter) WL is an electro-magnetic radiation beam whose intensity is modulated with data to be recorded The writing light WL may be focussed on the recording medium 50b via an imaging lens (not shown).
When the writing light WL is incident to the PCL member 53 of the recording medium 50b via the substrate 61 and transparent electrode 62 of the writing head 60, the electric resistance of the PCL member 53 varies accordingly with the intensity of the writing light WL.
The field intensity distribution across the PCL member 53 and transparent electrode 58 also varies accordingly with the amount of the writing light WL, since the power supply 19 applies a voltage across the electrodes 58 and 62.
The data to be recorded is then memorized in the memory membrane 54 in the same manner as explained with reference to FIG. 3.
The recording medium 50b thus recorded with the data is charged uniformally at the entire surface of PCL member 53 by way of colona discharge or other ways in a dark room.
Then, in FIG. 5, when a beam for data-reading (abbreviated in a reading light hereinafter) RL is incident to the PCL member 53 via the memory membrane 54 of the recording medium 50b from the light source 21, the reading light RL is scattered accordingly with the data memorized in the memory membrane 54. Thus, the intensity of incident light on the PCL member 53 varies according to the data.
The elecrical resistance of the PCL member 53 therefore varies accordingly with the data and then a charge pattern corresponding to the data is formed on the PCL member 53.
The charge pattern can be developed and printed on printing papers one after another in the same manner as explained with reference to FIG. 2.
The recording mediums 50, 50a and 50b may be such as flat, cylindrical and belt-like. Furthermore, well known techniques for an electric copying machine are available for the process of charging, paper feeding, developing, transferring, fixing, cleaning and paper delivering.
Next, FIGS. 6 and 7 show other preferred embodiments of the recording medium according to the present invention. Both recording mediums 50c and 50d are composed of the PCL member 53, a dielectric layer 63 member enclosing photoconductive grains 64 which form a photoconductive grain (abbreviated in a PCG) layer 64a, a photo-modulation layer (abbreviated in a PML hereinafter) member 65, the transparent electrode 58 and substrate 59.
The difference between the configurations shown in FIGS. 6 and 7 is lamination order of the dielectric layer 63 and PML member 65. Recording/reproduction operation of the recording mediums 50c and 50d are the same with each other.
The PCG layer 64a is formed in such a manner that numberless photoconductive grains 64 are distributed therein separately from each other by depositing or sputtering photoconductive material on the dielectric layer 63 having high insulation resistance via a mask pattern and further a thin film of dielectric material is stacked onto the photoconductive material by deposition or sputtering.
The PML member 65 is composed of photoconductive material such as, liquid crystal, lithium niobate and lanthanum zirconate titanate which changes the optical state (scattering and the plane of polarization, etc.) of a light passing therethrough in accordance with the field intensity.
Furthermore, in FIGS. 6 and 7, a layer of an analyzer may be disposed between the PCL member 53 and PML member 65 on the way of the optical path.
In the case of recording with a writing light WL whose intensity is modulated with data to be recorded, the writing head 60 and the power supply 19 shown in FIG. are used. The power supply 19 is connected across the transparent electrode 62 of the writing head 60 and the transparent electrode 58 of the recording medium 50c or 50d.
Prior to the recording, light is radiated to the recording medium 50c or 50d to produce electron-hole pairs in the photoconductive grains 64 in the PCG layer 64a.
When the writing light WL is incident to the recording medium 50c or 50d via the writing head 60, the electrical resistance of the PCL member 53 varies accordingly with the intensity of the writing light WL so that spark discharge occurs to form a charge image on the recording medium 50c or 50d.
The charges of the charge image is neutralized with the holes of the electron-hole pairs so that the charge image corresponding to the data is recorded in the photoconductive grains 64 in the PCG layer 64a.
An electric field due to the charge image in the photoconductive grains 64 is applied to the PML member 65 in the recording medium 50c or 50d. A reading light RL passing through the PML member 65 is scattered accordingly with the data recorded in the phoconductive grains 64 and is emitted out from the recording medium 50c or 50d.
The recording medium 50c or 50d therefore can be applied to the recording apparatus described with reference to FIG. 1.
Furthermore, when the recording medium 50c or 50d is charged uniformally on the entire surface of the PCL member 53 by colona discharge produced by a charger (not shown) in a dark room, the reading light RL passing through the PML member 65 is scattered accordingly with the data recorded in the photoconductive grains 64.
The electrical resistance of the PCL member 53 varies accordingly with the data so that a charge pattern corresponding to the data is produced on the PCL member 53.
Therefore, the recording medium 50c or 50d can also be used in the same manner as the recording medium 50b shown in FIGS. 4 and 5.
Furthermore, the present invention in not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention.
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A method of electrophotographic printing is disclosed. A recording medium comprising a photoconductive member and photo-modulation member laminated to each other, both exhibiting a photoelectric effect and a sensitized member made of a chargeable photoconductive member are arranged so as to face each other. A first electro-magnetic radiation beam (abbreviated in a beam hereinafter) which is intensity-modulated with data to be recorded is radiated to the recording medium at the photoconductive member side thereof to record the data to the photo-modulation member with the photoelectric effect. A second beam of constant intensity is radiated to the recording medium to emit therefrom a third beam exhibiting intensity variation subjected to the recorded data. The sensitized member is exposed with the third beam to form thereon a charge image corresponding to the recorded data. Toner is stacked onto the sensitized member formed with the charge image to form thereon a toner image. The toner image is then transferred onto a printing paper, thus to perform repeated printing utilizing the data once recorded to the recording medium.
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BACKGROUND AND SUMMARY OF THE INVENTION
Priority is claimed to German Patent Application, Ser. No. 101 33 438.9, filed Jul. 10, 2001.
The invention relates to a commercial vehicle, rail or bus vehicle entry door.
Such a door is known from the prior art and has a grip recess and a door lock held on the door frame, the grip recess and the door lock representing separate components. The door lock contains a closing device acting upon a latching mechanism in order to move at least one latch of the latching mechanism into the closing or opening position. According to the type of the selected door lock, a correspondingly constructed receiving device must be worked into the door frame. In addition, different door locks are provided for doors hung on the left or on the right.
The present invention is directed to a commercial vehicle, rail or bus vehicle entry door comprising: a grip recess; a door lock; a closing device; a latching mechanism having at least one latch; a lock carrier area; and a latching mechanism carrier; wherein the door lock is held on the door and the closing device acts upon the latching mechanism in order to move the at least one latch of the latching mechanism into a closed or opened position; and wherein the lock carrier area can be fastened on the door and which, together with the grip recess, forms a one-piece basic component on which the latching mechanism carrier carries the latching mechanism in a detachable and reversible manner for the optional mounting of the door lock for a door hung by one of a right side mounting and one of a left side mounting.
Because of the one-piece basic component, in which the grip recess as well as the lock carrier are integrated, the number of components to be manufactured, to be stored and to be mounted is reduced. As a result of the latching mechanism carrier being fastened in a reversible manner on the basic component, a door lock for a right-hung door as well as for a left-hung door can be produced by means of identical components because, by reversing the latching mechanism, the latch will then project either to the right or to the left. On the whole, variants of the door according to the invention can thereby be produced at low cost.
Special preferable embodiments may provide that the basic component is constructed as a standardized carrier element for different door locks. Every door can therefore, on the one hand, be provided with identical connection measurements for the basic component, whereby the tool and manufacturing costs are lowered. On the other hand, because of the standardized construction of the basic component, several door lock variants can be presented by means of a single structural element.
According to a further possible development, the latching mechanism carrier contains at least one plate with bores which can be fitted onto at least one carrying pin projecting away from the basic component. As a result, the latching mechanism carrier can be mounted and demounted on the basic component in a simple and rapid manner. Furthermore, a mounting is also easily possible in a reversed position.
According to another possible embodiment, the door lock may have a receiving device for different closing devices, such as a 90-degree or a 180 degree closing device. This may be accomplished by a nut which is rotatably disposed between two parallel plates forming the latching mechanism carrier. The receiving device has a center opening on whose radially interior circumferential surface a polygonal surface is provided for the engagement of different connection elements or inserts of closing devices. As a result, the door lock can be provided with different closing devices without additional changes, which results in a cost-effective manufacturing of variants.
According to another possible embodiment, the door may have a door frame surrounding the door circumference, at which door frame a door glass pane is fastened which essentially extends along the entire door height and door width. The basic component can then be fixed at the door glass pane without any direct connection to the door frame, and can preferably be glued to the door glass pane. Advantageously, the previously customary high-expenditure machining of the door frame for producing an individual receiving device for the door lock can be eliminated. Only a passage bore, as a passage for the latch and which is aligned with the latch, is to be provided in the door frame.
Additionally, the glass pane can have an area of a blackening extending around in the immediate vicinity of the door frame, wherein a latch position indicator may be provided which is integrated in the latching mechanism and by means of which the currently existing latched or unlatched position of the latch is visible through a gap in the blackening.
As an additional possible measure, an opening device acting upon the latching mechanism is provided for unlatching the latched door lock from the inside, which opening device is preferably formed by a handwheel. This complies with the requirements of ECE-R 36, according to which it must be possible to open the door from the inside in the event of an emergency situation.
Other aspects, advantages and novel features of the present invention will become apparent from the following detail description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective exterior view of a door lock, according to the principles of the present invention;
FIG. 2 is a perspective interior view of the door lock of FIG. 1;
FIG. 3 is a broken-open interior view of the door lock of FIG. 1;
FIG. 4 is a sectional view along Line IV—IV of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For reasons of scale, FIG. 1 shows only a door lock 1 of a bus door in a view from the outside as a preferred embodiment of an entry door according to the invention. In the following, the interior side is the side of the bus door pointing to the vehicle occupant compartment and the exterior side is the side of the bus door pointing to the open air.
As seen in FIGS. 1 and 2, the door lock 1 comprises a lock carrier area 2 which, together with a grip recess 4 , is constructed as a one-piece basic component 6 preferably in the form of an injection-molded blank.
Viewed in an installed position in the bus door (not shown), the grip recess 4 has a preferably oval or rectangular grip recess opening 10 arranged above the lock carrier area 2 and constructed in a plate-shaped screen 8 . Grip recess 4 has a surrounding grip recess wall 12 , which has a rectangular cross-section, projects away from the screen 8 toward the interior side and is spaced laterally with respect to the edge of the grip recess opening 10 , so that a hand can reach behind the grip recess 4 , as illustrated particularly in FIG. 2 . The lock carrier area 2 of the basic component 6 , arranged below the grip recess 4 , comprises an essentially oval section 14 projecting toward the exterior side. The basic component 6 is axially symmetrical with respect to its vertical enter axis 16 and can therefore be used for doors hung on the left as well as for doors hung on the right, as will be explained later. In addition, the basic component 6 is constructed as a standardized carrier element for different door locks.
The oval section 14 of the lock carrier area 2 is provided in its lower area with a passage bore 18 which tapers in a funnel shape toward the interior side and leads into a cylindrical section 20 , as indicated in FIG. 4 . This cylindrical section 20 forms a receiving device for a closing device (not identified) which is constructed as connection elements or an insert 22 and which, at its end pointing to the exterior side, has a square application surface 24 for a square wrench. The other end of the insert 22 pointing to the interior side has a connection element in the form of another square application surface 26 which engages in a coaxial, polygonal passage opening 28 of a nut 30 and, as a result, is non-rotatably connected with the latter. The passage opening 28 of the nut 30 and the cylindrical section 20 in the basic component 6 are constructed such that, instead of an insert 22 with a square application surface 24 , other closing devices can also be inserted into the door lock 1 , as, for example, a closing cylinder of the Type YMOS, BN or PS with a 90 degree or 180 degree angle of rotation.
The bus door (not shown) has a door frame 32 extending around the door circumference in a rectangular manner with a hollow door profile (not identified) illustrated in its cross-section in FIG. 4 . At the hollow door profile, a door glass pane 34 is fastened to a surface pointing toward the exterior side and extends essentially along the entire door height and door width. In this case, the door glass pane 34 preferably completely covers the door frame 32 although such is not necessary.
The basic component 6 of the door lock 1 is not fixed directly to the door frame 32 but to the door glass pane 34 . For this purpose, the door glass pane 34 has, close to the door frame 32 , a receiving device in the form of a vertically extending oblong hole 36 , which is preferably arranged in the area of a blackening 38 of the door glass pane 34 extending around preferably in the area of a direct vicinity of the door frame 32 . At an edge of the oblong hole 36 pointing to the interior side, the basic component 6 is preferably fastened by means of a glued connection 39 , although other types of connections can be used. In this case, a center axis 40 of the oblong hole 36 and the center axis 16 of the basic component 6 are superimposed. In addition, the oblong hole 36 is dimensioned such that a gripping into the grip recess 4 of the basic component 6 is possible from the exterior side. The oval section 14 of the basic component 6 projects as a centering collar through the oblong hole 36 of the door glass pane 34 , a surrounding lip seal 42 , which is arranged between the basic component 6 and the edge of the oblong hole 36 , to provide that splashing water cannot penetrate to the interior side. On its side pointing to the door glass pane 34 , a flat screen 8 of the basic component 6 has a pulled-back groove-like surrounding area 44 for receiving the glue of the glued connection 39 as well as contact points 46 (see FIG. 1 ). The contact points 46 are constructed as short pins to contact the door glass pane 34 , which contact points 46 act as spacers, permitting a gluing of the essentially flat basic component 6 to slightly curved door glass pane 34 .
As illustrated in FIG. 4, a transverse bore 48 is provided in the door frame 32 which is used as a passage opening for a basic latch 50 of a latching mechanism 52 of the door lock 1 . Latch 50 extends transversely to the longitudinal direction of the basic component 6 . The passage opening or bore 48 aligned with the latch 50 permits the latch 50 to engage beyond the door frame 32 in a door portal engaging device, which is not shown, in the closed position of the latch. A latching mechanism carrier (not identified) carrying or supporting the latching mechanism 52 is fixed to the basic component 6 . For this purpose, the latching mechanism carrier preferably has two plates 54 , which are arranged at a parallel distance from one another, are provided with bores 56 and can be fitted onto at least two carrying pins 58 projecting away from the basic component 6 toward the interior side. The two plates 54 , act as a bearing point, with a bore 60 therebetween aligned with the passage opening 28 of the nut 30 to hold the nut 30 rotatably so that rotating movements introduced into the insert 22 by way of the square application surface 24 can be transmitted to the nut 30 .
As illustrated in a right-handed hung door of FIG. 3, the nut 30 has a radially projecting lever 62 which can strike by means of its face onto inclined stop surfaces 64 , 66 of latch holder 68 of the latching mechanism 52 , which latch holder 68 acts upon the latch 50 . According to FIG. 3, the lever 62 of the nut 30 is caused to impact, for example, on the right stop surface 64 by the right-hand rotation of the insert 22 , whereby the assigned latch holder 68 transports the latch 50 toward the right into a moved-in position, in which it can no longer engage with its free end in the door portal engaging device and the door lock 1 is therefore opened. In contrast, by means of a left-hand rotation of the insert 22 , the lever 62 of the nut 30 , by resting against the left stop surface 66 , moves the latch 50 into a moved-out position, in which it locks the door lock 1 . According to the preferred embodiment, the insert 22 is a 90-degree closing device, that is, for an opening or closing operation, the insert 22 must be rotated 90 degrees. However, a 180-degree closing device can also be used, in which case the lever 62 of the nut 30 will then rotate empty after the implemented stop on the stop surfaces 64 , 66 until its angular end position is reached.
For a left-handed pivoting door, the latch 50 extends out the other side of the lock carrier area 2 and the latching mechanism 52 is appropriately reversed.
Alternatively, in some constructions, the lock 1 could be mounted with the grip recess opening 10 located in a reverse position from that shown.
A bolt position indicator 72 , which can be operated by the latch holder 68 by means of a lever mechanism 70 to permit the recognition of the locked or unlocked condition of the door lock 1 from the exterior side. For example, for the unlocked condition, an indicating surface 74 with a green color field and, for the locked condition, an indicating surface 76 with a red color field is transported into a bottom-side recess 78 of the screen 8 arranged in the area of the center axis 16 of the basic component 6 (see FIGS. 1 and 3 ). The bottom-side recess 78 of the screen 8 is situated opposite a gap in the blackening 38 of the door glass pane 34 , so that the surface with color fields 74 , 76 are easily visible from the exterior side. Lever mechanism 70 is operated by the latching mechanism 52 to move surface 76 into the location shown by surface 74 in FIG. 3 when the latch 50 is extended.
The latching mechanism carrier, preferably formed by the two plates 54 , is detachably fastened on the carrying pins 58 of the basic component 6 and can also be fitted onto the carrying pins 58 in the reverse position, in which the latch 50 points in the opposite direction. The door lock 1 can then optionally be mounted for a door hung on the right or for a door hung on the left. The indicating surfaces 74 , 76 are each provided on both sides with a color field so that, also in the case of a reversed latching mechanism 52 , the color fields will be visible in the center recess 78 of the screen 8 . Toward the exterior side, the latching mechanism 52 is covered by the screen 8 and, toward the interior side, it is covered by a covering 86 fastened on the door frame 32 . When the latching mechanism support, including plates, 54 is removed from the basic component 6 , the insert 22 , instead of being inserted from the exterior side, can also be inserted from the interior side into the cylindrical section 20 of the basic component 6 .
Furthermore, as shown in FIG. 4, an opening device 80 , which acts upon the latching mechanism 52 , is provided for unlocking the latched door lock 1 from the inside. Opening device 80 is formed, for example, by a handwheel 82 which, by means of its cylindrical end, is rotatably disposed in the nut 30 and is non-rotatably connected with a disk 84 which acts upon the latch holder 68 of the latching mechanism 52 . By rotating the handwheel 82 , the door lock 1 , which is in the locked position, can therefore be unlocked from the interior side, for example, in the event of emergencies.
Although the present invention has been described and illustrated in detail, it is to be clearly understood that this is done by way of illustration and example only and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims.
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A commercial vehicle, rail or bus vehicle entry door comprising: a grip recess; a door lock; a closing device; a latching mechanism having at least one latch; a lock carrier area; and a latching mechanism carrier; wherein the door lock is held on the door and the closing device acts upon the latching mechanism in order to move the at least one latch of the latching mechanism into a closed or opened position; and wherein the lock carrier area can be fastened on the door and which, together with the grip recess, forms a one-piece basic component on which the latching mechanism carrier carries the latching mechanism in a detachable and reversible manner for the optional mounting of the door lock for a door hung by one of a right side mounting and one of a left side mounting.
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PRIORITY CLAIM
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/391,560 filed Jun. 25, 2002.
FIELD OF THE INVENTION
[0002] This invention relates generally to computer systems and, more specifically, to a computer system for creating user selected customized digital data compilations.
BACKGROUND OF THE INVENTION
[0003] There currently is an “underground” market for customized compact discs (“CDs”) including custom music CDs. These custom CDs are made, for example, by obtaining copies of songs in digital format, by either downloading the desired songs from the Internet or copying or “ripping” the songs onto a personal computing system from borrowed CDs, and then recording or “burning” the songs onto blank CDs using a CD-R drive. Custom music CDs are assembled in minutes, and represent lost revenue to the record companies, since unauthorized copies of property are made that would otherwise be subject to royalties.
SUMMARY OF THE INVENTION
[0004] The system described herein provides for the creation of customized data compilation utilizing a variety of media types (e.g., CD, DVD, DAT, Mini-disc, MPEG 3 Digital file, etc.), with proper royalty payments, and thus facilitates greatly expanding a newly emerging market for customized audio products. These customized data compilations are typically created at distributed locations (such as record stores) using a central database or distributed databases, a local workstation and a high-speed media specific recording device, such as a CD-Recorder, DVD-Recorder, DAT recorder, Mini-disc recorder, etc.
[0005] It should be noted that the audio information is not necessarily constrained to music, and can encompass additional areas suitable for customization, including currently existing markets for personal self-improvement, business lectures, and other forms of audio data marketed to the public. Additionally, still-video or visual text information may also be associated with the music audio data, including textual data on recording artists, still photos of the artists and graphics for custom label or other media production. For other custom audio products, such as customized business lectures, scientific material, and integration of excerpts from books and/or speeches, still-visual data (such as text, graphs, drawings and/or photos) may be included for off-line publication and use while listening to the audio information, or included in a multi-media, integrated media type, such as a CD-ROM, or DVD-ROM playable, for example, on current personal computer systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
[0007] [0007]FIG. 1 is a block diagram of a system for creating user selected customized digital data compilations in accordance with the present invention;
[0008] [0008]FIG. 2 is a block diagram of a representative portion of the Internet;
[0009] [0009]FIG. 3 is a block diagram of an illustrative architecture for a workstation computer system in accordance with the present invention;
[0010] [0010]FIG. 4 is a block diagram of an illustrative architecture for a remote central server utilized to transmit data files to the workstation computer in accordance with the present invention;
[0011] [0011]FIG. 5 is a flow diagram of a routine implemented by the workstation computer for creating a customized data compilation in accordance with the present invention;
[0012] [0012]FIGS. 6A and 6B are a flow diagram of a subroutine implemented by the workstation computer for procuring the selected data files for creating a customized data compilation in accordance with the present invention;
[0013] [0013]FIG. 7 is a flow diagram of a sub routine implemented by the workstation computer for publishing a customized data compilation in accordance with the present invention; and
[0014] [0014]FIG. 8 is a flow diagram of a sub routine implemented by the workstation computer for selecting billing information from the selected data files in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] In accordance with the present invention, an illustrative embodiment of a digital customized system for creating user-selected customized digital data compilations is shown in FIG. 1. Generally described, the system 10 allows a user to select data files, such as audio files, from a plurality of data files stored on a workstation computer 28 located at a point of sale location, such as a record store, for creating customized digital data compilations. The workstation computer 28 is connected via a communications network 20 to a remote server(s) 32 , which stores an additional mass quantity of data files for selection by the user.
[0016] In operation, a user wishing to create a custom compilation selects one or more data files from a list of data files on the workstation computer 28 . The workstation computer 28 obtains the user selected data files by first searching the memory of the workstation computer 28 . If one or more of the user selected data files is not located on the workstation computer 28 , the workstation computer communicates with one or more remote servers 32 to search for the selected data files. If the selected data file is located on the remote server 32 , the remote server 32 transmits a copy of the data file over the communications network 20 to the workstation computer 28 to be added to the user's list of selected data files. Once all of the data files are located and added to the user's list, the data files are published as a customized compilation containing all of the selected data files in any one of a plurality of media types, such as CD, DAT, DVD, miniature disk, flash memory, or memory sticks, by utilizing a corresponding output device. In addition to the selected data files, associated data, such as royalty billing information, may be assembled by either the workstation or the remote server.
[0017] Referring now to FIG. 2, an illustrative operating environment for an embodiment of the present invention will be described. Aspects of the present invention are implemented as an executable software component located on a workstation computer, accessible via the Internet. As is well known to those skilled in the art, the term “Internet” refers to the, collection of networks and routers that use the Transmission Control Protocol/Internet Protocol (“TCP/IP”) to communicate with one another. A representative section of the Internet 20 is shown in FIG. 2, in which a plurality of local area networks (“LANs”) 24 and a wide area network (“WAN”) 26 are interconnected by routers 22 . The routers 22 are special purpose computers used to interface one LAN or WAN to another. Communication links within the LANs may be twisted wire pair, or coaxial cable, while communication links between networks may utilize 56 Kbps analog telephone lines, 1 Mbps digital T-1 lines, 45 Mbps T-3 lines or other communications links known to those skilled in the art. Furthermore, a consumer computer 28 and other related electronic devices can be remotely connected to either the LANs 24 or the WAN 26 via a modem and temporary telephone or wireless link. It will be appreciated that the Internet 20 comprises a vast number of such interconnected networks, computers, and routers and that only a small, representative section of the Internet 20 is shown in FIG. 2.
[0018] A consumer or other remote user may retrieve hypertext documents from the World Wide Web (“WWW”) via a WWW application, which can include WWW browser application programs. A WWW browser, such as Netscape's NAVIGATOR® or Microsoft's Internet Explorer, is a software application program for providing a graphical user interface to the WWW. Upon request from the user via the WWW browser, the WWW browser accesses and retrieves the desired hypertext document from the appropriate WWW server using the URL for the document and a protocol known as HyperText Transfer Protocol (“HTTP”). HTTP is a higher-level protocol than TCP/IP and is designed specifically for the requirements of the WWW. It is used on top of TCP/IP to transfer hypertext documents between servers and clients. The WWW browser may also retrieve application programs from the WWW server, such as JAVA applets, for execution on the consumer computer 28 . Further, a WWW browser may retrieve data files using other protocols known in the art, such as File Transfer Protocol (“FTP”). While the present invention as been described herein utilizes the Internet as one type of communications network, a private network suitably configured as known in the art may be used, if desired.
[0019] Referring back to FIG. 1, an actual embodiment of the present invention will now be described. A workstation computer 28 is connected to the Internet 20 through a modem, private network, virtual network, or other type of connection. Once connected to the Internet 20 , a user of the workstation computer 28 may utilize a WWW browser to retrieve data files from WWW sites, such as a WWW site provided by the remote server 32 . As is known to those skilled in the art, the workstation computer 28 may comprise, for example, a workstation, a computer kiosk, or a general purpose computer, all capable of executing a WWW application or WWW browser. The computer 28 may also comprise another type of computing device such as a palm-top computer, a cell phone, personal digital assistant, and the like. Computer 28 is described in greater detail below with respect to FIG. 3.
[0020] Turning now to FIG. 3, an illustrative architecture for the workstation computer 28 will now be described. The workstation computer 28 includes many more components than those shown in FIG. 3. However, it is not necessary that all of these generally conventional components be shown in order to disclose an illustrative embodiment for practicing the present invention.
[0021] As shown in FIG. 3, the workstation computer 28 includes a network interface 44 for connecting directly to a LAN or a WAN, or for connecting remotely to a LAN or WAN. Those of ordinary skill in the art will appreciate that the network interface 44 includes the necessary circuitry for such a connection, and is also constructed for use with the TCP/IP protocol, the particular network configuration of the LAN or WAN it is connecting to, and a particular type of coupling medium. The workstation computer 28 may also be equipped with a modem 48 for connecting to the Internet through a point to point protocol (“PPP”) connection or a SLIP connection as known to those skilled in the art.
[0022] The workstation computer 28 also includes a processing unit 46 , a display 50 , and a memory 52 . The memory 52 generally comprises a random access memory (“RAM”), a read-only memory (“ROM”) and a permanent mass storage device, such as a disk drive, optical drive, or the like. The memory 52 stores an operating system 56 for controlling the operation of the workstation computer 28 . In one actual embodiment of the invention, the operating system 56 provides a graphical operating environment, such as Microsoft Corporation's WINDOWS® graphical operating system in which activated application programs are represented as one or more graphical application windows with a display visible to the user.
[0023] The memory 52 also includes a WWW browser 54 , such as Netscape's NAVIGATOR® or Microsoft's Internet Explorer browser, or other WWW applications for accessing the WWW. It will be appreciated that these components may be stored on a computer-readable medium and loaded into the memory 52 of the workstation computer 28 using a drive mechanism associated with the computer-readable medium, such as a floppy, CD-ROM or DVD-ROM drive. The memory 52 may also include a data compilation creation application 60 . As will be described in greater detail below, the data compilation creation application 60 is capable of creating a published compilation of user selected digital data files. Further, the memory 52 may include data resource files 62 , preferably contained in a searchable database. Optionally, an external database 64 may be connected to the memory 52 and accessible by the processing unit 46 .
[0024] The memory 52 , network interface 44 , display 50 , and modem 48 are all connected to the processing unit 46 via one or more buses. Workstation computer 28 may also include various input devices 66 such as pointing devices, keyboards, or light pens, which are connected to the processing unit 46 via one or more buses. As would be generally understood, other peripherals may also be connected to the processing unit in a similar manner. The workstation computer 28 further includes output or publishing devices 68 , for example, CD-R drives, DVD-R drives, miniature disk drives, and printers, which are also connected to the processing unit 46 via one or more buses. Other output devices 62 of the workstation computer 28 may include interface devices, such as USB ports, or devices such as drive mechanisms for transferring the selected data files onto a storage medium, such as flash memory, memory sticks, and the like.
[0025] Additionally, it will be appreciated that the workstation computer 28 may include the necessary components (not shown) to provide wireless data transmission over any known protocol, such as 802.11, Bluetooth, infra-red, to name a few, to a wireless digital device, such as a palm-top computer, a cell phone, personal digital assistant, and the like. It will be appreciated that the data may be transmitted in any known uncompressed format or compressed format, such as MPEG 3.
[0026] As mentioned briefly above, a remote central server computer 32 is also connected to the Internet 20 . The central server 32 comprises a general purpose server computer and is described in more detail below with reference to FIG. 4. The central server 32 stores additional data files 62 , such as audio, video, text, and graphic files, and receives requests for such data files 62 from the workstation computer 28 . The data files 62 may be cataloged in a database, as will be described below, by searchable fields, such as title, artist, publisher (e.g. Sony®, Capital®, Arista®, etc.). Additionally, each data file 62 may be associated with other data, which may include, for example, billing information for the payment of royalties, graphic or photographic files, and text files (e.g. lyrics, biographical data).
[0027] Referring now to FIG. 4, an illustrative architecture for a remote central server 32 utilized to provide data files 62 to the workstation computer 28 will be described. The server 32 includes many more components than those shown in FIG. 4. However, it is not necessary that all of these generally conventional components be shown in order to disclose an illustrative embodiment for practicing the present invention. Moreover, although the computer system described in FIG. 4 is described as a server, the function of the server may be implemented by computer systems not generally classified as server-type computer systems. Further, although only one remote central server 32 is depicted in FIG. 1, the central server may be a distributed server that may utilize other servers 32 located elsewhere on the Internet 20 to serve data files 62 to the workstation computer 28 .
[0028] As shown in FIG. 4, the server 32 includes a network interface 72 for connecting directly to a LAN or a WAN, or for connecting remotely to a LAN or WAN. The network interface 72 includes the necessary circuitry for such a connection, and is also constructed for use with the TCP/IP protocol, the particular network configuration of the LAN or WAN it is connecting to, and a particular type of coupling medium.
[0029] The server 32 also includes a processing unit 74 , a display 76 , and a mass memory 80 . The mass memory 80 generally comprises a RAM, a ROM and a permanent mass storage device, such as a hard disk drive, tape drive, optical drive, floppy disk drive, or combination thereof. The memory 80 stores an operating system 82 for controlling the operation of the central server 32 . The operating system component 82 may comprise a general-purpose server operating system as is known to those of ordinary skill in the art, such as UNIX, LINUX™, or Microsoft WINDOWS NT®.
[0030] The memory 80 includes one or more date files 62 which are to be provided in response to requests from the workstation computer. The data files 62 are preferably contained in a database in memory 80 . Optionally, the data files 62 may be retrieved from an external database 84 . The memory 80 also includes server application 100 operable to receive such requests from the workstation computer and transmit the selected data files to the workstation computer. These components may be stored on a computer-readable medium and loaded into memory 80 of the server 32 using a drive mechanism associated with the computer-readable medium, such as a floppy, CD-ROM or DVD-ROM drive. The memory 80 , network interface 72 , and display 76 are all connected to the processing unit 74 via one or more buses. Other peripherals may also be connected to the processing unit in a similar manner.
[0031] Referring now to FIG. 5, an illustrative routine 500 of the data compilation creation application 60 for creating user customized digital data compilations will now be described. The routine 500 begins at block 502 , and proceeds to block 504 , where the user operating the workstation is prompted to select one or more data files 62 for creating the user's customized compilation. For example, the user may wish to select songs for a music compilation representing their favorite songs for a specific decade. After the user selects one or more data files 62 at block 504 , the routine proceeds to block 506 , where the workstation computer 28 executes a routine for obtaining the selected data files 62 for creating the custom compilation. As will be described in more detail below with respect to FIG. 6, the procurement routine retrieves the selected data files 62 from the memory 52 of the workstation, or transmits a request for the data files 62 to the central server 32 .
[0032] Once a copy of the data files 62 are obtained at block 506 , the routine proceeds to block 508 , where the copy of each data files 62 is added to a compilation list representative of the custom compilation to be created. Then, at block 510 , a test is run to determine if the compilation list is complete. If the compilation list is not complete, the routine 500 returns to block 504 , where the user may select another data files 62 . If the compilation list is complete, the routine proceeds to block 512 , where a publication routine is executed. As will be described in more detail below with reference to FIG. 7, the publication routine allows the user to select what media type the compilation will be published on, formats the selected data files 62 for publication, and sends the data files 62 to the selected output device 68 for publication. After the compilation has been published, for example, written to a Compact Disk (CD) with a Compact Disc Recorder drive mechanism, the routine ends at block 514 .
[0033] As briefly described above with respect to FIG. 5, FIGS. 6A and 6B depicts the execution of an illustrative procurement routine 600 in greater detail. The routine 600 begins at block 602 , and proceeds to block 604 , where the memory 52 of the workstation computer 28 is searched first for the one or more selected data files 62 . At block 606 , a determination is made as to whether the selected data files 62 are located locally in the memory 52 of the workstation computer 28 . If the selected data files 62 are located locally on the memory 52 of the workstation computer 28 , the routine 600 proceeds to block 608 where the routine 600 retrieves a copy of the selected data files 62 from the memory 52 . Once a copy of the selected data files 62 has been retrieved at block 608 , the routine 600 ends at block 610 .
[0034] If the selected data files 62 has not been located locally in the memory 52 of the workstation computer 28 , the routine 600 proceeds to block 612 , where a search is conducted of the remote server 32 for the, selected data files 62 . The routine 600 continues to block 614 , where a determination is made as to whether the selected data files are located in the memory 80 of the remote server 28 . If so, the routine 600 retrieves a copy of the selected data files 62 from the memory 80 or database 84 of the remote server 32 at block 616 , and transmits the copy of the data files 62 to the workstation computer 28 at block 618 . After the copy of the selected data files 62 has been transmitted to the workstation computer 28 , the routine 600 ends at block 620 . If, however, the selected one or more data files 62 are not located on the remote server 32 , the routine 600 proceeds to block 622 , where the user receives an error message that the selected data files 62 are unavailable. The routine 600 then proceeds to add the unavailable data file(s) to a remote list for further procurement at block 624 , and ends at block 626 .
[0035] As described briefly above with respect to FIG. 5, FIG. 7 depicts the execution of an illustrative publishing routine 700 in greater detail. The routine 700 begins at block 702 and proceeds to block 704 , where the user is prompted to select the type of media for the published compilation. For example, the user is prompted to select media types, such as a compact disc (CD), digital audiotape (DAT), flash memory, or the like. After the user is prompted to select the type of media at block 704 , the routine 700 proceeds to block 706 , where the user is prompted to select the format type for the compilation. For example, the user may be prompted to select any known compressed or uncompressed data format known in the art. The routine 700 then proceeds to format the selected data files of the type selected at block 708 for publication. Optionally, the routine 700 may proceed to block 710 , where a billing routine is executed. As will be described in more detail below with respect to FIG. 8, the billing routine collects royalty data from the data files for future payment to the necessary parties.
[0036] The routine 700 then proceeds to block 712 , where the selected data files 62 are published for example, by writing the selected data files to the selected media type (e.g. CD, DAT, etc.) by the corresponding output device 68 , thereby creating a custom compilation of user selected data files for later use. After the user selected data files 62 are published at block 712 , routine 700 ends at block 714 . It will be appreciated by those skilled in the art that routine 700 may include other steps, if desired. For example, routine 700 may prompt the user as to whether the user would like a case for the selected media type, or a printed label or other printed text or graphic information associated with the selected data files.
[0037] As briefly described above with respect to FIG. 7, FIG. 8 depicts the execution of an illustrative billing routine 600 in greater detail. The routine 800 begins at block 802 , and proceeds to block 804 , where billing information is obtained from the user selected data files 62 . As was described in detail above, specific billing information is associated with each data file for the correct payment of royalties. After the billing information is obtained, the routine proceeds to block 806 , where the billing information is transmitted to the central server 32 . It will be appreciated that the server application 100 may be configured to contain a program module for the collection and storage of billing information. Optionally, the billing information may be collected locally at the workstation computer 28 by a program module located in the memory of the workstation computer 28 . After the billing information is received by either the local or remote server, the routine proceeds to block 808 , where the customer is billed based on the billing information obtained from the user selected data files 62 . Once the customer (or user) is billed, the routine ends at block 810 .
[0038] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment.
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The present invention provides for the creation of customized data compilation utilizing a variety of media types and with proper royalty payments. These customized data compilations are created at distributed locations using central database or distributed databases, a local workstation, and a high-speed media specific recording device.
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FIELD OF THE INVENTION
The present invention relates to an apparatus for use in connecting a fluid conduit carried by an ROV (Romotely Operated Vehicle) to a fluid conduit or receptacle of a subsea equipment assembly, such as hydraulically operated device, in a nonbinding manner.
BACKGROUND OF THE INVENTION
As offshore drilling operations progress into deeper waters, especially in depths of water greater than 1000 feet, many relatively simple suface operation become complex and costly. One frequent operational requirements is that of engaging a hydraulic stab sub receptacle with a probe for the propose of applying hydraulic flow and pressure to operate a function. The function can be a valve, blowout preventer, test port, or other such items.
Systems which provide guidelines or wire ropes from the surface vessel to the ocean flooor equipment provide a predetermined path to the equipment which can be easily followed by service systems and can be keyed off of to locate the appropriate receptacle.
In operations conducted with dynamically positioned vessels, there are no typically guidelines to direct equipment and service systems to the ocean floor. Dynamically positioned vessels are those which are held in place by the power of their propellers rather than by anchors. In this case, finding the general location of the equipment and keying into a specific area for service operations such as hydraualic stabs is typically done by an ROV. An ROV is a remotely operated vehicle which is small unmanned submarine equipped with sonar and television systems.
The hydraulic stab receptacles are characteristically designed to contain relatively high pressures such as 3000, 5000 or 10,000 p.s.i. The close fit fit between the bore of the hydraulic stab receptacles and the outer diameter of the hydraulic stabs required to prevent the extrusion of the seals provides the conventional disadvantage of requiring a close angular alignment to allow this installation. It is generally estimated that a stab needs to make an engagement to a depth equal to the diameter of the stab to prevent binding. For a typical 1.375" outer diameter stab and a 0.010" diametrical tolerance, this mens that the stab must be aligned with the receptacle within less than 1/2 degree.
This degree of alignment is difficult to control on devices which are guided down guidelines to fixed positions before attempting to make the stab. When a free swimming vehicle such as an ROV attempts to make the engagement the problems are even more difficult. The stab and receptacle are viewed with one or more televisions cameras on the ROV. An operator at the surface must watch the television screens and make the engagement with remote manipulator arms or vehicle movement. The ROV is typically moving and the cameras' fisheye lenses distort the view of the parts.
The task can be accomplished in this fashion. It may take a long time, but the stab can eventually be worked into the receptacle. On a recent installation in the Gulf of Mexico, an ROV service company attached a piece of relatively stiff wire rope to a hydraulic stab receptacle and the flexibility assisted in the stabbing process. Making the devices oversized enough to allow for a stepped engagement will assist in eliminating the binding at the expense of size on each of the receptacles. U.S. Pat. No. 4,682,913 gives an illustration of this style design.
In shallower waters where divers are required engage hydraulic stab subs into receptacles, the close alignment is still a problem, but to a lesser degree. The diver is capable of wiggling the stab into alignment by hand much more readily than can be done by remote operations.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a hydraulic stab sub which is capable of being inserted into a receptacle at angles greater than those associated with conventional high pressure components by providing for radial relative movement of sealing rings and seal holding rings with reference to the centerline of the hydraulic stab sub.
By having the various outer diameters and seal rings on the hydraulic stab receptacle capable of moving radially about the centerline of the hydraulic stab sub, simple angular misalignment can be achieved before, during, and after the engagement process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of an underwater vehicle positioned adjacent to a subsea equipment assembly.
FIG. 2 is a half section of a hydraulic stab sub and receptacle of this invention which has the centerline of the hydraulic stab sub and the centerline of the receptacle in alignment.
FIG. 3 is a half section of a hydraulic stab sub and receptacle of this invention which has the centerline of the hydraulic stab sub and the centerline of the receptacle at an angle with respect to each other.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a vessel 10 is shown floating upon the surface 11 of the body of water 12. A riser assembly 13 extends downwardly from the vessel 10 towards the bottom 14 of the body of water 12. The lower elements of the riser assembly 13 consist, in this example, of a subsea wellhead assembly 20 typically positioned on or near the bottom 14 of the body of water 12. Extending downwardly into the earth formation for drilling and completion operations is housing assembly 21 which suspends one or more strings of casing and is landed on landing base 22.
It is recognized that the term subsea wellhead assembly is meant to include any assemblage of components either fixedly or removably secured to the top the housing assembly 21, either during the drilling, completion, production, reworking, or maintenance of a well. Thus, during the drilling of a well, the subsea wellhead assembly may comprise certain components such as blowout preventers, valves, connectors, etc.
The subsea wellhead assembly 20 comprises various components such as a hydraulically operated connector 23 and hydraulically actuated valves 24 and 25 which are actuated by valve actuators 26 and 27 respectively. The operator 28 for the connector 23 is made typically made integally with connector.
Receptacles 30, 31, and 32 aare provided for receiving hydraulic flow and pressure to operate connector 21 and valves 24 and 25 respectively. Receptacles 31 and 32 are connected to valves 24 and 25 thru shuttle valves 33 and 34. Shuttle valves 33 and 34 are further connected to a control means 35 thru hoses 36 and 37. Control means 35 is connected by control hoses 38 to the surface. Normal control of these functions is thru the control means 35 from the surface. When required, secondary or emergency control can be achieved by pressuring thru the receptacles. The shuttle valves 33 and 34 prevent the signal from one port to communicate with the opposite port, as is well known in the industry.
Receptacle 30 is connected to the hydraulically operated connector 21 by hose 39 and is not operated redundantly from the surface. The only means of operating this connector is thru the receptacle.
ROV 40 is shown with a manipulator arm 41, a hydraulic stab sub 42, hose 43 which receives hydraulic and/or electric power from the surface to operate the ROV, and hose 44 which receives hydraulic power from the surface for the hydraulic stab sub 42.
On the vessel 10 at the surface the hose 43 connects to reel 45 and the hose 44 connects to the reel 46. Both reel 45 and reel 46 are shown connected to the hydraulic accumulator skid 47.
The ROV 40 is capable of vertical or horizontal movement and is capable of positioning itself near any of the receptacles 30, 31, or 32 at the conmmands of the operator at the surface.
Referring now to FIG. 2, receptacle 50 is shown to have smooth bores 51 and 52 which are of close tolerance manufacture, typically with a tolerance range of from 0.003" to 0.005". Chamfer 53 provides for the smooth entrance of the seals into the bore 51 and provides some lateral guidance for entrance into the hole. Threaded port 54 provides for the connection of and outlet hose, such as hose 39 of FIG. 1. An enlarged portion of the bore 55 provides a clearance for seals to pass along the bore without being damaged on the inner end of the threaded port 54.
The hydraulic stab sub 60 comprises body 61, seals 62, 63 and 64, nose 65, seal carrier 66, sliding ring 67, and sliding spacer 68.
The body 61 provides threaded port 70 for connection of a hose such as hose 44 in FIG. 1. Body 61 further provides gripping profile 71, close tolerance diameter 72, O-Ring seal diameter 73, dlow passages 74, 75, and 76, male thread 77, and stop surface 78. Close tolerance diameter 72 provides a relatively close fit with respect to diameter 51, yet with a sufficiently short axial length as to not prevent angular misalignment of the receptacle 50 with the hydraulic stab sub 60. On a standard 1.375" diameter receptacle, with a minimum diametrical clearance of 0.010"an maximum axial length of 0.165" will provide this capability.
Nose 65 provides female thread 80, a stop surface 81 for engaging stop surface 78 when female thread 80 is engaged onto male thread 77, a seal groove 82 for receiving seal 64, and an outer tapered diameter 83. I FIG. 3, if a line is drawn from the close tolerance diameter 72 at 3 degrees from the centerline of the hydraulic stab sub 60, it will coincide with the outer tapered diameter 83 of the nose 65.
When the nose 65 is installled on the body 61, a distance is provided between the face 84 on the nose 64 and the face 85 on the body 61. The combined axial length of the seal carrier 66, the sliding ring 67, and the sliding spacer 68 is slightly less that the length provided between the faces 84 and 85.
When assembled, it allows the seal carrier 66, the sliding ring 67, and the sliding spacer 68 to move radially about the centerline of the body 61. The seal carrier 66, the sliding ring 67, and the sliding spacer 68 each have a close tolerance diameter similar to 72 and can tolerate angular misalignment.
In this way, when the hydraulic stab sub 60 is moved to a position of angular mismatch with respect to the receptacle 50, the seal carrier 66, the sliding ring 67, and the sliding spacer 68 can slide against each other like a stack of washers to accommodate the angular mismatch.
The angular mismatch of the body 61 and the seal carrier 66 provide a radial mismatch in the position the inner sealing diameters for the seal rings 62 and 63. On a 1.375" outer diameter hydraulic stab sub at 3 degrees angular mismatch, the center of the seal groove is offset approximately 0.0038"which is considerably less than the nominal seal squeeze of 0.013", and is not detrimental to the sealing charcteristics.
Referring now to FIG. 3, hydraulic stab sub 60 is at a mismatch angle 90 with respect to receptacle 50. In this case, this is the maximum mismatch angle possible as the outer taper diameter 83 of nose 65 is contacting athe bore 52 of receptacle 50. The seal carrier 66, the sliding ring 67, and the sliding spacer 68 are each offset from the centerline of 91 of hydraulic stab sub 60, and are in fact generally aligned with centerline 92 of the receptacle 50. Each of the seals 62, 63, and 64 are in sealing position and fluid flow can be pass thru the assembly generally as is indicated by the arrow 94.
Further, as the hydraulic stab sub 60 is presently positioned with it connecting end 95 in a down position, it can be equally well moved to an up, left, right, or centered position. This complete universal movement capability within the maximum angle 90 can be done with or without pressure and or flow passing along the line as indicated by the arrow 94.
Further, the hydraulic stab sub 60 can be removed and installed while being held at any angle and at any direction up to the maximum angle 90.
An obvious reversal of parts on this invention is to fix the seal 63 with respect to the centerline of the body 61 and allow the seal 62 to have the radial movement presently illustrated in the figures. An additional application of this invention would be to allow both seal, 62 and 63 to have radial movement freedom to increase the amount of angular mismatch which can be tolerated.
The foregoing disclosure and description of this invention are illustrative and explanatory thereof, and various changes in the size, shape, and materials, as well as the details of the illustrated construction may be made without departing from the spirit of the invention.
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A hydraulic stab sub especially for use in remote and harsh environments which is capable of being inserted into a close fitting receptacle at a relatively high angular mismatch by providing for radial relative movement of sealing rings and seal holding rings with reference to the centerline of the hydraulic stab sub.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods and apparatus for assembling articles such as trouser-fly units.
2. DESCRIPTION OF THE PRIOR ART
The prior art, as exemplified in U.S. Pat. Nos. 2,697,227, 2,731,643, 3,263,238, 3,570,104, and 3,765,348 contains a number of apparatus and methods for producing trouser-fly units. In one method and apparatus as illustrated in the above mentioned U.S. Pat. Nos. 2,731,643 and 3,263,238 continuous strips of trouser-fly material are sewn to the tapes of continuous slide fastener chains and are surged; this method requires the added expense of a continuous length of fly material whereas it is more economical to use fly pieces cut from short lengths of scrap material. In the above mentioned U.S. Pat. Nos. 2,697,227, 3,570,104 and 3,765,348 individual fly pieces are sewn to a continuous slide fastener chain; however, these methods and apparatus cannot be used upon fly pieces which have a curved edge which is to be surged.
There are a number of prior art sewing machines such as that described in U.S. Pat. No. 2,973,732, which contain both an overedge stitching mechanism and a straight line stitching mechanism for simultaneously surging the edge of an article and sewing a line of stitches on an article; some of such prior art sewing machines having been employed in simultaneous surging of an edge of a fly piece and sewing the fly piece to a continuous slide fastener chain.
SUMMARY OF THE INVENTION
The invention is summarized in a method of simultaneously sewing two separate lines of stitches on an article with variable spacing between the lines of stitches including the steps of advancing the article through a sewing machine having two sewing mechanisms which are spaced apart transversely relative to the direction of advancement of the article to produce two separate lines of stitches on the article, and selectively puckering the article between the two sewing mechanisms so as to vary the spacing between the two lines of stitches on the article.
An object of the present invention is to provide a method and apparatus for producing garment units, such as trouser-fly units of the type used in dungarees, blue jeans, work pants, overalls, etc., with increased speed and efficiency.
Another object of the invention is to provide for the simultaneous surging of a curved edge of a trouser-fly piece and the sewing of the trouser-fly piece to a continuous slide fastener chain.
It is still another object of the invention to provide for aiding an operator in feeding fly pieces to a sewing machine.
One advantage of the invention is that selective puckering of an article, such as a trouser fly piece, between two stitching mechanisms, such as a straight line stitching mechanism and a surging mechanism, permits selective variation of the spacing between the two lines of stitching being formed simultaneously on the article.
In another feature of the invention, the trailing edge of a preceding fly piece is lifted so that the leading edge of the succeeding fly piece may be positioned for feeding into the sewing machine without waiting for the trailing edge of the preceding fly piece to move past the positioning point.
Other objects, advantages and features of the invention will be apparent from the following description of the preferred embodiment taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a trouser-fly unit manufactured in accordance with the present invention.
FIG. 2 is a side elevational view of an apparatus for manufacturing a train of the trouser-fly units of FIG. 1 in accordance with the invention.
FIG. 3 is a plan view of a train of the units of FIG. 1 illustrating several steps of the manufacture.
FIG. 4 is an enlarged side elevational view, partially in cross section, of a portion of the apparatus of FIG. 2.
FIG. 5 is a plan view of the apparatus portion of FIG. 4.
FIG. 6 is a cross-sectional view taken at line 6--6 of FIG. 5.
FIG. 7 is a view similar to FIG. 6 but at later step in the assembly of a trouser-fly unit.
FIG. 8 is a cross-sectional view taken at line 8--8 in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIG. 1, a trouser-fly unit manufactured in accordance with the invention includes an elongated fly piece 10 having a straight side edge 11 and a curved edge 12 which is surged by a line of overedge stitches 14, and includes a slide fastener chain indicated generally at 16 which is sewn to the fly piece 10 by a pair of straight lines of stitches 18 and 20. The slide fastener chain 16 includes a pair of tapes 22 and 24 with respective rows of interengaging fastening elements 26 and 28 mounted on the inner edges thereof. The elements 26 and 28 are removed at both the top and bottom ends of the slide fastener chain 16 to form gaps 30 and 32 between the tapes 22 and 24. A bottom stop such as a conventional staple 34 is applied to one end of the rows of interengaging fastening elements 26 and 28 to secure the opposite tapes 22 and 24 or halves of the slide fastening chain together at that point.
An apparatus for manufacturing a plurality of the trouser-fly units of FIG. 1 is shown in FIG. 2 and includes a sewing machine 40; a gapper, bottom stop applier and cutter 42; and a stacker 44; all mounted on a suitable support such as a table top 46. The sewing machine 40 is a conventional sewing machine, except for a modified presser foot 48 as described herein, which includes at least two spaced sewing mechanisms, one including the needle 45, FIG. 6, and trimmer 77, FIG. 5, for forming the line of overedge stitches 14 and the other including the needles 41 and 43 for forming the lines of straight stitches 18 and 20. Alternately the sewing machine 40 can have a stitching mechanism with only one needle for forming a single line of straight stitches in place of the double line of stitches 18 and 20. The gapper, bottom stop applier and cutter 42 is a conventional apparatus or assembly of apparatus for forming the gaps 30 and 32, applying the bottom stops 34 and severing the continuous chain 16 between the fly pieces 10. The stacker 44 is a conventional mechanism for forming stacks of the fly units; alternately a receptacle or bin may be provided in place of the stacker 44 to receive a plurality of the trouser-fly units. Feed wheels 50, 52, and 54 are provided at the output of the sewing machine 40, at the input of the gapper, bottom stop applier and cutter 42, and between the gapper, bottom stop applier and cutter 42 and the stacker 44, respectively, for advancing the train of the trouser-fly units.
As shown in FIGS. 5 and 8, a pair of elongated parallel members 56 and 58 are mounted on the support 46 forming a pathway leading to the sewing mechanisms of the sewing machine 40, the member 56 being mounted stationary while the member 58 is mounted for sliding movement perpendicular to the pathway between the members 56 and 58 for the fly pieces 10. The members 56 and 58 have upper inward extending flanges 60 and 62 for cooperating with the table top 46 to form channels 64 and 66 for receiving the respective opposite edges 11 and 12 of the fly piece 10. Means such as a cam 68 is provided for moving the guide member 58 in synchronism with the operation of the sewing machine 40. Also a pucker assist bar 70 parallel and between the guide members 56 and 58 is mounted in the table top 46 for vertical movement into the pathway between the members 56 and 58; suitable moving means 72 operated in synchronism with the cam 68 is connected to the pucker assist bar 70.
The presser foot 48 has a slide fastener portion 74, see FIGS. 5, 6, and 7, and an overedge portion 76 which are spaced leaving a gap or channel 78 therebetween for receiving a longitudinal pucker or fold 80 in the fly piece 10. The slide fastener portion 74 is provided with conventional means, such as a loop and a fastener element channel in the sole thereof, for guiding the slide fastener chain while the overedge portion 76 is formed in a conventional manner to permit operation of the overedge stitching mechanism.
The moving means 68 and 72 for the respective member 58 and bar 70 are designed to move the member 58 and to raise bar 70 gradually and continuously in correspondence with the movement of the curved portion of the fly piece 10 to the sewing machine 40 such that the pucker 80 is gradually formed during this portion of movement of the flypiece 10 to maintain a predetermined spacing between the edge 12 and the slide fastener chain 16 as they pass through the stitching mechanisms of the sewing machine. The moving means 68 and 72 are designed to retract the member 58 and lower the bar 70 after the pucker 80 is formed.
A pair of sensors 82 and 84, as illustrated in FIGS. 2, 4 and 5, are mounted in the table top 46 beneath the path of the edge 11 of the fly piece 10 emerging from the guide member 56 and passing beneath the presser foot 48. The sensors 82 and 84 are positive air flow sensors, photoelectric cells, or any other suitable device for sensing the presence of the fly piece 10 and the end thereof. The sensor 82 is positioned before the sensor 84 in the path of the fly pieces 10. A stop 86 is movably mounted on the table top 46 for movement perpendicular to the path of the fly piece 10 between the presser foot 48 and the exit end of the guide members 56 and 58. The stop 86 is connected to a suitable moving mechanism 88 for advancing and retracting the stop 86 into and out of the path of the movement of the fly pieces 10. A vertical air jet tube 90 is provided beneath the path of the fly pieces 10 between the exit from the guide members 56 and 58 and the front of the presser foot 48, while a horizontal air jet tube 92 is positioned above the table top 46 and directed toward the presser foot 48 from the side of the pathway of the fly piece 10 between the presser foot 48 and the guide members 56 and 58. The sensors 82 and 84 are operatively connected to the air jets 90 and 92 and the stop moving means 88. Also the sensor 84 is operatively connected to the sewing machine 40.
In operation of the trouser fly unit making apparatus, as shown in FIGS. 2 and 3, the fly pieces 10 are fed to the sewing machine 40 with the continuous slide fastener chain 16 being superimposed thereon. The sewing machine 40 forms an overedge stitch 14 on the curved edge 12, FIG. 1, of the fly piece 10 and simultaneously sews the straight lines of stitches 18 and 20 securing the tap 22 of the slide fastener chain 16 to the fly piece 10. From the sewing machine 40 the train of fly piece units are advanced to the gapper, bottom stopper applier and cutter 42 where the gaps 30 and 32 are cut, the bottom stops 34 are applied, and the chain 16 is cut between the fly pieces 10 to form individual units. Subsequently the individual fly units are fed to the stacker 44 where they are stacked for subsequent use in the manufacture of garments.
Referring to FIGS. 4, 5, 6, 7 and 8, the fly pieces 10 are fed between the guide members 56 and 58 with the edges 11 and 12 of the fly piece 10 received in the respective channels 64 and 66 beneath the flanges 60 and 62 of the members 58 and 60. Initially the guide member 58 is in a retracted position, as shown in FIG. 5 to advance the narrow end of the fly piece 10 beneath the presser foot 48. As the fly piece 10 is advanced, the cam 68 rotates gradually through 180° to move the guide member 58 toward the other guide member 58 to push the edge 12 toward the edge 11 of the fly piece 10, and the pucker assist bar 70 is gradually raised by the raising means 72 to lift an intermediate portion of the piece 10 to form a longitudinal pucker or fold 80 in the fly piece 10. This pucker 80 is formed so as to maintain a predetermined spacing between the edges 11 and 12 of the piece 10 or between the edge 12 and the slide fastener chain 16 as they pass beneath the presser foot 48. The pucker 80 is received in the channel 78 in the presser foot 48 to thus allow the overedge line of stitches 14 to be formed on the curved edge 12 without changing the spacing between the overedge stitching mechanism and the straight line stitching mechanism of the sewing machine 40. Subsequently the cam 68 rotates through another 180° to retract the guide member 58 and the means 72 lowers the pucker assist bar 70.
After the trailing edge of a fly piece 10 has passed the sensor 82, the air jet 90 is activated for a short duration to raise the trailing end of the fly piece 10, as shown in phantom FIG. 4, and then the horizontal air jet 92 is activated to maintain the end of the fly piece raised. The stop advancing mechanism 88 is activated to move the top 86 into the path of the next fly piece 10 beneath the trailing end of the fly piece 10 being sewn and between the presser foot 48 and the guide members 56 and 58. This permits the operator to position the next fly piece 10 before the sewing of the preceding fly piece has been completed. The sensor 84 senses the passing of the end of the first fly piece to stop the sewing machine 40 and to operate the stop moving means 88 to retract the stop 86 as well as to deactivate the air jets 90 and 92 so that the operator may then advance the leading end of the next fly piece 10 beneath the presser foot 48. Another cycle of operation of the sewing mechanism can then be initiated in a conventional manner.
Since the present invention is subject to many modifications, variations and changes in detail, it is intended that all matter in the foregoing description or in the drawings be interpreted as illustrative and not in a limiting sense.
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Trouser-fly pieces are sewn to a continuous slide fastener chain and at the same time are surged along a curved edge. Variable spacing between the surged curved edge and the line or lines of stitches sewing the fly pieces to the fastener chain is made by selective puckering of each fly piece between two sewing mechanisms. The trailing end of each fly piece is lifted during the sewing to permit the positioning of the next fly piece against a stop.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a linear motion rolling guide unit providing guide operation by rolling rollers on four raceway faces formed in a track-rail having raceway face.
[0003] 2. Description of the Related Art
[0004] One of the conventional linear motion rolling units of the type described above is illustrated in FIGS. 13 to 19 . The conventional unit has a pair of raceway faces formed on each side face of a track-rail R, that is, the lower raceway faces 1 a, 2 a and the upper raceway faces 1 b, 2 b. The lower and upper raceway faces 1 a and 1 b, 2 a and 2 b, are positioned forming an approximate right angle with each other. A recessed portion 3 is formed between the lower race way face 1 a and the upper race way face 1 b. Likewise, a recessed portion 4 is formed between the lower raceway face 2 a and the upper raceway face 2 b.
[0005] A slider S runs on the track rail R having such raceway faces. The slider S includes end caps 5 and 6 respectively combined with the front and back ends of a casing c. The casing c and the end caps 5 and 6 straddle the track-rail R having the raceway faces, tomove along the track-rail R. The slider S is bilaterally symmetrical with respect to the axis the track-rail R having the raceway faces. Therefore, the structural elements in bilateral symmetry will be hereinafter described by use of the same reference numerals or symbols. The description is given relating only to the raceway faces 1 a and 1 b as a representative example.
[0006] A pair of guide holes 7 and 8 is located in the casing c to extend flush with and parallel to the raceway faces 1 a and 1 b (and to the raceway faces 2 a and 2 b ) formed on the track-rail R. The guide holes 7 and 8 extend through the casing c in the axis direction and are parallel to each other in upper and lower positions. Guide cylinders 9 and 10 shown in FIG. 14 are respectively inserted into the guide holes 7 and 8 .
[0007] Each of the guide cylinders 9 and 10 is made up by combining two semicircular cylinder members together. Rollers 11 and 12 roll in the respective guide cylinders 9 and 10 in a such manner as to be parallel to the respective raceway faces 1 a and 1 b (to the respective raceway faces 2 a and 2 b ) . As can be seen from FIG. 13 , the rollers 11 , after rolling in the guide cylinder 9 of the upper guide hole 7 , are guided in a direction that brings them into contact with the lower raceway face 1 a ( 2 a ), while the rollers 12 , after rolling in the guide cylinder 10 of the lower guide hole 8 , are guided in a direction that brings them into contact with the upper raceway face 1 b ( 2 b ) . In this manner, the rollers 11 and 12 individually alternate between the upper and lower positions during their rolling movement, and the turning points are provided in the end caps 5 and 6 .
[0008] As shown in FIG. 15 , a pair of intersecting passage grooves 13 and 14 is provided in each of the end caps 5 and 6 . The passage groove 13 is deeper than the passage groove 14 , as shown in FIG. 16 . The passage groove 13 would obstruct the continuity of the passage groove 14 . To avoid this, abridge member 15 as illustrated in FIG. 16 is installed across the location where the continuity is obstructed. The bridge member 15 has a U-shaped end face. As can be seen from FIG. 16 , the bottom 15 a is formed in an arc shape continuous with the groove portions 14 a and 14 b of the passage groove 14 . The U-shaped bridge member 15 rests on bridge steps 16 which are provided parallel to the passage groove 13 . FIG. 17 illustrates the bridge member 15 on the bridge steps 16 .
[0009] FIG. 17 illustrates the end cap 5 . By mounting the bridge member 15 in this manner, the groove portion 14 a, the bottom 15 a and the groove portion 14 b are connected continuously to each other to form the passage groove 14 . By mounting the bridge member 15 as shown in FIG. 17 , the passage grooves 13 and 14 are defined by the bridge member 15 and intersect with each other in a multilevel manner in a position corresponding to the bridge member 15 . FIG. 17 further shows a cap member 17 which is mounted in a direction at right angles to the passage groove 14 and has two ends resting on supporting steps 18 as shown in FIG. 16 .
[0010] Two pairs of convexities 19 and 20 are provided on the respective ends of the passage grooves 13 and 14 which are father away from the track-rail R having the raceway faces, as shown in FIG. 15 . A fitting recess 21 is formed between the pair of convexities 19 , and a fitting recess 22 is formed between the pair of convexities 20 . Two pairs of convexities 23 and 24 are provided one step higher up than the respective pairs of convexities 19 and 20 . The outer peripheries of the convexities 19 and 23 are combined together to form an arc shape in alignment with the outer periphery of the guide cylinder 9 , and likewise the outer peripheries of the convexities 20 and 24 are combined together to form an arc shape in alignment with the outer periphery of the guide cylinder 10 .
[0011] As is clear from FIG. 14 , projections 9 a and 10 a are provided at ends of the guide cylinders 9 and 10 , and designed to be tightly fitted into the respective fitting recesses 21 and 22 . By tightly fitting the projections 9 a and 10 a into the fitting recesses 21 and 22 , each of the guide cylinders 9 and 10 which are each made up of two members is kept in one piece. The ends of the guide cylinders 9 and 10 with the projections 9 a and 10 a fitted into the fitting recesses 21 and 22 are in contact with the convexities 19 , 20 and the convexities 23 , 24 , so that the continuity between the guide cylinders 9 and 10 and the respective passage grooves 13 and 14 is maintained.
[0012] Accordingly, the rollers 11 and 12 , which have been respectively guided from the guide cylinders 9 and 10 to the passage grooves 13 and 14 , are further guided from access portions 25 and 26 which are the other ends of the passage grooves 13 and 14 , onto the lower raceway face 1 a and the upper raceway face 1 b of the track-rail R having the raceway faces. Alternatively, the rollers 11 and 12 , which have reached the end cap 5 or 6 from the lower raceway face la and the upper raceway face 1 b, are then guided from the access portions 25 and 26 into the passage grooves 13 and 14 . Note that FIG. 19 is a sectional view of the slider S straddling the track-rail R having the raceway faces. FIG. 13 also shows a retaining plate 29 provided for preventing the rollers 11 and 12 guided from the access portions 25 and 26 as described above from falling out of the slider S.
[0013] FIG. 14 also shows underside sealing members 27 that are provided for sealing the underside of the slider S for preventing the intrusion of dust and the like from the underside to the slider. In addition, end seal members 28 are provided on the outer sides of the respective end caps 5 and 6 for preventing the intrusion of dust and the like from the directions of movement of the slider.
[0014] Upon the movement of the slider S along the track-rail R having the raceway faces, the rollers 11 and 12 installed in the slider S roll along move on the raceway faces 1 a and 1 b (and 2 a and 2 b ) to ensure a smooth movement of the slider S. The following is the moving path of the rollers 11 and 12 .
[0015] In accordance with the moving direction of the slider S, for example, the rollers 11 and 12 are introduced from the access portions 25 and 26 shown in FIG. 15 into the passage grooves 13 and 14 or onto the raceway faces 1 a and 1 b (also 2 a and 2 b ). First, the case of the rollers 11 and 12 introduced from the access portions 25 and 26 into the passage grooves 13 and 14 .
[0016] Let us assume the slider S is moved and the rollers 11 are introduced from the access portion 25 and the rollers l 2 are introduced from the access portion 26 of the end cap 5 or 6 which is located to the rear of the moving direction of the slider S. The rollers 11 , after entering the access portion 25 , are guided into the passage groove 13 and then into the guide cylinder 9 that is connected to the end of the passage groove 13 opposite to the access portion 25 . Similarly, the rollers 12 , after entering the access portion 26 , are guided into the passage groove 14 and then into the guide cylinder 10 that is connected to the end of the passage groove 14 opposite to the access portion 26 . At this point, the row of rolling rollers 11 and the row of rolling rollers 12 intersect with each other on either side of the bridge member 15 , as can be seen from FIG. 17 . This intersection of rows of the rolling rollers is represented by the rollers 11 and 12 in FIG. 14 .
[0017] The rollers 11 and 12 after having intersected with each other in one end cap 5 or 6 in this manner are guided from the passage grooves 13 and 14 through the guide cylinders 9 and 10 into the other end cap 6 or 5 that is located to the front of the moving direction of the slider S. Then, in the end cap 6 or 5 located to the front of the moving direction, the rollers 11 and 12 are introduced into the ends of the passage grooves 13 and 14 opposite to the access portions 25 and 26 . Then, the rows of rolling rollers 11 and 12 intersect with each other while moving through the passage grooves 13 and 14 .
[0018] Such a conventional linear motion rolling guide unit as described above needs a large number of parts incorporated in the end caps 5 and 6 , and in addition the guide cylinders 9 and 10 are independent of these incorporated parts. In consequence, the problem of a significantly low efficiency of the assembly process for the entire unit arises. It is needless to say that another problem is the increase in the manufacturing cost for the parts because of the large number of parts.
[0019] Further, when the number of parts incorporated in the end caps is large, the dimensional tolerance and the like of the parts affects the junction between the parts, and inevitably a gap and/or a difference in level easily occur at such a junction. Once the gap and/or the difference in level occur, they cause the rollers 11 , 12 to tilt or to catch, or alternatively cause the abrasion of the guide cylinders 9 , 10 . As a result, the smooth circulation of the rollers 11 and 12 is impeded. A problem rising for this reason is variation in the frictional resistances of the slider S to the track-rail R when the slider S runs on the track-rail R having the raceway faces.
SUMMARY OF THE INVENTION
[0020] It is an object of the present invention to provide a linear motion rolling guide unit which has the number of junctions between parts reduced through a reduction in the number of parts in order to overcome the conventional problems.
[0021] The present invention provides a linearmotion rolling guide unit which is provided with a track-rail which has two raceway faces formed on each of its two sides, and a slider which straddles and moves along the track-rail having the raceway faces and incorporates a plurality of rollers forming four endless rolling rows. In the slider, two sets of outward guide paths for guiding the respective endless rows of the rollers rolling in one direction and return guide paths for guiding the corresponding endless rows of the rollers rolling in the opposite direction are provided on each of the two sides of the track-rail having the raceway faces. The outward guide paths are parallel to the respective raceway faces. The return guide paths extend through the inside of the slider. Each of the outward guide paths and the return guide path paired therewith intersect with each other in an end cap provided in the slider.
[0022] In the linear motion rolling guide unit of the present invention, the slider contains a pair of guide holes provided for forming the return guide paths. Guide cylinders in which the rollers roll are inserted in the respective guide holes. The end cap contains a pair of passage grooves having different depths and intersecting with each other. A divider frame is provided integrally with one end of each of the guide cylinders for providing apartition between the intersecting passage grooves. The divider frame is fitted into a cross portion of the passage grooves intersecting with each other, whereby the outward guide path and the return guide path are defined while still intersecting. The types of rollers described in the present invention include a cylindrical roller, a long cylindrical roller, a needle roller and the like.
[0023] Further, in the linear motion rolling guide unit of the present invention, the divider frame forms a passage hole enabling the rollers which have moved through the guide cylinder to continue to roll. The outer face of the divider frame serves as a guide face for the rollers which have rolled through another guide cylinder.
[0024] According to the present invention, the parts required for forming the return guide path are only the guide cylinders having the divider frames formed integrally therewith and the end caps. In other words, the required number of parts incorporated in the end cap is only one. Hence, as compared with the conventional linear motion rolling guide units, a significant reduction in the manufacturing cost is possible. A small number of parts leads to a reduction in the number of processes for assembly. In consequence, the assembly process can be simplified, which in turn aids in reducing the cost.
[0025] Further, the reduced number of parts incorporated in the end cap as described above results in a reduction in the number of junctions. In consequence, the occurrence of gaps and differences in level in the junctions caused by the dimensional tolerance and the like of the parts is reduced. If the gaps and differences in level are not produced in this manner, the disadvantages of the roller tilting or catching or the abrasion of the guide cylinders are eliminated. For this reason, when the slider runs on the track-rail having the raceway faces, a stable frictional resistance of the slider to the track-rail is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a perspective exploded view of a slider according to the present invention.
[0027] FIG. 2 is a view of an end cap when viewed from a casing.
[0028] FIG. 3 is a plan view of a guide cylinder.
[0029] FIG. 4 is a side view of the guide cylinder.
[0030] FIG. 5 is a bottom view of the guide cylinder.
[0031] FIG. 6 is a sectional view taken along the VI-VI line in FIG. 3 .
[0032] FIG. 7 is a sectional view of the guide cylinder with a divider frame mounted on the end cap.
[0033] FIG. 8 is a sectional view of the guide cylinder with a step mounted on the end cap.
[0034] FIG. 9 is a partial perspective view of the divider frame of the guide cylinder.
[0035] FIG. 10 is a partial perspective view including a partial sectional view of a connection portion of a passage groove in the end cap.
[0036] FIG. 11 is a perspective view illustrating the intersection of rows of rolling rollers with each other.
[0037] FIG. 12 is a partial perspective view of the guide cylinder installed in the end cap.
[0038] FIG. 13 is a perspective view with a partial sectional view illustrating a conventional linear motion rolling guide unit.
[0039] FIG. 14 is a perspective exploded view of the conventional guide unit.
[0040] FIG. 15 is a view of a conventional end cap when viewed from a casing.
[0041] FIG. 16 is a partial perspective view including a partial sectional view of the conventional end cap.
[0042] FIG. 17 is a sectional view of the conventional end cap with a cap member, taken along the line XVII-XVII line in FIG. 15 .
[0043] FIG. 18 is a perspective view of a bridge member to be incorporated in the conventional end cap.
[0044] FIG. 19 is a sectional view of the conventional slider straddling a track-rail having raceway faces.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] FIG. 1 to FIG. 12 illustrate an embodiment of the present invention, in which the principal elements of a slider S are a casing c and a pair of end caps e 1 and e 2 . The slider S moves on a conventional track-rail R having raceway faces as described earlier. The structure of the casing c is practically the same as that of the conventional one. A pair of guide holes 31 and 32 is formed in each of the two side portions of the casing c. Reference numeral 33 in FIG. 1 denotes an underside seal for preventing the intrusion of dust and the like from under the slider S.
[0046] The biggest feature of the embodiment is the structure of a guide cylinder 34 incorporated in each of the guide holes 31 and 32 . The four guide cylinders 34 used here are identical in shape. All the guide cylinders are designated by the same reference numeral 34 . Eachof the guide cylinders 34 is composed of a cylinder 35 inserted into the guide hole 31 or 32 , and a divider frame 36 formed integrally with the cylinder 35 , as can be seen from FIG. 3 to FIG. 6 .
[0047] The cylinder 35 has a hollow portion provided for allowing rollers 37 to roll therein, and enables the rollers 37 to roll in the hollow portion with the axis of each roller 37 placed at right angles to the axis of the cylinder 35 , as can be seen from FIG. 11 . Two slits 38 a are formed in the cylinder 35 and extend in the axis direction. A leaf spring 38 is formed between the slits 38 a. For example, when the interval between each of the rolling rollers 37 is lessened and the regularly spacing and lining up of the rollers 37 is disturbed, the leaf spring 38 is provided for correcting the disturbed row and elastically retreating.
[0048] The divider frame 36 is provided integrally with one end of the cylinder 35 , and provided with a passage hole 36 a extending in a direction at right angles to the axis of the cylinder 35 , and with a surrounding wall 36 b on the periphery of the passage hole 36 a, as can be seen from FIGS. 3 to 6 . As can be seen from FIGS. 6 to 9 , a pair of projecting arms 39 is formed integrally with the surrounding wall 36 b on the top thereof, or on an extension of the cylinder 35 . In addition,a guide piece 40 having an arc-shaped inner face is also formed integrally with the surrounding wall 36 b at the lower end of the divider frame 36 located opposite to the projecting arms 39 . Further, as can be seen from FIG. 6 , a step 49 is formed at the other end of the guide cylinder 34 .
[0049] The end caps e 1 and e 2 provided at the respective ends of the casingare identical instructure, sothat eachof the structural elements is hereinafter described with the same reference numeral. As can be seen from FIG. 2 , a pair of passage grooves 42 and 43 is formed in each end cap e 1 , e 2 . The passage grooves 42 and 43 intersect with each other. The groove depth of each passage groove 43 is deeper than that of each passage groove 42 . Hence,the continuity of the passage groove 42 is obstructed by the passage groove 43 . Incidentally, the description is given relating to only one of the right and left passage grooves 42 and one of the right and left passage grooves 43 in each end cap in FIG. 2 , as a representative example.
[0050] The passage groove 42 has one end serving as an access portion 42 a and the other end serving as a connection portion 42 b. As illustrated in FIG. 7 , the connection portion 42 b has a bottom face 42 c formed in an arc shape. As illustrated in FIG. 10 , receiving grooves 42 d are formed on either side of the connection portion 42 b, into which the projecting arms 39 formed in the guide cylinder 34 are respectively inserted. By inserting the projecting arms 39 into the receiving grooves 42 d, the divider frame 36 of the guide cylinder 34 is placed in a position corresponding to a cross portion 44 between the passage grooves 42 and 43 .
[0051] As shown in FIG. 7 , the divider frame 36 is disposed at the cross portion 44 . Specifically, by disposing the divider frame 36 in a position corresponding to the cross portion 44 , the discontinuity of the passage groove 42 is reconnected through the passage hole 36 a of the divider frame 36 , and the passage formed by the passage groove 42 and the passage formed by the passage groove 43 are defined by the surrounding wall 36 b of the divider frame 36 . At this point, the outer periphery face of the surrounding wall 36 b is combined with the passage groove 43 to guide the rollers 37 , thus constituting the guide face of the present invention.
[0052] When the divider wall 36 of the guide cylinder 34 is fitted into each of the end caps el and e 2 , the passage groove 42 is reconnected. The connection portion 42 b is continuous with the cylinder 35 and the access portion 42 a is combined with the guide piece 40 to form an introducing portion 45 . As illustrated in FIG. 12 , a guide piece 46 is formed integrally with each of the end caps el and e 2 , and forms a passage 47 which is structured to be continuous with the raceway face of the track-rail R having the raceway faces.
[0053] On the other hand, the passage groove 43 also has one end serving as an access portion 43 a and the other end serving as a connection portion 43 b. As shown in FIG. 2 and FIG. 8 , a step 50 is formed in the connection portion 43 b. The bottom face 43 c of the connection portion 43 b is structured to be continuous with the cylinder 35 . The access portion 43 a is continuous with a passage 48 formed by the guide piece 46 as shown in FIG. 12 . The passage 48 is also structured to be continuous with the raceway face of the track-rail R having the raceway faces.
[0054] A step 49 is formed at the other end. of the guide cylinder 34 . The step 49 is in contact with the step 50 formed in the end cap e 1 (e 2 ) as illustrated in FIGS. 2 and 8 , in order to achieve a continuous connection between the cylinder 35 of the guide cylinder 34 and the passage groove 43 , as illustrated in FIG. 8 .
[0055] Next,the assembly process for the components will be described with reference to FIG. 1 . Initially, the divider frame 36 of the guide cylinder 34 is fitted into each of the cross portions 44 of each of the end caps e 1 and e 2 . The guide cylinder 34 of which the divider frame 36 is thus fitted into the cross portion 44 is inserted in the guide hole 31 ( 32 ) of the casing c. The guide cylinder 34 is formed in dimensions such that the step 49 provided at the end of the guide cylinder 34 opposite the divider frame 36 projects from the casing c when it is inserted in the guide hole 31 ( 32 ). The projecting step 49 is adjoined with the step 50 of the end cap e 1 (e 2 ), such that the guide cylinder 34 communicates with the passage groove 43 .
[0056] The guide groove 43 inserted in the guide hole 31 ( 32 ) constitutes the return guide path of the present invention. The area continuous with the introducing portion 45 and extending parallel to the corresponding raceway face 1 a, 1 b, 2 a or 2 b constitutes the outward guide path of the present invention.
[0057] A plurality of rollers 37 is loaded in each of the outward guide paths and each of the return guide paths. A row of rollers 37 rolling in the guide cylinder 34 inserted in the guide hole 31 and a row of rollers 37 rolling in the guide cylinder 34 inserted in the guide hole 32 are formed. The rows of the rolling rollers 37 intersect with each other at the cross portion 44 of each of the end caps e 1 and e 2 for circulation.
[0058] More specifically, for example, the rollers 37 entering the introducing portion 45 (see FIG. 7 ) of the end cap 1 e from the outward guide path move through the passage groove 42 while moving trough the passage hole 36 a of the divider frame 36 . Then, the rollers 37 are guided from the connection portion 42 b of the passage groove 42 to one end of the cylinder 35 . The rollers 37 reaching the end of the cylinder 35 move to the other end of the cylinder 35 , and are then guided from the other end of the cylinder 35 to the connection portion 43 b of the passage groove 43 formed in the other end cap e 2 , thus passing through the return guide path. The rollers 37 guided to the connection portion 43 b of the end cap e 2 move through the passage groove 43 in the end cap e 2 and reach the introducing portion 45 . Then, the rollers 37 are guided,via the passage 48 formed in the end cap e 2 , to the corresponding raceway face 1 a, 1 b, 2 a or 2 b, and then pass through the outward guide path.
[0059] The rollers 37 , which have moved through the outward guide path, reach the passage 47 formed in the end cap e 1 , then move to the access portion 42 a of the end cap e 1 , and then repeat the motion through the same route. Which everway,the rollers 37 rolling between the end caps e 1 and e 2 roll through the outward guide path and the return guide path while keeping the row of rollers rolling endlessly.
[0060] The rollers 37 move in the opposite direction to whichever the moving direction of the slider S is, but the moving route of the rollers 37 is the same as in the foregoing case, and it is simply the rolling direction that is different.
[0061] According to the foregoing embodiment, the guide cylinder 34 is formed integrally with the divider frame 36 . Hence, the component which must be mounted in each of the end caps e 1 and e 2 is only the guide cylinder 34 . For this reason, the number of parts is significantly reduced and accordingly the number of assembly processes is reduced. If the number of assembly processes is reduced, it is needless to say that this makes a reduction in the total manufacturing cost possible.
[0062] The reduction in the number of parts results in a reduction in the number of junctions between parts. In consequence, occurrence of gaps and differences in level in the junctions caused by the dimensional tolerance and the like of the parts as is found in the conventional linear motion rolling guide units is eliminated. Thus, the tilting and catching of the rollers is prevented.
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A reduction of the number of parts and the prevention of a gap and a difference in level from occurring in the passage route of the rollers. A slider S is provided with a pair of guide holes 31, 32 for forming a return guide path. Guide cylinders 34 in which the rollers 37 roll are inserted in the guide holes 31, 32. A pair of passage groove 42, 43 having different depth and intersecting with each other is provided in each of the end caps e1, e2. A divider frame 36 is provided integrally with one end of each guide cylinder 34 for defining the intersecting passage grooves. The divider frame 36 is inserted in a cross portion of the intersecting passage grooves, whereby the outward guide path and the return guide path are defined while still intersecting.
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BACKGROUND
This invention relates to a system and method for connecting fluid devices and, more particularly, to such a system and method which permits the connection to be done easily and quickly.
In fluid flow environments, quick connect systems are often used to connect the corresponding ends of fluid devices, such as pipes, conduits, hoses, and/or fluid manifolds. However, the installation of many of the prior art quick connect systems is complicated, time consuming and often require tools and extensive manual labor. Also, when the flow lines or manifolds are relatively large, these quick connect systems are bulky and expensive. Moreover, these type of systems cannot be used when the fluid pressures in the flow lines and manifolds are relatively high. Also, these systems usually do not permit relative rotation between the connected flow lines and thus several limit the design possibilities when a multipipe assembly, including elbows, etc. is utilized. Although quick connect systems have been used in oilfield applications, they are usually made of iron, and are very heavy and hazardous. Also, hammer unions have been employed which are difficult and time consuming and often cause injuries.
Therefore, what is needed is a quick connect system and method which is simple, and easy to connect and disconnect without the need for tools, and employs components that are relatively small and easy to assemble and disassemble, yet permit relative rotation between the connected fluid lines.
SUMMARY
According to the system and method of the present invention, one end portion of a first tubular member is inserted in an end portion of a second tubular member in a telescoping relationship. An arcuate clamp extends over the telescoping portions of the tubular members, and a tapered locking surface is formed on at least one of the tubular members and on the clamp. The tubular members move relative to each other in an axial direction in response to fluid pressure therein to move the tapered locking surfaces into engagement to lock the clamp against radial movement relative to the tubular members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded isometric view of a quick connect system according to an embodiment of the present invention.
FIG. 2 is an elevational view of the assembled components of the system of FIG. 1 .
FIG. 3 is a longitudinal sectional view of the components of FIG. 2 shown assembled but prior to locking.
FIG. 4 is an enlarged view of the circled portion of FIG. 3 .
FIG. 5 is a view similar to that of FIG. 3, but depicting the components in a locked position.
FIGS. 6-8 are elevational views, on a reduced scale, depicting the system of FIGS. 1-5 incorporated in a piping assembly.
DETAILED DESCRIPTION
With reference to FIG. 1, a quick connect system according to an embodiment of the present invention is shown, in general, by the reference numeral 10 . The system includes a connector 12 , in the form of a tubular member having a reduced-diameter end portion 14 that forms a shoulder 16 . An external flange 18 extends between the end of the section 12 and the shoulder 16 and forms an annular groove 20 between the shoulder and the corresponding face of the flange. Two seal rings 22 and 24 are formed in corresponding grooves in the external surface of the end portion 14 .
A connector 30 is also provided and is in the form of a tubular member having a reduced-diameter end portion 34 that forms a shoulder 36 . An annular groove 38 is formed adjacent the shoulder 36 and extends between the shoulder and the corresponding opposite shoulder of the end portion 34 which will be described in detail later. The bore of the end portion 34 receives the end portion 14 of the pipe section 12 in a telescoping manner.
It is understood that any type of fluid flow device, such as a pipe, conduit, hose, or manifold (not shown), can be provided on the other end portions of the connectors 12 and 30 in any conventional manner such as by welding, molding, fastening or the like. The connectors 12 and 30 and/or the flow devices can be fabricated from a metal or a composite material.
An arcuate clamp 40 is provided and extends for approximately 180 degrees. Two arcuate flanges 42 and 44 extend from the inner surfaces of the respective end portions, and a central groove 46 is formed in the outer surface of the clamp 40 and extends for the entire arcuate dimension of the clamp.
An arcuate clamp 50 is also provided and is identical to the clamp 40 . As such, the clamp 50 extends for approximately 180 degrees and two arcuate flanges 52 and 54 extend from the inner surfaces of the respective end portion. A central groove 56 is formed in the outer surface of the clamp 50 and extends for the entire arcuate dimension of the clamp.
FIG. 2 depicts the components of FIG. 1 in an assembled condition, with the clamps 40 and 50 extending over the reduced end portions 14 and 34 of the connectors 12 and 30 with their respective ends in an abutting relationship to form a continuous ring. A retaining strap 58 can be placed in the continuous groove formed by the grooves 46 and 56 prior to the clamps being locked to the connectors 12 and 30 in a manner to be described. The strap 58 can be in the form of a elastic band, or a hook-and-loop arrangement of the type marketed under the trademark VELCRO, sheet-metal clamp, a rubber tube, or any other similar type device.
FIG. 3 depicts the components of FIG. 2 in greater detail and before the clamps 40 and 50 have been locked to the connectors 12 and 30 . In this position, that portion of the end portion 14 of the connector 12 extending from the flange 18 extends within the bore of the end portion 34 of the connector 20 in a telescoping relation. This telescoping portion of the end portion 14 is tapered radially inwardly in the direction towards the end of the pipe section 12 and forms a shoulder 14 a against which the corresponding end of the connector 30 abuts. Also, an inner surface of the telescoping portion of the end portion 34 of the connector 30 defining the bore of the connector is tapered in a manner to receive the tapered portion of the end portion 14 . The seal rings 22 and 24 engage the corresponding inner surfaces of the end portion 34 to seal against the egress of fluid from the continuous bore formed by the connectors 12 and 30 and their associated fluid flow devices.
The flanges 42 and 44 of the clamp 40 extend in the grooves 20 and 38 , respectively, to form annular gaps G 1 and G 2 between the corresponding surfaces of the flanges and the end portions 14 and 34 of the connectors 12 and 30 , respectively. Similarly, portions of the and the flanges 52 and 54 of the clamp 50 also extend in the grooves 20 and 38 , respectively and also form annular gaps. As better shown in FIG. 4, the wall 34 a of the end portion 34 extending opposite the shoulder 36 and forming, with the shoulder, the groove 38 , is tapered radially outwardly from the bottom of the groove. Similarly, the corresponding wall 44 a of the flange 44 of the clamp 40 is tapered in the same manner. In the unlocked position of FIGS. 3 and 4, the wall 44 a of the flange 44 is spaced from the wall 34 a to form the gap G 2 . The corresponding wall of the flange 42 , as well as the corresponding walls of the end portion 14 , are tapered in the same manner which, in the unlocked position of FIG. 3, form the gap G 1 . Similarly, the corresponding walls of the flanges 52 and 54 of the clamp 50 are configured in the same manner, which in the unlocked position, form gaps with the surface 34 a and the corresponding surface of the end portion 14 .
The system is initially placed in the unlocked position of FIGS. 3 and 4 and the retaining strap 58 is positioned in the continuous groove formed by the grooves 46 and 56 . The strap 58 functions to maintain the clamps 12 and 30 in the position shown before they are locked to the connectors 12 and 30 .
The respective ends of the connectors 12 and 30 opposite the end portions 14 and 34 are each connected to, or formed integrally with, a fluid flow device (not shown) in the form of a pipe, conduit, manifold, or the like. When fluid pressure is applied to the system 10 via at least one of the fluid flow devices, the pressure forces the connectors 12 and 30 to separate slightly in an axial direction and move to the position of FIG. 5 in which the end of the connector 12 is slightly spaced from the shoulder 14 a . In this position the tapered wall 34 a (FIG. 4) moves into engagement with the tapered wall 44 a of the flange 44 of the clamp 40 and the corresponding tapered wall of the flange 54 of the clamp 50 . Also, the tapered wall of the end portion 14 moves into engagement with the corresponding tapered walls of the flanges 42 and 52 of the clamps 40 and 50 , respectively to lock the clamps 40 and 50 to the connectors 12 and 30 , as shown in FIG. 5 . Although the strap 58 is shown in FIG. 5 it is not needed due to the above locking action.
Of course, when the fluid pressure in the system 10 is depleted, the strap 50 can be removed and the connectors 12 and 30 manually moved in an axial direction to the unlocked position of FIG. 3 to move the tapered wall 34 a out of engagement with the tapered wall 44 a of the flange 44 and the tapered wall of the flange 54 ; as well as move the tapered wall of the end portion 14 out of engagement with the corresponding tapered walls of the flanges 42 and 52 . The clamps 40 and 50 can then be manually removed, in a radial direction, from their clamping position, and the connectors 12 and 30 can be separated by moving them away from each other in an axial direction, to disassemble the system 10 .
Thus the system 10 is simple, and is quickly and easily connected and disconnected without the need for tools, while utilizing components that are relatively small and easy to handle.
It is noted from the above, that, in the assembled condition of the system 10 , the connectors 12 and 30 can rotate relative to each other. An embodiment employing this feature is shown in FIGS. 6-8 in which the system 10 is shown connected in a pipe assembly in a manner to permit relative rotation between the pipes in the assembly. More particularly, the connectors 12 and 30 of the assembled system 10 are connected to one leg of a pair of L-shaped, or elbow, pipes 60 and 62 , respectively, in the manner discussed above. Two quick connect systems 70 and 72 , which are identical to the system 10 , connect the other leg of the pipes 60 and 62 to pipes 74 and 76 , respectively. Although the pipes 74 and 76 are not shown completely, it is understood that they could be either straight or L-shaped.
The angular position of pipes 74 and 76 , can be varied by rotating the connector 30 relative to the connector 12 . Thus, as an example, the pipe 76 can be moved from a substantially vertical position, as viewed in FIGS. 6 and 7, in which it is in angular alignment with the pipe 74 , to the position shown in FIG. 8 in which it extends approximately 45 degrees to the pipe 74 . Of course, the angular positions which the pipe 76 can take are infinitely variable, and the angular position of the pipe 74 can be adjusted in the same manner. This feature is particularly advantageous in pipe assemblies including a series of L-shaped pipes since it permits a significant amount of flexibility in the particular angular positions of the pipes, and therefore the layout of the assembly.
It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the interlocking tapered walls referred to above can only be formed on one end portion 14 or 34 and engage the tapered surfaces of the corresponding flanges 42 and 52 , or 44 and 54 . Also, reference to “pipe”, and “conduit”, are not meant to be limited to any particular fluid flow device and any such device or devices can be used throughout the system. Further, the number of clamps that are used can vary. Also, spatial references, such as “vertical”, “angular”, etc. are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above. Still further, the specific design of the connectors 12 and 30 can be varied and, for example, may be formed integrally with the flow devices.
Since other modifications, changes, and substitutions are intended in the foregoing disclosure, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
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A quick connect system and method for fluid devices according to which one end portion of a first tubular member is inserted in an end portion of a second tubular in a telescoping relationship. An arcuate clamp extends over the telescoping portions of the tubular members, and a tapered locking surface is formed on at least one of the tubular members and on the clamp. The tubular members move relative to each other in an axial direction in response to fluid pressure therein to move the tapered locking surfaces into engagement to lock the clamp against radial movement relative to the tubular members. A pipe assembly including a first connection system for connecting one end of a first pipe to one end of a second pipe while permitting relative rotation between the pipes, and a second connection system for connecting the other end of the first pipe to a third pipe so that rotation of the first pipe relative to the second pipe causes angular movement of the third pipe.
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FIELD OF THE INVENTION
The disclosed invention is a display package for pull chains and similar articles sold to consumers by retailers and others. More particularly, the disclosed invention is a clam shell package in which an insert is positioned for holding the chain of a pull chain, so that the knob is suspended in a chamber to more realistically portray the appearance as same would occur when affixed to a ceiling fan.
BACKGROUND OF THE INVENTION
Retail establishments are under constraints to reduce costs while increasing sales. Suppliers to retail establishments are encountering similar constraints and demands, with retailers limiting display space to those products which achieve maximum sales potential. The manner in which a product is displayed, and thereby perceived by a consumer, frequently has a strong impact on sales of the packaged product. In addition, particularly with relatively small items, it is preferred that the package construction, size, or the like provide theft resistance.
A ceiling fan typically has a relatively short chain connected to a speed switch, with the switch being adjusted to set the speed of rotation of the fan blades to that which is desired. The short chain may not be reachable by the user, or same may be considered unattractive. Many consumers attach an extension chain to the short chain which comes with the fan, and the extension chain typically has a decorative knob or like ornament at its end. The knob and the chain may be colored or otherwise decorated in order to match the decor of the ceiling fan, the room in which the ceiling fan is positioned, or some other aesthetically pleasing attribute.
Ceiling fan extension pull chains have in the past been displayed to consumers on bubble cards. The typical bubble card has a cardboard base, to which a transparent bubble is secured. The extension chain and its knob are positioned within the bubble, and the card may be hung from a hook. In that configuration, however, the chain and knob are not presented to the consumer in an orientation corresponding to the orientation same would achieve when connected to the chain of the ceiling fan. The bubble package does not permit the consumer to easily recognize the coloring of the chain, or the ornamentation on the knob. The consumer must imagine how the chain and knob will appear with this sort of package, with the result that sales potential is potentially diminished.
Attempts have been made to increase consumer perception of the extension chain by display of the chain and its knob in a transparent carton having a cardboard insert. Those carton-type packages, however, do not display the extension chain and its knob in an orientation and configuration as would be achieved hanging from the ceiling fan. Additionally, portions of the chain remain loose in the package, and thus detract from an aesthetically pleasing appearance. Moreover, the carton-type package is relatively expensive to manufacture, and is relatively complicated to assemble.
Those skilled in the art will appreciate that there is a need for a relatively inexpensive, easy to manufacture, aesthetically pleasing, package suitable for display of ceiling fan extension pull chains, other sorts of pull chains, and similar types of products. The disclosed invention meets these needs and others in the art through provision of a transparent clam shell-type package, with an insert disposed in the package for securing the chain while allowing the knob to hang vertically within an open chamber, resulting in an appearance approximating the appearance of the pull chain and knob when hung from a ceiling fan.
SUMMARY OF THE INVENTION
A package for displaying pull chains and the like comprises a first transparent package component having a recess spanning substantially the entirety thereof The recess has first and second sections. The second section is sized and configured for receipt of a preselected article. A second package component is provided, with the second component having first and second spaced apart recess sections. The second component second recess section is aligned with the first component second recess section for therewith forming a chamber. An insert is positioned within the first component recess in overlying relation to the second component recess sections. The insert has a capture region for engaging an article, so that a portion of the article is disposed within the chamber for display. The first and second components are secured together.
A display package comprises a first transparent package component having a recess sized and configured for receipt of an article to be displayed. A second package component is secured to the first component. The second component has a first recess section and a second recess section. The second recess section is aligned with and cooperates with the recess for therewith forming a chamber. An insert has a first portion positioned within the recess, and a second portion disposed within the second component second recess section. The first portion of the insert includes a capture region. An article to be displayed has a portion immovably received within the capture region, and another portion extending therefrom and received within the chamber.
These and other objects and advantages of the invention will be readily apparent in view of the following description and drawings of the above-described invention.
DESCRIPTION OF THE DRAWINGS
The above and other advantages and novel features of the present invention will become apparent from the following detailed description of the preferred embodiment of the invention illustrated in the accompanying drawings, wherein:
FIG. 1 is a front elevational view of the package of the invention;
FIG. 2 is a rear elevational view thereof,
FIG. 3 is a cross sectional view taken along the line 3--3 of FIG. 1 and viewed in the direction of the arrows;
FIG. 4 is a fragmentary cross sectional view taken along the line 4--4 of FIG. 2 and viewed in the direction of the arrows;
FIG. 5 is a fragmentary cross sectional view taken along the line 5--5 of FIG. 1 and viewed in the direction of the arrows; and
FIG. 6 is a fragmentary plan view of the insert of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Package P, as best shown in FIGS. 1 and 3, is a clam shell-type package having a transparent package component 10 connected through hinge 12 to transparent package component 14. Components 10, 12 and 14 are integral, and are preferably made of a relatively thin transparent plastic of the sort suitable for vacuum molding. Because the plastic is transparent, then a consumer may easily view the contents of the package P.
Component 14 has an upper portion 16 in longitudinal alignment with hinge 12. A triangular opening 18 is formed therein for permitting the package P to be hung from a hook or other sort of fixture. Extending from first portion 16 is second portion 20, which is laterally offset from the plane of first portion 16. Finger portion 22 is formed in second portion 20, and creates a curved channel for reasons to be explained. As best shown in FIG. 1, finger portion 22 is centrally aligned relative to the oppositely disposed side edges 24 and 26, and preferably is in line with the longitudinal center line of the package P. Recess section 28 extends from second portion 20. Recess section 28 has an opening 30 communicating with finger portion 22. As best shown in FIG. 1, first portion 20 and recess section 28 combine to form a recess which spans substantially the entirety of second component 14. The recess formed by the portions 20 and 28 is disposed inwardly relative to peripheral rims 32 and 34 and downwardly from planar portion 16, and thereby provides strength and rigidity to the component 14.
Component 10 has an upper portion 36 having an opening 38 in alignment with the opening 18 of second component 14. Circular recess 40 is formed within component 10, as best shown in FIGS. 2-4. Spaced longitudinally downwardly from circular recess 40 is recess section 42, which is aligned with recess section 28 of component 14. The recess sections 28 and 42 form an open chamber 44, which is sized and configured for receipt and display of a preselected article. Preferably the chamber 44 is larger than the article, so that same achieves a realistic orientation when the package P is hung vertically for display.
The article to be displayed is preferably a ceiling fan extension chain, comprising a ball chain 46 and a knob 48. The chain 46 may be brass or otherwise colored, with the knob 48 having essentially any configuration and coloration as may be desired. It can be seen in FIG. 3 that the chain 46 and knob 48 hang vertically within chamber 44, so that they accurately represent the orientation which the chain 46 and knob 48 would have when attached to a ceiling fan. The consumer thus may more realistically and easily appreciate the appearance that the chain 46 and knob 48 would convey when hung from a ceiling fan, thus potentially increasing the likelihood of a sale. Moreover, because chain 46 extends along the channel of finger portion 22, then maximum display of the chain length consistent with package dimensions is provided. Naturally, alignment of finger portion 22 with circular recess 40 may be adjusted as desired.
In order to secure the chain 46 so that the chain 46 and knob 48 will hang vertically in essentially a longitudinally immovable manner when the package P is hung from a hook extending through openings 18 and 38, then I provide an insert 50 which preferably is formed of opaque cardboard or like material. Insert 50, as best shown in FIGS. 3-4 and 6, has a first portion 52 which is juxtaposed to second portion 20 of second component 14 and which overlies circular recess 40. Because the first portion 52 overlies the circular recess 40, then that portion of the ball chain 46 which is not disposed within chamber 44 is hidden from view and does not detract from the aesthetically pleasing appearance of the package P. Circular opening 54 is formed within insert 50, and a slot 56 extends downwardly therefrom in order to capture a chain link extending between adjacent balls 58 of ball chain 46. Preferably the opening 54 is slightly larger in diameter than the diameter of the balls 58, in order to permit same to be passed readily therethrough during assembly. The slot 56, on the other hand, need not extend very far, and simply provides a capture region for holding a link 60 and to permit the chain 46 from thereafter being able to move. The capture region alternative may be provided by glue, a twisted wire, or the like.
Insert 50 has flat portion 62 extending therefrom, disposed behind chain 46 in the area of finger portion 22. Insert 50 furthermore has portions 64, 66 and 68 extending about recess section 42 and overlying the lower portion 70 of recess section 28, as best shown in FIG. 3. Because the insert 50 is a stiff cardboard or similar fibrous material which may be printed upon, then the insert 50 is available to provide consumer information about the product being displayed, its manufacture, price, and like information. Additionally, shoulders 53 and 55 of insert 50 seat the insert within second portion 20, thus maintaining orientation of the insert 50 within package P.
Circular recess 40 and recess section 42 are preferably inwardly formed relative to the side edges 72 and 74 of component 10. I prefer that first component 10 be molded to form a plateau in order to align with and interfit with the stiffening recess of second component 14. In other words, the component 10 has a base or rim 75, and an upper planar section 77 within which the recess sections 40 and 42 are formed.
Because the package P is a clam shell package, then formed in upper portion 16 are detents 76 and 78, with the detent 78 being shown in cross section in FIG. 5. Locks 80 and 82 are formed in upper portion 36 of first component 10, and are received within the detents 76 and 78 in order to releaseably secure the components 10 and 14 together. Those skilled in the art will recognize that other types of securement may be used for locking the components together, such as adhesive, heat sealing, or the like. I prefer that it be relatively difficult to separate the components 10 and 14, in order to reduce theft losses which otherwise might occur. Similarly, because the package P is relatively much larger than the chain 46 and knob 48, it is more difficult to conceal same.
Use of the package P is relatively simple, because the components 10, 12, and 14 may be vacuum formed from a single plastic sheet. The insert 50 may be die cut or otherwise prepared, with the chain 46 and knob 48 being secured from any number of sources. In order to assemble the package P, then the chain 46 is caused to pass through the opening 54 by an amount sufficient to assure that the knob 48 will be spaced above insert portion 68 and hang freely and vertically within package P. The appropriate link 60 of the chain 46 is moved downwardly into the slot 56, in order to be captured there and thus be immovably retained. Excess chain 46 is then positioned within circular recess 40. Insert 50 is positioned so that portion 52 is seated within second section 20, and portions 64, 66, and 68 oriented within section 42. Chain 16 may thus be positioned within the channel of finger portion 22. Components 10 and 14 are then pivoted about hinge 12 into overlying relation, with the locking elements 76-82 then being secured together. The package P may be shipped to the retailer, and thus hung by openings 18 and 38 from a hook or other fixture for display to the consumer.
While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, uses, and/or adaptations of the invention. Following the general principles of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention of the limits of the appended claims.
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A package for displaying pull chains and the like includes a first transparent package component having a recess spanning substantially the entirety thereof. The recess has first and second sections and the second section is sized and configured for receipt of an article. A second package component has first and second spaced apart recess sections. The second component second recess section is aligned with the first component second recess section for therewith forming a chamber. An insert is positioned within the first component recess in overlying relation to the second component recess sections. The insert has a capture region for engaging an article having a portion thereof disposed within the chamber for display. The first and second components are secured together.
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This is a division of application Ser. No. 859,167, filed on Dec. 9, 1977, and now U.S. Pat. No. 4,158,237.
BACKGROUND OF THE PRESENT INVENTION
The present invention relates generally to a method for use as a liquid impregnator or as a washer or rinser in the continuous wet processing treatment of fibrous assemblies, and especially for use in processing continuous nonwoven batts or webs. Such continuous textile treating processes are frequently referred to as continuous "pad-dry" processes. Generally such continuous pad-dry processes begin with a "wet-on-dry" application stage in which the fiber assembly (batt, web, or fabric), hereinafter referred to as a batt, is fed as a continuous dry fiber batt into the first liquid impregnating stage. Following this first wet-on-dry impregnation, the web batt generally passes through the nip of a pair of high expression nip rolls to reduce the liquid (i.e., the treating "liquor") pickup to some level below that present on the batt before entering the nip of the high expression paired nip rolls. The wet pickup (WPU) of liquor on the batt as it leaves the impregnation tank and before passing through the high expression paired nip rolls may be on the order of 1,000% to 4,000% (meaning 10 to 40 pounds of liquor per pound of dry fiber in the batt) depending upon the porosity, capillarity and wet bulk of the batt, the time and distance required for the batt to emerge from the impregnating bath to the high expression paired nip rolls, and the nature of the impregnating liquor.
The design of the high expression paired nip rolls and the pressure applied to the batt at the nip of the high expression paired nip rolls may be varied to obtain various levels of residual wet pickup of liquor on the batt as it leaves the paired nip rolls. The desired level of residual wet pickup depends upon the nature and purpose of the next process stage. Generally, if the next process stage is a second wet impregnation stage (and hence a "wet-on-wet" impregnation stage), it is desirable to reduce the level of residual wet pickup on the fabric by means of the high expression paired nip rolls to as low a level as practicable in order either (a) to provide for sufficient additional wet liquor pickup on the batt during the subsequent wet-on-wet impregnation, or (b) to minimize the residual wet pickup on the batt before the batt enters the dryer. If the process stage following the paired nip roll expression is a "reacting" or "aging" stage, the desired level of wet pickup on the batt leaving the high expression paired nip rolls may be higher than the minimum level which can be achieved by very high pressure expression nip rolls.
Somewhat higher residual wet pickups may be desired to provide sufficient liquid mobility throughout the large and small capillary spaces between fibers in the fibrous assembly which forms the batt. Such liquid mobility is desirable during a "reacting" or "aging" period in the process to assure good distribution of chemical reactants such as alkali, hydrogen peroxide bleaches, dyestuffs, etc., throughout the batt. Frequently, high expression of liquor at the nip of the high expression paired nip rolls just prior to the rinsing stage or between each of a series of rinsing stages is also sought in order to reduce the amount of rinsing liquid used and to improve the rinsing efficiency of each rinsing stage.
It is readily apparent that, in continuous wet chemical textile finishing or treating processes, the design and resulting efficiencies of the various liquor impregnation stages and liquor extraction stages (high expression paired nip rolls are used in this illustrative discussion to serve as the liquor extraction means) play a major role in the cost of such process equipment and the effectiveness of such process methods. In order to achieve thorough impregnation of treating liquors into textile fabrics, or thorough rinsing of residual chemicals from such treated fabrics, two or more tandem "dip and nip" impregnators or wash boxes are frequently used. And for woven fabrics, the dwell time and washing or rinsing efficiency is generally improved by increasing the path length through which the fabric must travel in the washing or rinsing liquor. To obtain sufficient path length in such wash boxes, woven fabrics travel over and under a large number of rolls spaced relatively far apart (roughly 3 to 12 feet) vertically, and relatively close together (roughly 0.5 to 1.0 foot) horizontally. In this manner, a fabric passing over, say, 31 rolls and under 30 rolls (alternately over and under one roll to the next) will travel 120 yards in a wash box measuring roughly 16 feet long×7 feet high if the rolls are spaced 6 inches apart horizontally and 6 feet apart vertically.
At high linear speeds of woven fabric traveling through the wash box plus counter current flow of wash liquor relative to the fabric travel through the wash box, good exchange of fresh rinse liquor for residual treating liquor in the fabric can be achieved. Many innovations in design of washers have been made to increase liquor penetration and exchange for both wet-on-wet impregnators and for wash boxes, with many of these designs employing means to generate turbulent liquor flow, forced flow of the liquor through the fabric as it passes over suction drums or slots, etc.
In seeking to improve the design of impregnators and wash or rinse boxes for nonwoven fiber assemblies, for example a 16 oz. per square yard carded or garnetted cotton batt, it is not practicable to attempt to pass the batt up and down long vertical distances over a series of rolls as described above for a woven fabric, since the nonwoven fabric or batt does not have enough strength to hold together as it travels long spans up and down over such a series of rolls so spaced. One alternative is to pass the nonwoven batt under a shallow immersion roll and then through the nip of a pair of squeeze rolls. However, to achieve an efficient, thorough wet-on-wet liquor exchange or rinsing effect it is necessary to pass the batt through a number of such "dip-and-nip" stages in tandem sequence with one another. By using a shallow (essentially horizontal) immersion path through each dip tank the fiber batt can be transported on one conveyor belt (rather than between two belts) with little or no risk of breaking the batt as it passes into, through, and out of the dip tank and then to the nip of the paired squeeze rolls. Unfortunately, however, the equipment cost for a multi-stage series of single-dip-single-nip wash boxes or impregnators becomes economically burdensome. A major cost factor is each pair of squeeze rolls needed for each high expression nip following each impregnation dip. During immersion, it is also important that the web be treated without a substantial stretching of the web. One way of avoiding excessive stretching of the web is to convey the web through a treatment tank in a generally longitudinal direction with relatively short up and down fluctuations in the path of the web.
Various designs for impregnators or rinsers which have been disclosed prior to the present invention are unsatisfactory since they employ either one or two conveyor belts to pass between the nip of paired high expression rolls or between stationary paired pressure plates, or they require the batt itself to pass between the nips of a series of high expression paired nip rolls to achieve satisfactory liquor exchange or rinsing efficiencies. For example, to increase the effectiveness of the action of the fluid on the web, a repetitive squeezing of the web during travel within the tank has been utilized by providing a sequence of paired squeeze rollers or stationary pairs of opposed pressure plates along the path of the web such as is shown in U.S. Pat. No. 3,681,951 issued to Chaikin et al. Other fluid treatment systems include a sequence of rollers arranged in a generally circular configuration to provide a sort of zigzag path for the web. A single conveyor belt has been used with such a roller arrangement such as is shown in the German Patent No. 1,460,397 issued to Freudenberg on May 29, 1969. In this arrangement, however, a central roller cooperates with the circular arrangement of rollers to provide a repeated paired nip roll squeezing action of the web between the central roller and adjacent rollers. The Freudenberg arrangement is also undesirable because it is unsuitable for use with a countercurrent flow.
Other attempts at providing a fluid treatment system having a series of rollers and one or more conveyor belts are described in U.S. Pat. No. 3,457,740 issued to Korsch, and U.S. Pat. No. 2,742,773 issued to Chambers et al.
However, the need still exists for an efficient, economical apparatus and method for impregnating and/or washing a nonwoven batt, particularly adapted for use in a continuous fashion.
It is an object of the present invention to provide a method which substantially avoids or alleviates the problems of the prior art.
It is an object of the present invention to provide a method for fluid treatment of a web of fibers by intermittently gently squeezing the web within a tank of fluid.
Another object of the present invention is to provide a method for fluid treatment of a web of fibers by conveying the web on a single endless belt alternately beneath a squeeze roller and above a cooperating roller.
Yet another object of the present invention is to provide a fluid treatment for a web wherein the web is conveyed on a single endless conveyor belt and travels in a generally horizontal direction so as not to be excessively stretched during the fluid treatment.
Still another object of the present invention is to provide a method for a fluid treatment of a batt in which the batt is repeatedly compressed and allowed to expand between compressions during the treatment within a tank of fluid.
An apparatus which satisfies these and other objects includes a longitudinal tank and a perforate endless conveyor belt which carries a non-woven web of fibers into the tank and beneath a first squeeze roller. The perforate conveyor belt may travel entirely within the longitudinal tank or alternatively the belt may pass underneath the tank while the belt is not carrying the non-woven batt. The web is generally squeezed in a nip defined between the conveyor belt and the squeeze roller to remove fluid from the web. The conveyor then carries the web over a first singular or cooperating roller and to the next squeeze roller. The web, after being gently squeezed, expands significantly to absorb fluid in the longitudinal tank as the web passes from one squeeze roller, over the intermediate cooperating roller and to the next squeeze roller. The conveyor belt repeatedly carries the web alternately beneath a squeeze roller and above a cooperating roller throughout the longitudinal tank to repeatedly squeeze the web. Fresh fluid may be supplied to the tank by way of one or more orifices positioned above the tank or alternatively fluid may be supplied from a collecting tank which is located beneath the longitudinal tank. The fluid generally travels in a direction opposed to the direction of travel of the web to continuously provide relatively fresh fluid for the web throughout the longitudinal tank.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more readily understood, reference is made to the accompanying drawings in which like numerals refer to like elements and in which:
FIG. 1 is a schematic flow diagram of stages of representative cotton fiber treatment system utilizing the processes and apparatus of the present invention to provide continuous chemical cleaning;
FIG. 2 is a side view in partial cross section of a first embodiment of an apparatus for continuous chemical cleaning according to the present invention;
FIG. 3 is a top view taken along lines 3--3 of FIG. 2 showing the arrangement of rollers with the web within the tank of the present invention;
FIG. 4 is a side view in partial cross section of a second embodiment of an apparatus for continuous chemical cleaning according to the present invention; and
FIG. 5 is an enlarged side view of a series of squeeze rollers and a series of cooperating rollers showing the plaited web being compressed and allowed to absorb liquid as it is carried by the endless conveyor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process of the present invention is intended to achieve a high degree of "liquor-for-air exchange" efficiency for wet-on-dry impregnations and a high degree of "liquor B-for-liquor A exchange" efficiency for wet-on-wet impregnations, washes or rinses for heavyweight nonwoven fiber batts in a manner which will not significantly disrupt, tear or rupture the batt and which will significantly reduce the number of pairs of high expression nip rolls, conveyor belts, liquid circulation pumps and agitators, etc., which would otherwise be needed. The "ideal" wet-on-dry impregnation process is one which will replace air or other gases (entrained in the dry fiber batt entering the impregnation vessel) with treating liquor completely in a relatively short time., i.e., on the order of a few seconds. And, the "ideal" wet-on-wet impregnation, wash or rinse process for our purposes is one which will replace a liquor A (which is entrained in the wet fiber batt entering impregnator) with liquor B contained in the impregnator, completely in a relatively short time, i.e., on the order of a few seconds. The "ideal" process in either case will not disrupt nor entangle fibers in the batt, nor weaken, tear or rupture the batt as the batt passes through the process. Although it is recognized that any actual, real process is not likely to achieve the perfection sought in the ideal process, the improved process of the present invention approaches the ideal process more effectively and with simpler, less expensive means than any other known process or apparatus.
Although the process of the present invention may be utilized in any process requiring a liquid impregnator, rinser or washer, it is hereinafter described in conjunction with a representative cotton fiber treatment.
Referring to FIG. 1, a schematic flow diagram is shown of stages of a representative cotton fiber treatment system utilizing the processes and apparatus of the present invention to provide fiber batt formation.
First, greige cotton bales are segregated according to quality grades and/or cotton varieties or selections, with particular regard to trash (non-lint) content, and if pertinent by fiber length, strength and micronaire characteristics.
Bale opening may be accomplished by a gross bale opener of suitable design, the function of which is merely that of opening up the baled fiber from the relatively high density characteristic of incoming compressed baled fiber to smaller fiber aggregates of lower density, thereby facilitating the controlled automatic feed of the fiber to subsequent coarse opening and cleaning stages. The subsequent coarse opening and cleaning stages consist of one or more sub-stages of coarse opening and cleaning equipment such as an inclined step cleaner or other known fiber cleaners such as manufactured by Fiber Controls Corporation. Fiber leaving one or more coarse opening and cleaning stages may then be conveyed to one or more stages of intermediate fine opening and cleaning equipment such as the known Shirley opener-cleaner and/or opener-cleaners such as a Fiber Controls model 310 fine opener-cleaner or a Fiber Controls model C60 opener-cleaner.
Controlled uniform fiber feed transfer from the intermediate fine opening and cleaning stages is next achieved by fiber batt formation to satisfy the high fiber mass feed rate and fiber area density feed uniformity desired for efficient operation of a very fine opening and cleaning fiber treatment unit. Such a fiber batt may be formed using a modified fiber feed chute known for conventional textile carding feed systems, or the fiber may be discharged onto one or more condenser cylinders from which a more uniform batt of desired density can be removed or "doffed".
The very fine opening and cleaning stage consists of a further removal of foreign material from the formed batt. Output from the very fine opening and cleaning stage may, if desired, be passed directly to a chemical cleaning operation. Preferably, the output from the very fine opening and cleaning stage is first subjected to a primary batt forming stage, which may be followed by a plaiting stage if desired, and two or more of these webs may then be plied or otherwise combined to form a consolidated batt of desired weight (area density) and fiber blend ratios. The consolidated batts so formed, either batch, semi-continuously or continuously, serve as a uniform batt feed supplied to a continuous chemical cleaner or to a fiber opener to feed a batch kier for preparation of cleaned cotton fiber for non-woven or yarn spinning operations.
The continuous chemical cleaning state may be accomplished utilizing the process and apparatus of the present invention as more fully described herein.
With reference now to FIG. 2 of the drawings, a first embodiment of the apparatus of the present invention which may preferably be used as a rinser for the non-woven batt includes a longitudinal tank 10 having a bottom member 12 and a pair of end walls 14,16. A pair of side walls 18,20 (see FIG. 3) are joined both to the end walls and to the bottom member to form a container for fluid which is substantially longer than the width of the tank.
In this embodiment it may be desirable to provide a countercurrent flow for the fluid within the tank. Accordingly, the end wall 14, which forms a front wall for the tank, is lower in height than the other end wall 16 which forms a back wall for the tank. When the tank is supplied with fluid, the fluid will flow over the front wall 14 before flowing over the back wall 16. The said walls 18,20 each include a top edge which extends from the top of the front wall to the top of the back wall such that the upper liquid level of fluid will be effectively contained in the tank as it flows by gravity in a generally horizontal fashion which is inclined downwardly towards the front wall 14.
A perforate endless conveyor 22 includes a belt 24 which travels in a continuous path around the longitudinal tank 10. In the arrangement of the first embodiment shown in FIG. 2, the belt 24 travels on a plurality of rollers 26 arranged below and at either end of the longitudinal tank. One or more of the rollers 26 is connected by suitable gearing (not shown) to an electric motor (also not shown) to provide a driving force for the belt 24. The belt travels in a generally clockwise direction (see FIG. 2) with the belt moving from the front wall 14 towards the back wall 16 within the longitudinal tank.
A series of squeeze rollers 28 are arranged within the tank in a generally planar configuration with each of the rollers 28 being cylindrically shaped and having an axis 34 which is transverse to the direction of travel of the belt 24. All of the axes of the squeeze rollers are parallel both to one another and to the bottom member 12 of the tank. The axes 34 are mounted at either end in the side walls 18,20 of the tank to permit each squeeze roller to freely rotate about the respective axis.
With reference also to FIG. 2, the belt 24 conveys a non-woven batt 50 from an immediately preceeding stage in a fiber treatment process such as a consolidated batt forming stage into the longitudinal tank over the front end 14. The batt 50 is carried throughout the longitudinal tank on an upper surface of the belt 24 so that the batt is always above the belt.
With reference again to FIG. 2, a series of singular or cooperating rollers 30 are arranged within the tank in a generally planar configuration spaced alternately between the squeeze rollers 28. Each of the cooperating rollers 30 is cylindrically shaped and has an axis 32 which is transverse to the direction of travel of the belt 24. The cooperating rollers are oriented with the squeeze rollers so that a top surface of each of the cooperating rollers is both between adjacent squeeze rollers and above lower surfaces of the adjacent squeeze rollers. In this way, the number of cooperating rollers is one less than the total number of squeeze rollers. In the first embodiment, four cooperating rollers and five squeeze rollers are provided within the tank.
All of the axes 32 of the cooperating rollers are arranged parallel to one another and parallel to the axes 34 of the squeeze rollers. The axes 32 are mounted at either end in the side walls 18,20 of the longitudinal tank to permit each cooperating roller to freely rotate about each axis. Alternatively, both the squeeze rollers and the cooperating rollers may be mounted on an adjustable frame (not shown) to permit relative vertical movement of the squeeze rollers both with respect to each other and with respect to the cooperating rollers.
The belt 24 travels in a winding path alternately beneath the squeeze rollers and above the cooperating rollers. After passing above the front end 14 of the tank, the belt 24 carries the batt 50 beneath the first squeeze roller 28 where the web is gently squeezed in a nip defined between the belt and the roller. The perforations of the belt permit a large fraction of the fluid which has been absorbed by the batt to be squeezed out of the batt. Generally, the squeeze roller 28 reduces the gross wet fluid volume contained in the batt to about 1/5 or about 1/2 of the unsequeezed gross wet fluid volume, and more frequently from about 1/4 to about 1/3, without substantially detrimentally affecting the cohesiveness of the non-woven batt. Immediately after the batt has passed beyond the first squeeze roller the batt then absorbs additional fluid to replace that fluid removed during squeezing.
The batt 50 is now conveyed by the belt upwardly towards the first cooperating roller 30. During the travel of the batt between the first squeeze roller, over the first cooperating roller and to the second squeeze roller, the batt becomes completely saturated with fluid.
With reference now to FIG. 5, the travel of the batt 50 under the first squeeze roller 28 reduces the cross sectional thickness of the batt as a result of forces exerted by the belt 24 in a direction towards the axis 34 of the squeeze roller. As the belt passes beneath the squeeze roller, a tension provided throughout the entire length of the belt is comprised of tangential and radial components with the radial component reaching a maximum value at a lowermost portion of the squeeze roller. It is at the lowermost portion of the squeeze roller, therefore, that the batt undergoes the greatest compression between the belt 24 and the surface of the squeeze roller 28. After the batt has traveled beyond the lowermost portion of the squeeze roller, the radial component of force exerted by the belt on the web decreases. The radial component of force is equal to zero when the batt is no longer in contact with the surface of the squeeze roller.
As the batt is carried by the belt 24 from squeeze roll 28 to the adjacent cooperating roller, the batt is free to readily absorb fluid from the longitudinal tank. The cross sectional thickness of the batt increases to a maximum extent when the batt is completely saturated with fluid. The cooperating rollers enable the belt to obtain a desired radial component of force while traveling beneath the series of squeeze rollers without requiring an extremely high degree of tension on the belt.
As the batt is conveyed throughout the longitudinal tank, the batt is repeatedly squeezed while passing between a squeeze roller and the conveyor belt 24. As represented by the increased thickness of the batt in FIG. 5, the batt is allowed to absorb fluid between the series of intermittent squeezes and becomes completely saturated while passing between successive squeeze rollers.
After passing over the first cooperating rollers, the batt is conveyed beneath the second squeeze roller where the fluid is substantially removed from the batt as it is gently squeezed between the belt and the squeeze roller in the same manner and amount as described above. From the squeeze roller, the batt is conveyed to another cooperating roller with the non-woven batt again absorbing the liquid in the tank 10 in the manner and amounts as described above, and vice versa throughout the length of the longitudinal tank.
An important aspect of the present invention is achieving the significant increase desired in impregnation and rinsing efficiencies for a non-woven batt is the inclusion of a series of gentle repetitive squeezing actions applied to the batt while it is immersed in and traveling through the impregnation liquid. Each gentle squeezing action expresses a large fraction of the liquid contained by the non-woven batt while it is immersed. The subsequent release of squeezing pressure while the batt is still immersed in the treating or rinsing liquid then draws large fractions of fresh treating or rinsing liquor into the fiber batt, thereby increasing the liquor interchange within the batt. By subjecting the batt to a series of gentle squeezing pressures with intermediate removal of such pressures between squeezing positions, where both application and release of pressure occurs while the batt is immersed in the liquor, a highly efficient impregnation and/or liquor exchange can be obtained without damaging, tearing or rupturing the batt and without the need to use pairs of nip rollers to express the liquor between immersion dips.
Although two submerged squeezes are significantly better than one for improving the liquor exchange within the batt, three submerged squeezes are better than two, and four are better than three. Any number of from at least 3 and up to roughly 20 submerged gentle squeezing actions applied to the batt increase the efficiency of liquor impregnation, washing or rinsing to a very high degree. However, for most purposes, from 4 to 10 such gentle cycles of applied and released submerged squeezing pressure are sufficient for most nonwoven fiber batt treating purposes.
From the last squeeze roller, the batt is carried by the belt up over the rack end 16 of the tank to a pair of high-expression nip rolls 40,42 which remove most of the fluid from the batt before the web leaves the apparatus of the present invention. Generally, depending upon the next treatment to which the non-woven batt will be subjected, the nip rolls will remove the fluid in the batt to a level of from about 60% to about 300%, WPU, preferably from about 80% to about 150%, WPU (meaning 0.6 to about 3 pounds of liquor per pound of dry fiber in the batt, preferably from about 0.8 to about 1.5 pounds of liquor per pound of dry fiber in the batt).
With continued reference to FIGS. 2 and 3, a collecting pan 44 which is located beneath both the longitudinal tank 10 and the conveyor 22 receives fluid which is removed from the batt by nip rollers 40,42. This fluid is recycled to the longitudinal tank 10 via a sump 46, a pump 52 and a piping system 51 with the discharge orifice of 51 positioned preferably closer to end wall 16 of the longitudinal tank 10 to enhance countercurrent flow from the back wall 16 to the front wall 14. Since the front wall 14 of the longitudinal tank 10 is lower than the back wall 16, fresh liquor supplied by the orifice 54 also travels in a direction which is opposite to that of the moving batt within tank 10. Accordingly, a significant counterflow is obtained wherein the batt is progressively exposed to fresher fluid as the batt travels through the tank. When the apparatus is used as a rinser, fresh rinse liquor added to the tank through the orifice 54 flows generally countercurrent to the direction of the batt movement and overflows into a trough 55 connected either directly to the drain by gravity flow or, alternatively, to the inlet of a pump 53 from which a rinse effluent from tank 10 may be pumped to drain or countercurrent to another upstream rinsing stage. Alternatively, if the apparatus is used as an impregnator to apply a treating liquor (such as a bleach or dye liquor), the trough 55 and the pump 53 are not required.
With reference now to FIG. 4, a second embodiment of the present invention, which may be used as either a rinser or as an applicator of, for example, dye to the non-woven batt, includes a longitudinal tank 110 having a bottom member 112 and a pair of end walls 114,116. A pair of side walls 118,120 (shown as hatched lines) are joined both to the end walls and to the bottom member to form a container for fluid which is substantially longer than the width of the tank.
Referring again to FIG. 4, depending on the intended use of the present apparatus, for example as an impregnator or as a rinser, auxiliary liquor input and effluent piping and flow arrangements may be easily altered to enable the impregnator/rinser to serve more effectively as either an impregnator or as a rinser. When the apparatus is used simply as a rinser, fresh rinse liquor may be added directly to the tank 110 via a piping system 154 without the need for a liquid level control device 158 connected to a liquor flow control valve 157. And, if there is no need to reuse the spent rinse liquor effluent which spills over a weir at the front end 114 of the tank 110, the spent rinse liquor effluent may flow by gravity directly to a sewer drain, or, alternatively as shown in FIG. 4, into a sump 146 from which it may be pumped through a heat exchanger. If the rinse effluent is to be reused (e.g., as in the case of a bleach rinse effluent to serve as a rinse liquor for an up-stream alkali rinsing stage), then the rinse effluent may be pumped to another rinsing stage. In any alternative in which the sump 146 is employed in the discharge of the rinse effluent from the apparatus shown in FIG. 4, the rinse effluent may be transfered from the sump 146 through a piping system 156 using a pump 152, in which case it is desirable to use a level control device 159 and a sump recycle control valve 160 to protect the pump 152. In any alternative piping arrangement described above for use with the apparatus when it is used as a rinser, good generalized counter-current flow is achieved with the gross mass flow rate of rinse liquor entering tank 110 through the piping system 154 nearer the back wall 116, and flowing by gravity within the tank 110 in a path leading to the overflow wier at the top edge of front wall 114. Hence a concentration gradient is maintained within tank 110 with fresher, cleaner rinse water nearer the back wall 116 of tank 110, and dirtier, spent rinse water near the front wall 114 of tank 110.
When the apparatus shown in FIG. 4 is used simply as an impregnator for applying scouring, bleach or dye liquor, etc., fresh makeup liquor may be added directly to tank 110 via the piping system 154 using the liquor level control 158 in the tank 110 to open and close the control valve 157, in which case the sump 146 and associated piping need not be employed. However, it may often be preferable to employ the sump 146 for better control and mixing of fresh impregnation liquor makeup, in which case the fresh makeup liquor is supplied to the sump 146 through an alternative piping system 154', employing a liquor level control device 159 to open and close a control valve 161. The liquor in the sump 146 is constantly being mixed by recycle circulation through the pump 152 and a manual resistance valve 162, while a portion of the liquor from the pump 152 passes through a manual resistance valve 163 into the tank 110 via a piping leg 151. Since the level control device 159 is used in this case to open and close the control valve 161, the manual resistance valve 162 replaces the automatic control valve 160 in order to establish a flow ratio of liquor recycling directly back to the sump through the resistance valve 162 versus the amount flowing into the tank 110 through the resistance valve 163 and the pipe leg 151.
With continued reference to FIG. 4, a perforate endless conveyor 122 includes a belt 124 which travels in a continuous path within the longitudinal tank 110. Immediately above the bottom of the tank, the belt 124 travels on a plurality of rollers 126 arranged at spaced intervals. One or more of the rollers 126 is connected by suitable gearing (not shown) to an electric motor (also not shown) to provide a driving force for the belt 124. The belt travels in a generally clockwise direction within the tank with the belt moving from the front wall 114 towards the back wall 116 and then returning to the front wall along the bottom of the tank.
A series of squeeze rollers 128 are arranged within the tank in a generally planar configuration with each of the rollers 128 being cylindrically shaped and having an axis 134 which is transverse to the direction of travel of the belt 124. All of the axes of the squeeze rollers are parallel both to one another and to the bottom member 112 of the tank. The axes 134 are mounted at either end in the side walls 118,120 of the tank to permit each squeeze roller to freely rotate about the respective axis.
The belt 124 conveys a non-woven batt 150 from an immediately preceeding stage in a fiber treatment process such as a consolidated batt forming stage into the tank over the front end 114. The batt 150 is carried on an upper surface of the belt 124 so that the batt is always above the belt.
A series of cooperating rollers 130 are arranged within the tank in a generally planar configuration below the squeeze rollers 128. Each of the cooperating rollers 130 is cylindrically shaped with a cross sectional diameter which is preferably less than a cross sectional diameter of a squeeze roller 128, and has an axis 132 which is transverse to the direction of travel of the belt 124. The cooperating rollers are oriented with the squeeze rollers so that each of the cooperating rollers is located between adjacent squeeze rollers, with the axis of each squeeze roller located above the axis of each cooperating roller. However, the top surface of each cooperating roller is above the bottom surface of each corresponding squeeze roller.
In this embodiment, five squeeze rollers and four cooperating rollers are alternately arranged throughout the longitudinal tank. However, more or fewer rollers to provide from at least 3 and up to roughly 20 submerged gentle squeezing actions are desirable.
Depending upon the specific magnitude and duration of radial force desired, the vertical spacing of the upper portions of the cooperating rollers with respect to the lower portions of the squeeze rollers may be varied. Additionally, the magnitude of the diameters of the squeeze rollers and the cooperating rollers may be varied to obtain many different arrangements. For example, the series of squeeze rollers may include rollers which alternately have large and small radii so as to provide squeezes of alternately short and long duration.
A pair of high expression nip rolls 140,142 are positioned at the end of the tank to remove most of the fluid from the batt. This fluid is returned directly to the tank by positioning the rolls 140,142 in front of the back wall 116. Generally depending upon the next treatment to which the non-woven batt will be subjected, the nip rolls will remove the fluid in the batt to a level of from about 60% to about 300%, WPU, preferably from about 80% to about 150% WPU.
The process of the present invention is particularly effective on non-woven batts which possess a sufficiently large thickness dimension normal to the plane in which the batt is traveling, and a sufficiently large degree of wet resilience for alternating compression and recovery as the gentle, compressional squeezing forces are alternately applied and released as the batt passes under and over the rolls described above.
If the batt is too thin or too dense (such as is generally the case with woven fabrics), then the process is no longer as significantly effective. Hence the non-woven batt preferably should weight over 4 oz/square yard, most preferably over 8 oz/square yard (dry fiber basis for conventional textile fibers such as cotton, wool and conventional synthetic fibers). The bulk density of the fiber batt (dry fiber basis) should preferably be less than 30 pounds per cubic foot in the relaxed homogeneous state. Depending on the type of liquid treatment desired, the liquid in the tank 10 or the tank 110 may be, for example, water, alkaline scouring liquor, dye bath or other chemical treating baths.
SUMMARY OF ADVANTAGES OF THE PRESENT INVENTION
The new impregnator/rinser as disclosed herein employs a single endless conveyor belt which enters one end of a relatively long and shallow and relatively horizontal impregnation vessel, and which belt passes over one series of cooperating rolls and under another series of squeeze rolls. Each roll is positioned with the rotational axes of all of the rolls in the series over which the conveyor belt passes lying essentially in one horizontal plane, and the rotational axes of the combined series of rolls being also essentially parallel to each other and relatively close to each other, or they may actually coincide in one essentially horizontal plane. Such a spaced configuration of the turn rolls (within-and-between each series of turn rolls) allows one (a) first to control the movement of loose staple fiber (or of non-woven staple fiber batts characterized by low fiber to fiber cohesion or adhesion) in a continuous, uninterrupted path through the impregnation or rinsing liquid contained in the impregnation vessel, and (b) also to do so by means of only one endless conveyor belt, and thereby to convey the loose fiber or non-woven batt (resting upon or supported by only one conveyor belt as the batt and the belt pass alternately over one roll and then under the next roll, then over the next roll, and so on) continuously over and under the entire sequence of turn rolls throughout the entire length of the impregnation vessel. With such a spaced configuration of the turn rolls so employed to guide the travel motion of the loose fiber or batt as it is conveyed on the top of a single conveyor belt it is also possible to obtain an effective degree of controlled intermittent application and relaxation of squeezing pressure against the surface of the loose fiber or non-woven batt to obtain good impregnation and expression of treating or rinsing liquid, all without the need to employ nipping means such as pairs of squeeze rolls or opposed pressure plates which otherwise are used for such purposes.
For loose fiber or non-woven fiber batt processing purposes in which the fiber is treated in a series of wet processing and drying stages, it is advantageous (a) to maintain the integrity and uniformity of batt area and linear densities as the fiber is conveyed through each wet processing or drying stage in order that each treating stage process treatment can be carried out more efficiently with less energy and less consumption of liquid media and treating chemicals, and (b) to maintain sufficient cohesion of the batt to facilitate fiber transfer fron one liquid impregnator or rinser to the next in a continuous multi-stage process sequence. The design features of the impregnator/rinser of the present invention provide the means for applying all such treatments to loose staple fiber or to nonwoven batts formed from such fiber without significant disruption of the integrity and uniformity of the fiber batt linear and area densities as the fiber is conveyed as a continuous batt, first over a cooperating roll and then under a squeeze roll, throughout the entire series of rolls composed of cooperating rolls alternately spaced between squeeze rolls.
It is also highly desirable to retain the freedom of conveyor belt design to permit the selection and use of open porous belts fabricated at low cost from economical materials; and hence it is essential that such conveyor belts are not required to pass through the pressure nips formed between two or more squeeze rolls or pressure plates. It is also preferred that only one conveyor belt be used to support and convey the fiber batt as it travels over and under the sequence of cooperating rolls and squeeze rolls. In this fashion a wide range of preferred open wire mesh belt designs may be used on only the underside of the fiber batt. And in this manner such conveyance means avoids objectionable compressive interaction between two such wire mesh conveyors against each other and against the fiber batt, which otherwise would be the case if an upper and a lower belt were used to contain and control the movement of the fiber batt as it is conveyed over and under a series of rolls and/or between the nips of paired squeeze rolls. Such interaction between two belts (for example, open wire mesh belts) rubbing compressively against the fiber batt and/or against each other would damage the fiber batt and also inflict excessive wear on the belts and turn rolls.
The alternating squeezing compression and relaxation expansion of the fiber batt may be effectively carried out by the new and innovative impregnator/rinser in which only one endless conveyor belt need be used to transport the fiber batt and in a fashion which does not require the use of one or more pairs of nip rolls or pressure plates to obtain effective impregnation or rinsing liquor exchange into and out of the fiber batt, and in a fashion which readily facilitates counter current flow of treating liquors throughout the length of the impregnation vessel in essentially a horizontal flow from the liquor input end of the vessel to the liquor discharge end of the vessel without the need to employ auxiliary pumping means between the input liquor port and the discharge liquor port to cause such counter current flow.
By means of the novel process of the present invention, the fiber batt is effectively compressed between a turn roll and a single endless conveyor belt in such a fashion that
(a) there is no significant dragging friction and wear between the conveyor belt and the turn rolls (or any other cooperating rolls or compressive surfaces) as compressive forces are applied normal to the face of the fiber batt; and,
(b) the fiber batt is not under tension; and,
(c) there is no mussing or disarrangement of the fiber web or batt formation during successive and alternating compressive squeezings and relaxing expansions of the batt as it passes through the impregnating liquor.
Furthermore, the use of objectionable sprays are avoided as devices for forcing fresh liquor into the batt. Sprays are objectionable since they also muss and disarrange the fiber in the batt, and they require additional pumps and maintenance of equipment. Since at no time is the conveyor belt of the impregnator/rinser of the present invention required to pass between nip rolls or to pass over, under, or between fixed (i.e., motionless) surfaces in rubbing contact, the life of the conveyor belt is extended to a very large degree, and also the freedom to use preferred, economical, open wire mesh conveyor belts designs is feasible. And further, by avoiding the need to pass the conveyor belt between the pressure nip of two or more squeeze rolls, the conveyor belt tension may be adjusted by one simple tensioning device at one position in the endless conveyor belt path; and thereby the tension applied to the belt along the entire length of belt travel through the impregnator may be controlled; and hence thereby the compressive pressure applied by the conveyor belt against the fiber batt at each squeeze roll position may be controlled.
Furthermore, the use of many repetitive compressive paired nip roll actions (required by prior art means to obtain good liquid interchange into and out of such fiber batts) is highly objectionable where a series of wet processing stages with intermediate fiber transfer zones are needed in the total continuous processing system since each passage of the batt through a pair of nips tends to draft or elongate the batt. An excessive number of such incremental elongation drafts will eventually rupture the batt making further transfer from one conveyor belt zone to the next difficult (without stopping the belts and hence interrupting the smooth continuous flow of fiber batt through the processing system). The new impregnator design of the present invention avoids the use of paired squeeze roll nipping actions to accomplish effective treating and/or rinsing liquor exchange in the impregnation vessel; and hence the new impregnator design is much preferred for applying treating or rinsing liquors to such nonwoven fiber batts.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the present invention.
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An apparatus and method for providing an impregnation/rinsing of a web with fluid is disclosed wherein the web is repeatedly gently squeezed and allowed to open. A preforated conveyor belt carries the web within a longitudinal tank in which a series of squeeze rollers and a series of singular or cooperating rollers are arranged with the cooperating rollers being disposed intermediate the squeeze rollers. The web is carried by the conveyor belt beneath the first squeeze roller where the web is gently squeezed in a nip defined between the conveyor belt and the roller. The conveyor belt then carries the web above a cooperating roller. After the web has been gently squeezed, it is allowed to absorb the fluid in the tank without restraint until the web is gently squeezed again between the conveyor belt and the next squeeze roller. The steps of squeezing and absorbing are repeated throughout the longitudinal tank. Fluid is supplied to the longitudinal tank by one or more orifices which receive fluid from either a collection tank provided beneath the conveyor belt and longitudinal tank and/or from a supply of fresh fluid. The fluid in the tank typically travels in a path which is opposed to the general direction of travel of the web within the tank, especially when the apparatus is used as a rinser.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is continuation of co-pending U.S. application Ser. No. 10/202,739, which was filed Jul. 25, 2002, and is incorporated herein in its entirety by express reference thereto.
FIELD OF THE INVENTION
[0002] The present invention relates generally to golf balls. More specifically, the present invention relates to methods for heating golf ball components.
BACKGROUND OF THE INVENTION
[0003] Solid golf balls are usually two or more piece constructions. Two-piece golf balls include a single-piece core and a cover. The core forms a golf ball component that the cover surrounds. Multi-piece golf balls include one or more core layers, an intermediate layer, and a cover. In such balls, the core and intermediate layer form the golf ball component that the cover surrounds.
[0004] For a preferred cover, one material is a thermosetting composition. One method of making golf balls with a thermoset cover includes disposing the golf ball component into a cover mold and casting the cover thereon. During casting, heat is generated by an exothermic reaction of the thermoset processes. As a result of this heat, the ball component tends to undergo volumetric thermal expansion. The thermal expansion of the component can force the cover mold open and cause the component to shift in the mold so that the cover is uneven and has excessive flash. Also, the thermal expansion makes it difficult to maintain size accuracy in the finished ball. This can result in an unplayable ball.
[0005] Prior solid golf balls having cast urethane covers were made using a method that includes preheating the golf ball component to a predetermined elevated temperature. Preheating the component is done to the extent that causes the component to undergo volumetric thermal expansion. Thereafter, the cover is cast onto the component. For example, see U.S. Pat. No. 6,096,255, which is incorporated herein in its entirety.
[0006] It is well known in the art that preheating golf ball components decreases the total temperature change the component is exposed to and minimizes the thermal expansion of the component in the cover mold. Heating methods that have been utilized in the prior art are convection heating, whether it be a batch process or a continuous conveyor system. It is not unusual to require 34 hours of convection heating to raise the temperature of a golf ball core from 68° F. to 125° F. This length of time can be a production bottleneck and consume a large amount of energy.
[0007] Therefore, what is desired is a method of heating golf ball components by a much faster and energy efficient means.
SUMMARY OF THE INVENTION
[0008] The invention provides a method for heating a golf ball component, whether it be a core, core having multiple core layers, or a core with additional intermediate layer(s) thereon. The heating is preferably completed prior to the component having a layer or cover applied. The method comprises heating the ball components by radio frequency (RF). The golf ball components travel into a RF field between a series of electrodes. The electrodes are located at the top and bottom of a conveyor system for a predetermined RF exposure. A RF generator provides the energy for pre-heating. Ball components pass through a RF applicator and RF attenuation tunnels at both the feed and discharge ends. Energy levels are controlled based on the load requirements calculated by specific heat and desired change in temperature. A custom automation system moves a high volume of product in and out of the RF tunnel for a desired length of time to heat the component to a predetermined temperature. One embodiment adds supplemental convection heating to enhance consistent temperature on the component surface.
[0009] Preferably, a tight temperature gradient is achieved across the cross-section of each ball component as well as a low deviation in temperature between each ball component.
[0010] An increase in energy efficiency is achieved as only that energy which directly heats the ball components is necessary and expended.
[0011] The present invention provides for a ball component exhibiting a greater consistency as RF heats the product from the center to the outside.
[0012] An embodiment of the invention provides for a post cure of a polybutadiene core to reduce the time of the molding cycle.
[0013] The present invention provides for a rapid curing of urethane golf ball covers.
[0014] The present invention provides for pre-heating the golf ball prior to spray painting and for providing RF heat to cure the paint.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an elevational partially cut-out front view of a conveyor feed of product into and out of an RF heater.
[0016] FIG. 2 is a top view of the system shown in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present invention relates generally to the heating of golf ball components by radio frequency (RF). The components can include a core, a center and at least one core layer, or a core, and a combination of at least one core layer and/or at least one intermediate layer. RF heating can also be employed to post-cure golf ball polybutadiene cores, cure urethane castings and cure the spray paint on a finished golf ball. The golf balls may also be pre-heated by RF waves prior to the application of the paint.
[0018] A golf ball component experiences a dramatic increase of heat when a core layer or especially an intermediate layer or cover layer is cast to it. The volumetric expansion of the ball component during this process often causes manufacturing difficulties. One problem area is that the thermal expansion of the component can force the cover mold open and cause the component to shift in the mold so that the cover is uneven and has excessive flash. This can result in an unplayable ball. To alleviate and counteract excessive thermal expansion during the casting process, manufacturers may preheat the ball component to a predetermined elevated temperature, usually between about 100° F. to about 160° F. and up to 300° F. when used for post curing of polybutadiene cores. The pre-heated ball component is therefore not exposed to the dramatic volumetric thermal expansion as would an unheated component. It is well known in the art that preheating the golf ball components decreases total temperature change the component is exposed to and therein minimizes the thermal expansion of the component while in the cover mold. Thus, manufacturers may preheat the golf ball components prior to casting over them with another layer. Methods that have been utilized in the prior art are primarily two types of convection heating; a batch process and a continuous conveyor process. It is not unusual with the batch process to require about 3-4 hours of convection heating to raise the temperature of a golf ball core from 68° F. to 125° F. In a continuous conveyor process this time can be reduced to about 45 to 60 minutes. This length of time can be a production bottleneck in both space and energy costs.
[0019] The present invention utilizes a method of heating the golf ball component by means of radio frequency (RF) waves. This as accomplished by feeding golf ball components into the system by automatic conveyor feed system and subsequently into an RF generated field, where the temperature rise in a golf ball component from about 68° F. to 125° F. can be achieved in 30 to 60 seconds. (Chart I below) It is to be appreciated that while the method as described herein utilizes a conveyor feed system, the present invention may also be employed utilizing a batch process.
COMPARISON OF GOLF BALL SUBASSEMBLY PRE-HEATING METHODS INITIAL CORE TEMP. FINAL CORE TEMP. TEMPERATURE RISE (PRIOR TO HEATING) (AFTER HEATING) (Δ T) PROCESS TIME HEATING METHOD (DEG. F.) (DEG. F.) (DEG. F.) (HRS: MINS; SECS;) CONVECTION HEAT 68 125 57 3-4 HRS. BATCH PROCESS CONVECTION HEAT 68 125 57 45-60 MINS. CONTINUOUS CONVEYOR RADIO FREQUENCY 68 125 57 30-60 SECS. CONTINUOUS CONVEYOR
[0020] The present invention provides for a product with a greater consistency as RF waves heat the golf ball component from the center to the outside. The heating occurs instantly and uniformly throughout all three dimensions. No temperature differential is required to force heat by conduction from the surface to the center as in surface heating processes. An increase in energy efficiency is achieved as only energy is used that directly heats the product. No long warm-up or cooling time is required. Power is consumed only when the load is present and only in proportion to the load.
[0021] In a radio frequency heating system, the RF generator creates an alternating electric field between two electrodes. The component to be heated is conveyed between the electrodes where the alternating energy caused polar molecules in the product material to continuously reorient themselves to face opposite poles much like the way bar magnets behave in an alternating magnetic field. The friction resulting from molecular movement causes the material to rapidly heat throughout its entire mass. The amount of heat generated in the component is determined by the frequency, the square of the applied voltage, dimensions of the component and the dielectric loss factor of the material which is essentially a measure of the ease with which the material can be heated by RF waves.
[0022] The process of the present invention is shown on FIGS. 1 and 2 . A continuous conveyor 11 accepts a continuous supply of golf ball components 12 and transports them into and through a RF generator 13 where a pair of electrodes, a ground electrode 14 and a plate electrode 15 , create a RF field 16 therebetween. The golf ball components 12 are passed through the RF field 16 by a custom automation system at such a rate to cause an increase in golf ball temperature from room temperature (about 68° F.) to about 100° F. to 160° F. The rate of speed in which the golf ball components 12 are moved within the RF waves is a function of the energy that is required to raise the temperature of the components to the predetermined temperature. The time is preferably between 30 to 60 seconds. Energy levels are controlled based on the load requirements calculated by specific heat and desired temperature change. The time is a function of the energy level capacity of the machine 10 and the number, size and composition of the components 12 moving through the field 16 at any given time. The present invention employs a conveyor feed system that handles rows of multiple golf ball components. As the components pass through the field 16 , the conveyor has means to constantly rotate them, thereby allowing for a more uniform heating of each component. Although the drawings show rows having 9 components across, this number is merely a convenience item that relates directly to the size of each component and the RF equipment. Preferably the number of ball components in a row is greater than 3 and between 6 to 12.
[0023] In another embodiment of the invention, supplemental convection heating is added to enhance a consistent temperature across the surface of the component.
[0024] The definition of a golf ball component 12 includes a single layer core; a core of a center and at least one outer core layer; and a core of one or more layers covered by at least one intermediate layer. The method of the present invention is intended to heat the golf ball component 12 prior to casting a subsequent core, intermediate layer or cover layer thereon, and if further core or intermediate layers are desired they are preferably subsequently cast prior to the ball component cooling down.
[0025] The type of preheating equipment used to generate the RF waves is preferably a Macrowave™ Model L-200 such as supplied by the Radio Frequency Company, Millis, Mass.
[0026] The core composition can be made from any suitable core materials including thermoset polymers, such as natural rubber, ethylene propylene rubber or epdiene monomer, polybutadiene (PBD), polyisoprene, styrene-butadiene or styrene-propylene-diene rubber, and thermoplastics such as ionomer resins, polyamides, polyesters, or a thermoplastic elastomer. Suitable thermoplastic elastomers include Pebax®, which is believed to comprise polyether amide copolymers, Hytrel®, which is believed to comprise polyether ester from Elf-Atochem, E.I. Du Pont de Nemours and Company, various manufacturers, and Shell Chemical Company, respectively. The core materials can also be formed from a castable material. Suitable castable materials include those comprising a urethane, polyurea, epoxy, silicone, IPN's, etc.
[0027] The polybutadiene rubber composition preferably includes between about 2.2 parts and about 5 parts of a halogenated organosulfur compound. The halogenated conventional materials for such cores include core compositions having a base rubber, a cross-linking agent, filler and a co-cross-linking agent. The base rubber typically includes natural or synthetic rubbers. A preferred base rubber is 1,4-polybutadiene having a cis-structure of at least 40%. Natural rubber, polyisoprene rubber and/or styrene-butadiene rubber may be optionally added to the 1,4-polybutadiene. The initiator included in the core composition can be any known polymerization initiator that decomposes during the cure cycle. The cross-linking agent includes a metal salt of an unsaturated fatty acid such as a zinc salt or a magnesium salt of an unsaturated fatty acid having 3 to 8 carbon atoms such as acrylic or methacrylic acid. The filler typically includes materials such as tungsten, zinc oxide, barium sulfate, silica, calcium carbonate, zinc carbonate and the like. The polybutadiene rubber composition preferably includes between about 2.2 parts and about 5 parts of a halogenated organosulfur compound. The halogenated organo-sulfur compound may include pentafluorothiophenol; 2-fluorothiophenol; 3-fluorothiophenol; 4-fluorothiophenol; 2,3-fluorothiophenol; 2,4-fluorothiophenol; 3,4-fluorothiophenol; 3,5-fluorothiophenol 2,3,4-fluorothiophenol; 3,4,5-fluorothiophenol; 2,3,4,5-tetrafluorothiophenol; 2,3,5,6-tetrafluorothiophenol; 4-chlorotetrafluorothiophenol; pentachlorothiophenol; 2-chlorothiophenol; 3-chlorothiophenol; 4-chlorothiophenol; 2,3-chlorothiophenol; 2,4-chlorothiophenol; 3,4-chlorothiophenol; 3,5-chlorothiophenol; 2,3,4-chlorothiophenol; 3,4,5-chlorothiophenol; 2,3,4,5-tetrachlorothiophenol; 2,3,5,6-tetrachlorothiophenol; tetrafluorothiophenol; 4-chlorotetrafluorothiophenol; pentachlorothiophenol; 2-chlorothiophenol; 3-chlorothiophenol; 4-chlorothiophenol; 2,3-chlorothiophenol; 2,4-chlorothiophenol; 3,4-chlorothiophenol; 3,5-chlorothiophenol; 2,3,4-chlorothiophenol; 3,4,5-chlorothiophenol; 2,3,4,5-tetrachlorothiophenol; 2,3,5,6-tetrachlorothiophenol; pentabromothiophenol; 2-bromothiophenol; 3-bromothiophenol; 4-bromothiophenol; 2,3-bromothiophenol; 2,4-bromothiophenol; 3,4-bromothiophenol; 3,5-bromothiophenol; 2,3,4-bromothiophenol; 3,4,5-bromothiophenol; 2,3,4,5-tetrabromothiophenol; 2,3,5,6-tetrabromothiophenol; pentaiodothiophenol; 2-iodothiophenol; 3-iodothiophenol; 4-iodothiophenol; 2,3-iodothiophenol; 2,4-iodothiophenol; 3,4-iodothiophenol; 3,5-iodothiophenol; 2,3,4-iodothiophenol; 3,4,5-iodothiophenol; 2,3,4,5-tetraiodothiophenol; 2,3,5,6-tetraiodothiophenoland; and their zinc salts, the metal salts thereof, and mixtures thereof, but is preferably pentachlorothiophenol or the metal salt thereof. The metal salt may be zinc, calcium, potassium, magnesium, sodium, and lithium, but is preferably zinc.
[0028] Additionally, suitable core materials may also include cast or reaction injection molded polyurethane or polyurea, including those versions referred to as nucleated, where a gas, typically nitrogen, is incorporated via intensive agitation or mixing into at least one component of the polyurethane. (Typically, the pre-polymer, prior to component injection into a closed mold where essentially full reaction takes place resulting in a cured polymer having reduced specific gravity.) These materials are referred to as reaction injection molded (RIM) materials. Alternatively, the core may have a liquid center.
[0029] The core preferably has a compression in the range between about 30 to 110. For a core that is relaively soft the compression should be about 40 to 80, and for a relatively hard core, the compression should be about 90 to 110. The core preferably has a Coefficient of Restitution greater than 0.80.
[0030] The intermediate layer, if desired, can be formed by joining two hemispherical cups of material in a compression mold or by injection molding, as known by one of ordinary skill in the art. The intermediate layer may be a thermoplastic or a thermoset material. For example, a recommended ionomer resin material is SURLYN® and a recommended thermoplastic copolyetherester is Hytrel®, which are commercially available from DuPont. Blends of these materials can also be used. Another example of a suitable intermediate layer material is a thermoplastic elastomer, such as described in U.S. Pat. Nos. 6,315,680 and 5,688,191, which are both incorporated herein by reference in their entireties.
[0031] The intermediate layer may be formulated wherein vulcanized PP/EPDM. Santoprene® 203-40 is an example of a preferred intermediate layer comprises of dynamically vulcanized thermoplastic elastomer, functionalized styrene-butadiene elastomer, thermoplastic polyurethane or metallocene polymer or blends thereof. Suitable dynamically vulcanized thermoplastic elastomers include Santoprene®, Sarlink®, Vyram®, Dytron® and Vistaflex®. Santoprene® is the trademark for a dynamically Santoprene® and is commercially available from Advanced Elastomer Systems. Examples of suitable functionalized styrene-butadiene elastomers include Kraton FG-1901× and FG-1921×, which is available from the Shell Corporation. Examples of suitable thermoplastic polyurethanes include Estane® 58133, Estane® 58134 and Estane® 58144, which are commercially available from the B. F. Goodrich Company. Suitable metallocene polymers whose melting points are higher than the cover materials can also be employed in the mantle layer of the present invention. Further, the materials for the intermediate layer described above may be in the form of a foamed polymeric material. For example, suitable metallocene polymers include foams of thermoplastic elastomers based on metallocene single-site catalyst-based foams. Such metallocene-based foam resins are commercially available from Sentinel Products of Hyannis, Mass. Suitable thermoplastic polyetheresters include Hytrel® 3078, Hytrel® 3548, Hytrel® 4078, Hytrel® 4069, Hytrel® 6356, Hytrel® 7246, and Hytrel® 8238 which are commercially available from DuPont. Suitable thermoplastic polyetheramides include Pebax® 2533, Pebax® 3533, Pebax® 4033, Pebax® 5533, Pebax® 6333, and Pebax® 7033 which are available from Elf-Atochem. Suitable thermoplastic ionomer resins include any number of olefinic based ionomers including SURLYN® and lotek®, which are commercially available from DuPont and Exxon, respectively. The flexural moduli for these ionomers is about 1000 psi to about 200,000 psi. Suitable thermoplastic polyesters include polybutylene terephthalate. Likewise, the dynamically vulcanized thermoplastic elastomers, functionalized styrene-butadiene elastomers, thermoplastic polyurethane or metallocene polymers identified above are also useful as the second thermoplastic in such blends. Further, the materials of the second thermoplastic described above may be in the form of a foamed polymeric material.
[0032] Such thermoplastic blends comprise about 1% to about 99% by weight of a first thermoplastic and about 99% to about 1% by weight of a second thermoplastic. Preferably the thermoplastic blend comprises about 5% to about 95% by weight of a first thermoplastic and about 5% to about 95% by weight of a second thermoplastic. In a preferred embodiment of the present invention, the first thermoplastic material of the blend is a thermoplastic polyetherester, such as Hytrel®.
[0033] The present invention includes urethane/polyurea intermediate layer having a Shore D hardness less than 60, and for a soft layer a Shore D of less than 50, and a flexural modulus between 500 and 30,000 psi.
[0034] The present invention also includes the use of a variety of non-conventional cover materials. In particular, the covers of the present invention may comprise thermoplastic or engineering plastics such as ethylene or propylene based homopolymers and copolymers including functional monomers such as acrylic and methacrylic acid and fully or partially neutralized ionomers and their blends, methyl acrylate, methyl methacrylate homopolymers and copolymers, imidized, amino group containing polymers, polycarbonate, reinforced polyamides, polyphenylene oxide, high impact polystyrene, polyether ketone, polysulfone, poly(phenylene sulfide), reinforced engineering plastics, acrylonitrile-butadiene, acrylic-styrene-acrylonitrile, poly(ethylene terephthalate), poly(butylene terephthalate), poly(ethylene-vinyl alcohol), poly(tetrafluoroethylene) and their copolymers including functional comonomers and blends thereof. These polymers or copolymers can be further reinforced by blending with a wide range of fillers and glass fibers or spheres or wood pulp.
[0035] Additional preferred cover materials include thermoplastic or thermosetting polyurethane, such as those disclosed in U.S. Pat. Nos. 6,371,870; 6,210,294; 6,193,619; and 5,484,870; and metallocene or other single site catalyzed polymers such as those disclosed in U.S. Pat. Nos. 5,824,746; and 5,981,658.
[0036] While it is apparent that the illustrative embodiments of the invention disclosed herein fulfill the objectives stated above, it is appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments which would come within the spirit and scope of the present invention.
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A method of heating a golf ball component by using radio frequency waves to reduce the thermal expansion experienced by a golf ball component such as a core, core and at least one core layer or a core and a combination of core and/or intermediate layers. The component is heated prior to having a layer applied in order to reduce the dramatic temperature increase the component experiences upon an intermediate layer being applied. The preheating reduces the amount of thermal expansion the component undergoes in the casting process.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the United States national phase under 35 U.S.C. §371 of PCT International Application No. PCT/EP2008/008053, filed on Sep. 23, 2008.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the invention relate to methods and devices for transmitting and determining location information for wireless devices.
2. Background of the Related Art
In phone networks, the calling number of the terminal device initiating a communication link—known as the calling party number in the industry—is transmitted as identification to the network. In contrast to traditional phone networks, the location or local area of the terminal device—mobile terminal devices in particular—can no longer be determined in internet-protocol-based networks based on the calling party number.
Especially in mobile communication terminal devices, there are processes and components realized with which the exact or general location may be identified. For instance, many mobile terminal devices contain a GPS function (Global Positioning System) with which the position of the mobile terminal device may be identified, independent of the network. The information indicating the location of a terminal device is called “location information” in the industry.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the invention relate to informing a network, for instance, based on the internet protocol about the geographical location of its communication terminal devices.
An important aspect of the method according to the invention is that location information available in the terminal device and indicating the location of the terminal device is embedded in messages of a SIP protocol (Session Initial Protocol),
which during the establishment of a session or during a session between terminal and network or during registration of a terminal device in the network (or upon prompting by a service or function are being exchanged.
An important advantage of embodiments of the invention is that by adding the SIP protocol, the location information can be transmitted from a mobile or hard-wired terminal device to the network during the initialization phase of a session and also during a session. This allows a reduction of costs for implementing transmission of location information to the network; for instance, because implementing an additional protocol for the transmission of the location information is not necessary.
According to embodiments of the invention, location information may also be transmitted outside of a session from the terminal device to the network, i.e., without a conversation or information transmission taking place at the same time. Therefore, the network also knows the location information in situations where no session from the terminal device is in progress, and may use it for different applications.
The FIGURE below shows the invention and its advantageous developments in detail.
BRIEF DESCRIPTION OF THE FIGURE
The single FIG. 1 , for instance, shows a schematic drawing of an example of one of several possible terminal devices ME with a telephone function T-called ME-T in the following, which, for example, is subscribed to a wireless network—e.g. a wireless, local network WLAN. The procedure according to the invention is also advantageous in other hard-wired networks, e.g., local networks or it may be used in other wireless networks like UMTS—not shown.
DETAILED DESCRIPTION OF THE INVENTION
The mobile terminal device ME-T has a function with which it can identify or determine its geographical position P or its local geographic area P. The geographical position P of the terminal device ME-T can for instance be determined by a GPS function GPS-GPS receiver and appropriate programs—implemented within the terminal device ME-T, indicated in the drawing as GPS. Alternatively, the local geographical area P can be determined by a function in a terminal device ME-T, which calculates the local area P based on the strengths and direction of reception of the radio signals of multiple radio areas of the radio stations—not shown. Information indicating the local geographical area P or the geographical position P is called location information in the industry. The location information can, for instance, also be indicated with coordinates of the Cartesian Coordinate System, also called geolocation, or with so-called civic address information, e.g. postal information like mailing addresses—city, street, house number, zip code—or other geophysical information.
For the exemplary embodiment, it is assumed that the wireless network WLAN is operated according to the internet protocol IP, wherein the mobile terminal device ME-T is turned off as the IP terminal device—indicated as WLAN (IP) in the FIGURE. For signaling the phone or voice connections of the mobile terminal device ME-T to other mobile terminal devices—not shown—a SIP protocol SIP is advantageously provided and indicated as SIP on the FIGURE. An SIP protocol SIP is currently specified in the RFC standard 3261 and is provided especially for internet telephony or for terminal devices with transmission functions of voice information or multimedia information.
According to embodiments of the invention, the location information li is transmitted by the SIP protocol SIP from the mobile terminal device ME-T to the wireless network WLAN. For the embodiment, it is assumed that the location information li is transmitted wirelessly to a server S in the wireless network WLAN and stored there—indicated with an arrow labeled SIP (li) or SIP(m(hli, dli), B(li,ai)) in the FIGURE. The SIP protocol can manage multiple sessions with one or more mobile terminal devices ME-T, allowing sessions not only for voice or telephony but any sessions with transmission of multimedia streams for conferences, for example, or other terminal devices like PC.
Within the SIP protocol SIP there are several messages m specified that are transmitted during the initialization of a session between two mobile terminal devices ME-T or during a session from the mobile terminal device ME-T to the wireless network WLAN or vice versa.
According to the current SIP standard, the INVITE message is provided for the initialization of a session and the NOTIFY, UPDATE; and PUBLISH messages are provided during a session. For initiating subscription of a mobile terminal device ME-T in a network, a SUBSCRIBE message is provided and for initiating a registration of a mobile terminal device ME-T in the network a REGISTER message is provided. According to the invention, location information li can be transmitted in all these messages m.
A SIP message m is generally formed by a header H and a user agent, wherein the user agent of the SIP standard SIP is called Body B. This term shall be used in the following. The embodiment assumes that the header H is expanded by an indicator hli that the transmission of location information li is supported and location information li is contained within the body B.
An INVITE message of the SIP protocol shows an example of how a header SIPH and body B can be designed for the transmission of location information li.
Header:
INVITE sip:1002@10.26.12.102:5060; transport=udp SIP/2.0
1)
From: Bob <sip:49897221001@10.26.12.102>; tag=5f6205144a23d
2)
To:sip:1002@10.26.100.102
3)
Via:SIP/2.0/UDP10.26.12.103:5060; branch=z9hG4bKd143e9ba3
4)
Call-ID: 9e9cf76b830011e
5)
CSeq: 1 INVITE
6)
Max-Forwards: 70
7)
Content-Length:239
8)
Supported: locationMap
9)
Allow: INVITE, ACK, CANCEL, BYE, REFER, NOTIFY, MESSAGE, UPDATE
10)
Content-Type: application/location
11)
Contact: Bob <sip:49897221001@10.26.100.23:5060; transport=udp>
12)
Excerpt of body B:
<location>
13)
<locationServer>
http://www.server.enterprise.com/
14)
get<locationServer>
<x-location>364.938</x-location>
15)
<y-location>57.9834</y-location>
16)
<z-location>578.0</z-location>
17)
</location>
18)
Explanations:
1) Message type, target address (URI), SIP version
2) URI (Universal Address Information) of a terminal device being called (i.e., the telephone number of the terminal device being called)
3) Display name of the calling terminal device and its URI
4) IP address, port number and the transport protocol for the response to the message
5) Random character string as unique number for a communication relationship
6) Sequence number (relating to message type)
7) Maximum number of proxy servers (decreasing with each passed proxy)
8) Length of body
9) Indicator hli in the header SIPH, that the transmission of location information li is supported.
10) Permitted messages m
11) Data type (dli) in the body (according to the invention an application for the transmission of location information li)
12) SIP address of the terminal device ME-T for direct communication
13) Beginning of the location information li
14) Name of the WEB server WS, to which the location information li is to be transmitted by server S
15) x-coordinate value of the Cartesian Coordinate System
16) y-coordinate value of the Cartesian Coordinate System
17) z-coordinate value of the Cartesian Coordinate System
18) End of the location information li
The configuration of the header H in the other SIP messages m is handled basically according to the example shown. The location information li in the body B of an SIP message m can have varying forms.
In a first variation shown in the exemplary embodiment for a body B, address information ai of a WEB server WS specifies which the location information li is to be transmitted. In this WEB Server WS, a WEB Service WD has been implemented with the address information aid, with which the location information li can be processed in different ways and provided in WEB format to the terminal devices ME or to applications. Also indicated are the x and y-coordinates of a Cartesian Coordinate System, which can be provided by a GPS function GPS, as previously described. Optionally, as long as this information is available in the terminal device, the z-coordinate value of a Cartesian Coordinate System is also indicated—e.g., height above sea level. In this variation, location information li is transmitted together with address information ai to the server S. The latter recognizes that the location information li is to be passed on to the addressed WEB server WS via the wireless network WLAN—indicated with an arrow in the FIGURE.
In the WEB server WS it is possible to make location information li available, using an implemented WEB Service WD, e.g., to be processed, stored, and available for different applications for display in WEB format. The processing can, for instance, be handled in such a way where the location information li is inserted as geographical information in a map and then is transmitted in WEB format to a mobile terminal device ME or an application in the network WLAN—not shown—for display or processing there. Other processing for uses in applications, for example, can be implemented advantageously with other services in the WEB server WS or other servers—not shown—or other components of the wireless network WLAN. Examples for processing are forms of representation, e.g., 3D representation of buildings/landscapes, 2D representation of map materials/overview maps or simply spreadsheet processing.
Another variation—not shown—is transmitting the location information li to the server S only as x, y and z-coordinate values of the Cartesian Coordinate System inserted into the body B and stored there. The stored location information li can then be made available to or be accessed by different terminal devices ME and applications.
Another variation is transmitting the location information li plus download address information with which the processed location information li′ can be downloaded to mobile terminal devices or applications. The download address information dai could be the network address, for example, of the WEB server WS, from where the location information li′, after appropriate processing, can be downloaded to the respective mobile terminal devices ME or applications.
The location information li can also be indicated in different ways within the body B. First of all, it can be indicated with x and y and optional z-coordinate values of the Cartesian Coordinate System but secondly also in form of postal information or different geophysical information or input. The type of input in this case depends on what type of location information li the function can provide for determining the local geographical area P in the mobile terminal device ME-T. An expanded range GPS function GPS, for instance, can also provide postal information like the names of cities, streets or buildings or companies. Another type of geophysical information is the input of a local area, from which one geographical area is selected based on an alphanumeric value from several specified local areas in a larger geographical area.
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A location information (li) which is available in a mobile terminal device (ME-T) and which indicates the geographical location of the terminal device (ME-T) is embedded in messages (m) of a SIP protocol (SIP) which are exchanged between the terminal device (ME-T) and the network (WLAN) during the establishment of a session and/or during a session and/or during the registration of a terminal device (ME-T) in the network (WLAN), e.g. LAN or UMTS, or during request of a service or a function. By advantageously complementing the SIP protocol (session initiation protocol), the location information can be transmitted from a mobile terminal device (ME-T), which optionally has a telephone function, to the network (WLAN) in any signaling state, thereby substantially reducing the economic outlay for implementing the transmission of location information (li) to the network (WLAN).
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TECHNICAL FIELD
[0001] The invention relates to a weighting circuit for a multicarrier signal receiver which is provided for receiving a multicarrier signal comprising carrier signals, particularly for an OFDM receiver.
BACKGROUND
[0002] In the case of multicarrier signal transmission, the data information is transmitted on a plurality of carrier signals which have different carrier signal frequencies. Known multicarrier reception systems are DMT and OFDM (Orthogonal Frequency Division Multiplexing). Particularly in the case of mobile radio transmission, data symbols expand or overlap one another. If the delay spread of the data transmission channel is in the region of the data symbol duration, a high level of intersymbol interference may arise which makes error-free decoding impossible unless appropriate countermeasures, such as equalizers, are used. In the case of application at high data transmission rates such channel equalizers are very complex, however. Multicarrier transmission allows these drawbacks to be avoided. In the case of OFDM, the data stream to be transmitted is split into a plurality of portions and is transmitted in parallel on various signal carrier. Each subchannel may be submodulated for its part. The data transmission rate of a carrier is reduced by the parallelization. This reduces the intersymbol interference for the data transmission. The OFDM receiver performs the splitting into the subchannel or carrier signal. After filtering, sapling and demodulation, the parallel data are converted back into a serial data stream.
[0003] FIG. 1 shows a signal spectrum for a multicarrier signal transmission. The data are transmitted in a transmission frequency band which contains a multiplicity of sub-bands SB 1 . The sub-bands SB i normally have the same frequency bandwidth Δ 1 . In many cases, the multicarrier system has more than 1000 sub-bands SB i . During transmission using frequency-selective multipath channels, one or more attenuation maxima, i.e. amplitude minima, may fall into the transmission band. In this case, by way of example, one sub-band SB i may be situated at an attenuation maximum while another sub-band SB i is situated at an attenuation minimum. The amplitudes of the various sub-bands SB are therefore very different. Close to an attenuation maximum, the amplitude of the useful signal is relatively small. As FIG. 1 shows, the sub-band SB i has a very small amplitude on account of a very high attenuation transmission channel.
[0004] Besides the useful signal, the receiver receives a background noise N 0 , which is essentially constant over the entire transmission frequency band, and external spurious signals. These external spurious signals may be signals from other signal sources or television signals, for example. The external spurious signals NF are overlaid on the background noise N 0 to form a cumulative spurious signal, as shown in FIG. 1 .
[0005] The received signal in the receiver is made up as follows:
E=N 0 +NF ( f ) +S ( f ) (1)
where N 0 is a largely evenly distributed background noise, NF(f) is a frequency-dependent spurious signal, and S(f) is the useful signal.
[0006] FIG. 2 shows a multicarrier signal receiver based on the prior art.
[0007] The receiver contains a tuner for tuning to the received signal, a downstream antialiasing filter AAF and an analog-digital converter for converting the received analog signal into a digital received signal. At the output of the analog-digital converter, the digital received signal is firstly supplied to a subtraction circuit SUB and to an estimation unit. The estimation unit calculates the cumulative spurious signal. The estimated cumulative spurious signal is deducted from the input signal E by the subtraction unit SUB, so that ideally just an undisturbed useful signal S remains and is processed further. The estimation unit shown in FIG. 2 performs cross correlation between the output signal from the ADC and one or more spurious signals which are to be expected.
[0008] In the case of an OFDM receiver, based on the prior art, the data are lined up symbol by symbol and are separated by one another by the guard interval. Normally, an unknown sudden phase change occurs between the data symbols. Accordingly, to subtract the estimated signal with the correct phase, the estimation unit ascertains a first cross correlation value between the received signal and a stored spurious signal which is to be expected and also a second cross correlation value between the received signal and the spurious signal to be expected which has been phase-shifted through 90°. The estimation unit then calculates the phase of the spurious signal on the basis of the cross correlation values. The calculation of this phase is severely susceptible to error.
[0009] One drawback of the conventional multicarrier signal receiver as shown in FIG. 2 is that the spurious signal needs to be estimated on the basis of magnitude and phase, which makes such estimation difficult and susceptible to error. Estimating the spurious signal becomes a very imprecise affair if the variance in the estimate result ‘measurement time’ is relatively high, e.g. because the available measurement time is too short.
[0010] The greater the discrepancy between the estimated spurious signal and the spurious signal which actually occurs, the more the bit error rate BER of the received data stream which is output by the channel decoder increases.
SUMMARY OF THE INVENTION
[0011] It is therefore the object of the present invention to increase the reception quality of a multicarrier signal receiver.
[0012] The invention achieves this object by means of a weighting circuit for a multicarrier signal receiver which has the features indicated in patent claim 1 .
[0013] The invention provides a weighting circuit for a receiver which is provided for receiving a multicarrier signal comprising a plurality of carrier signals, where the weighting circuit weights the carrier signals ideally such that the spurious signal energy is of equal magnitude for all weighted carrier signals.
[0014] In one preferred embodiment of the inventive weighting circuit, said circuit has at least one multiplier which multiplies an associated carrier signal by a stored weighting coefficient.
[0015] The stored weighting coefficients represent reliability information for the various carrier signals. The greater the noise on a subcarrier signal or a carrier signal, the lower the associated reliability or the weighting coefficient. A subcarrier with a high level of noise or a carrier signal with a high level of noise is weighted with a smaller weighting coefficient than a carrier signal with a lower level of noise.
[0016] In one preferred embodiment, the weighting circuit has a memory which stores a plurality of weighting coefficient sets G i which each comprise a plurality of weighting coefficients g i .
[0017] The memory can preferably be programmed via an interface.
[0018] This allows the weighting coefficients to be matched to the transmission properties of the data transmission channel.
[0019] In another preferred embodiment, the weighting circuit has a selector which selects a particular weighting coefficient set G i from the weighting coefficient sets stored in the memory.
[0020] In this context, the selector preferably selects a weighting coefficient set on the basis of an expected spurious signal energy.
[0021] In another preferred embodiment, the selector selects a weighting coefficient set additionally on the basis of an averaged frequency offset between the maximum of the spurious signal spectrum and the next closest carrier signal of the multicarrier signal.
[0022] The multicarrier signal is preferably broken down into the carrier signals by a computation circuit.
[0023] The computation circuit is preferably a Fast Fourier Transformation circuit.
[0024] The carrier signals broken down by the computation circuit are preferably buffer-stored in a buffer store for the subsequent multiplication.
[0025] In a first embodiment, the expected spurious signal energy can be set externally.
[0026] In an alternative embodiment, the expected spurious signal energy is calculated by an estimation unit on the basis of the received multicarrier signal.
[0027] Further preferred embodiments of the inventive weighting circuit and further features which are fundamental to the invention are described below with reference to the appended figures, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 shows a signal spectrum for a received signal;
[0029] FIG. 2 shows a multicarrier signal receiver based on the prior art;
[0030] FIG. 3 shows a multicarrier signal receiver which contains an inventive weighting circuit based on a first embodiment;
[0031] FIG. 4 shows a multicarrier signal receiver which contains an inventive weighting circuit based on a second embodiment;
[0032] FIG. 5 shows a multicarrier signal receiver which contains an inventive weighting circuit based on a third embodiment;
[0033] FIG. 6 shows a multicarrier signal receiver which contains an inventive weighting circuit based on a fourth embodiment;
[0034] FIG. 7 shows a table of the memory content of a programmable memory in the inventive weighting circuit;
[0035] FIG. 8 shows a flowchart to explain the way in which the inventive weighting circuit works;
[0036] FIG. 9 a shows the amplitude distribution of a multicarrier signal at the signal input of an inventive weighting circuit;
[0037] FIG. 9 b shows the amplitude distribution of the multicarrier signal shown in FIG. 9 a at the output of the inventive weighting circuit; and
[0038] FIG. 10 shows a signal spectrum to explain the way in which the inventive weighting circuit works.
DETAILED DESCRIPTION OF THE INVENTION
[0039] FIG. 3 shows a multicarrier signal receiver 1 which contains a first embodiment of the inventive weighting circuit. The multicarrier signal receiver 1 contains a tuner 2 for tuning to the received signal, the tuner 2 having an antialiasing filter 3 connected downstream of it. The filtered received signal is converted into a digital received signal by an analog-digital converter 4 and is supplied to a computation circuit 5 . the computation circuit 5 breaks down the received digital multicarrier signal into various carrier signals which have different carrier signal frequencies f 1 , f 2 , f 3 , . . . , f N . The computation circuit 5 is preferably a filter bank, particularly a Fast Fourier Transformation circuit (FFT). The amplitudes of the carrier signals are supplied via lines 6 - 1 , 6 - 2 , 6 - 3 , . . . , 6 -N to a multiplier circuit 7 having an appropriate number of multipliers 7 - 1 , 7 - 2 , 7 - 3 , . . . , 7 -N. The multipliers 7 - i multiply the respective carrier signal by a weighting factor G i which is read from a programmable memory 9 via an associated line 8 - i . The weighted carrier signals are supplied via lines 9 - i to a channel decoder 10 which decodes the weighted carrier signals and compiles them to form a digital data stream for further data processing. The channel decoder 10 is preferably a Viterbi decoder, which often has a Read-Solomon decoder connected downstream of it. The channel decoder 10 outputs the serial digital data stream via a line 11 for further data processing.
[0040] The programmable memory 9 can be programmed externally via an interface circuit 12 . The interface circuit 12 is connected to the programmable memory 9 via internal data lines 13 . The programmable memory 9 contains a plurality of weighting coefficient sets G i , as shown schematically in FIG. 7 by way of example. Each weighting coefficient set G i contains a multiplicity of weighting coefficients G i , with the number N of weighting coefficients corresponding to less than or equal to the number of sub-bands SB within the transmission frequency band. The number N of different weighting coefficient sets G i can be chosen and is 8, for example.
[0041] The programmable memory 9 is connected to a selector 15 via address lines 14 . The selector 15 selects a particular weighting coefficient set G i from a plurality of M different weighting coefficient sets which are stored within the memory 9 . To this end, the selector 15 generates an address for selecting the appropriate weighting coefficient set G.
[0042] In the case of the first embodiment of the inventive weighting circuit, shown 15 in FIG. 3 , the weighting coefficient set G i is selected on the basis of an expected spurious signal energy, the expected spurious signal energy EP spurious in the first embodiment shown in FIG. 3 being set externally via a line 16 . The spurious signal energy is proportional to the square of the amplitude of the cumulative spurious signal, which is made up of the background noise N 0 and external spurious signals. The expected spurious signal energy EP spurious is applied via a setting input 17 . The first embodiment of the inventive weighting circuit 18 comprises the multiplier circuit 7 for multiplying the carrier signals by the selected weighting coefficients, the programmable memory 9 with the associated interface circuit 12 and also the selector 15 for selecting the weighting coefficient set.
[0043] FIG. 4 shows a multicarrier signal receiver 1 which contains a second embodiment of the inventive weighting circuit 18 . Corresponding components have been provided with corresponding reference symbols.
[0044] In the case of the second embodiment of the inventive weighting circuit, shown in FIG. 4 , the selector 15 makes the selection of the weighting coefficient set G i not only on the basis of the spurious signal energy EP spurious which has been set but also on the basis of an average frequency offset. To this end, the weighting circuit 18 additionally contains carrier frequency detectors 19 - 1 , 19 - 2 , . . . , 19 -N, which are connected to the output lines 6 - 1 , 6 - 2 , . . . , 6 -N via lines 20 - 1 , 20 - 2 , . . . , 20 -N. The carrier frequency detectors 19 - i ascertain each carrier signal's actual carrier frequency f i and output the discrepancy or the offset Δ fi between the current or actual carrier frequency fi and the nominal frequency f nominal for this carrier signal to an offset averaging circuit 22 via an associated output line 21 - i . Such carrier frequency detectors 19 - i are described in “Digital Communications Receivers” by Heinrich Meyr, Stephan, A. Fechtel in John Wiley and Sons, 1998, Section 8 (pp. 445-504). The offset averaging circuit 22 calculates an average f OFFSET-mean for all ascertained frequency offsets of the various carrier signals. The offset averaging circuit 22 is preferably a proportional-integral computation element. In this case, the averaging time is preferably settable.
[0045] FIG. 10 shows the spectrum of an OFDM received signal with a sinusoidal spurious signal. As can be seen in FIG. 10 , the nonorthogonal sinusoidal spurious signal is situated outside of the framework of the received OFDM signal, which comprises a multiplicity of carrier signals with carrier frequencies f i . Demodulating the OFDM signal using the Fast Fourier Transformation circuit 5 distributes the energy of the spurious signal over the surrounding subcarriers or carrier signals, with the attenuation being dependent on the subcarrier and on the parasitic frequency. The disturbances which occur on the output lines 6 - i of the Fast Fourier Transformation circuit 5 are reduced by the inventive weighting circuit 18 for a stipulated number of carrier signals such that a previously determined noise level is set.
[0046] The energy level of the cumulative spurious signal, which is made up of an external spurious signal and the noise, is obtained as:
EP spurious =10·log [10 0.1*N 0 +10 0.1*NF ] in dB (2)
where the energy level of the cumulative spurious signal EP spurious is dependent on the external spurious signal NF and on the background noise N 0 .
[0047] The weighting coefficient g i is calculated on the basis of the expected spurious signal energy EP spurious as follows:
g i =10 EPspurious/20 (3)
[0048] If, by way of example, the noise is normalized to zero decibels and if the level of the spurious signal after Fast Fourier Transformation on a subcarrier is 10 dB higher than that of the noise signal, the total energy EP spurious of the spurious signal and the noise in line with equation (2) is:
10·log [10 0 +10 0.1 10 ]=10.414 dB.
[0049] From this, the weighting factor G i is calculated as
10 (−10.414:20) =0.3015.
[0050] In the case of the implementation of the inventive weighting circuit 18 , a weighting set G i , which comprises suitably dimensioned weighting coefficients g i , is calculated in advance and is written to the memory 9 via the interface circuit 12 . The weighting coefficients selected by the selector 15 are multiplied by the carrier signals by the multiplier circuit 7 . In this case, either amplitudes of the various carrier signals can be buffer-stored by a buffer store 24 , which comprises various latch components 24 ′i, before the multiplication, as FIG. 4 shows, or the weighting coefficients which have been read are used for multiplication by the next block of N-composed carrier signal amplitudes which are output by the FFT circuit 5 .
[0051] FIG. 5 shows a third embodiment of the inventive weighting circuit 18 .
[0052] In this embodiment, the selector 15 makes the selection of the weighting coefficient set G i within the memory 9 not on the basis of an expected externally set spurious signal energy but rather on the basis of an estimated spurious signal energy which is ascertained by an estimation unit 25 . The estimation unit 25 is connected downstream of the analog-digital converter 4 via line 26 and calculates a maximum spurious signal level on the basis of the received digital multicarrier signal. The estimation unit 25 performs first cross correlation between the received signal which is present at the output of the ADC 4 and with at least one spurious signal which is to be expected, in order to calculate a first cross correlation value k 1 , and second cross correlation between the received signal and a spurious signal to be expected which has been phase-shifted through 90°, in order to calculate a second cross correlation value k 2 . On the basis of the two cross correlation values k 1 , k 2 , the energy of the current disturbance in the received signal is calculated by the estimation unit,
E spurious ˜k 1 2 +k 2 2
[0053] The estimation unit 25 preferably stores a plurality of spurious signals which are to be expected, for example spurious signals whose frequency has been shifted relative to one another. The spurious signals to be expected alternatively have different signal shapes, so as to simulate spurious signals from different signal sources or signal distortions. The estimation unit 25 outputs the calculated maximum spurious signal energy E spurious max via line 26 and the associated spurious signal association number via line 27 to the selector 15 , the spurious signal association number indicating the associated spurious signal.
[0054] The selector 15 selects a weighting coefficient set on the basis of the spurious signal association number, which indicates the type of spurious signal or this signal shape, and the calculated spurious signal energy.
[0055] FIG. 6 shows a further preferred embodiment of the inventive weighting circuit 18 in which the data are processed serially. In this preferred embodiment, the weighting circuit 18 comprises just one multiplier 7 . The amplitudes which the computation circuit 5 has ascertained for the various carrier signals are read out serially and buffer-stored in the buffer store 24 in the embodiment shown in FIG. 6 . A carrier frequency selector 19 ascertains the current carrier frequency of the carrier signal and stores the discrepancy from the nominal value in a buffer store in the averaging circuit 22 . If the number of sub-bands is 1024 , for example, the buffer store 24 buffer-stores 1024 amplitudes for the various carrier signals, and the buffer store in the averaging circuit 22 has 1024 sequence discrepancies written into it in succession, these being averaged by the offset averaging circuit 22 . In this case, a rolling average over the last 1024 *K carrier signals is preferably calculated. In one preferred embodiment, the number K is settable in this case. The amplitudes buffer-stored in the buffer store 24 for the various carrier signals are read out serially and are weighted by the multiplier 7 using the associated weighting coefficient G i , which are likewise read out serially. The embodiment of the inventive weighting circuit 18 which is shown in FIG. 6 affords the advantage that just one multiplier 7 is provided, which means that the circuit complexity for implementing the weighting circuit 18 is low.
[0056] FIG. 8 shows a flowchart to explain the way in which the inventive weighting circuit works.
[0057] Following the start S 0 , the receiver receives the multicarrier signal in a step S 1 and converts it into a digital carrier signal using the tuner 2 , the antialiasing filter 3 and the analog-digital converter 4 .
[0058] The computation circuit 5 breaks down the multicarrier signal into N different subcarriers or carrier signals having different carrier signal frequencies f i in a step S 2 . The signal is preferably broken down using Fast Fourier Transformation. The amplitudes are preferably buffer-stored in a buffer store 24 in a step S 3 . In a further step S 4 , the carrier frequency selector 19 ascertains the frequency offsets for the various carrier signals.
[0059] In a further step S 5 , the offset averaging circuit calculates an arithmetic mean for the frequency offsets which are activated by the carrier frequency selectors.
[0060] In a step S 6 , the selector 15 selects the suitable weighting coefficient set G i , which comprises a multiplicity (N) of weighting coefficients g i , on the basis of the expected spurious signal energy and the average frequency offset. The selected weighting coefficient set G i is read out in step S 7 , where the weighting coefficients are already being multiplied by the respective multicarrier signals by the multipliers 7 - i in to weight them.
[0061] Next, channel decoding is performed in step S 8 using the channel decoder 10 .
[0062] The process ends in step S 9 .
[0063] FIG. 9 a shows three carrier signals, for example, with different carrier signal frequencies f 1 , f 2 , f 3 on the lines 6 - 1 , 6 - 2 , 6 - 3 , which are weighted by the inventive weighting circuit 18 . The energy of the various carrier signals is proportional to the square of the amplitudes of the carrier signals. In the example shown in FIG. 9 a , the first carrier signal with the carrier signal frequency f 1 has a comparatively high useful signal energy S 1 and a low spurious signal energy N 1 . The spurious signal energy N 1 is made up of the energy in the background noise N 0 and external spurious signals NF. The second multicarrier signal at the carrier signal frequency f 2 has the same total energy as the first carrier signal in the example shown, but the proportion of spurious signal energy N 2 is significantly higher in the second carrier signal. Accordingly, the signal energy S 2 of the second carrier signal is lower. FIG. 9 a shows the energy of a third carrier signal, by way of example, whose spurious signal energy is at exactly the same level as the spurious signal energy N 1 , of the first carrier signal.
[0064] FIG. 9 b shows the weighted carrier signals on the output lines 9 - i of the inventive weighting circuit 18 . The inventive weighting circuit 18 weights the three carrier signals such that the spurious signal energy N 1′ of the weighted first carrier signal, the spurious signal energy N 2′ of the second weighted carrier signal and the spurious signal energy N 3′ of the third weighted carrier signal are of the same magnitude. As can be seen from FIG. 9 b , the carrier signal 2 , which has a relatively small proportion of the useful signal energy in the total signal energy, has a lower weighting than the carrier signal 1 , where the ratio of useful signal energy S 1 to spurious signal energy N 1 is much more favorable or greater. If the carrier signal 2 still has the same weight as the carrier signal 1 at the input of the inventive weighting circuit 18 , the output of the inventive weighting circuit 18 produces the carrier signal 2 lowered to the weight of the carrier signal 3 . In the inventive weighting circuit 18 , the carrier signal with the higher signal-to-noise ratio SNR is provided with a higher weighting than carrier signals with a lower signal-to-noise ratio SNR. The carrier signals or subcarriers with disturbances are assessed by the inventive weighting circuit as being less reliable than the carrier signals or subcarriers with lower levels of disturbance. The inventive weighting circuit 18 strews the output disturbance profile over all subcarriers. On account of the inventive weighting circuit 18 , the bit error rate BER in the data stream at the output of the channel decoder 10 is significantly reduced, which means that the reception quality of the receiver 1 is greatly improved overall.
[0000] List of Reference Symbols
[0000]
1 Receiver
2 Tuner
3 Antialiasing filter
4 Analog-digital converter
5 Computation circuit
6 Lines
7 Multiplier
8 Lines
9 Memory
10 Channel decoder
11 Output line
12 Interface
13 Programming lines
14 Address lines
15 Selector
16 Setting line
17 Setting input
18 Weighting circuit
19 Carrier frequency detector
20 Line
21 Line
22 Offset averaging circuit
23 Line
24 Buffer store
25 Estimation unit
26 Line
27 Line
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The invention relates to a weighting circuit for a receiver ( 1 ), which is designed to receive a multi-carrier signal consisting of carrier signals. According to the invention, the carrier signals are weighted by the weighting circuit ( 18 ) in such a way that the parasitic signal energy has the same intensity in all weighted carrier signals. In a preferred embodiment of the invention, the weighting circuit comprises at least one multiplier that multiplies an assigned a carrier signal by a stored weighting co-efficient. The stored weighting coefficients constitute reliability information for the various carrier signals.
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BACKGROUND OF THE INVENTION
The present invention relates to a hydraulic torque converter.
A hydraulic torque converter is one type of device used as a hydraulic transmission for a road vehicle. Normally it is arranged between the engine and the gearbox, and includes an impeller vane wheel attached to the output shaft of the engine, a turbine vane wheel attached to the gearbox input shaft, and a stator vane wheel. All these three are maintained in a bath of transmission fluid, and the turbine vane wheel has a fluid circulation inlet which is disposed directly adjacent to the fluid circulation outlet of the impeller vane wheel and which receives the fluid ejected therefrom. The fluid flow out from the fluid circulation outlet of the turbine vane wheel is received by the fluid circulation inlet of the stator vane wheel, which deflects this flow and supplies it from its fluid circulation outlet back to the fluid circulation inlet of the impeller vane wheel.
The general structure of such a torque converter is that the fluid circulation substantially occurs between two toruses which are coaxial, and one of which is inside the other, the pattern of circulation being rather like that of a smoke ring. In this type of torque converter it has been considered necessary for maintenance of operational efficiency that the velocity component of the circulating fluid in a plane which includes the axis of the torque converter should be constant as the fluid passes round its path. In order to achieve this, a basic design condition of conventional torque converters has been as follows. If we consider a section of the abovementioned inner and outer toruses by a plane which contains the axis of these two toruses (any plane will do, since the torque converter is cylindrically symmetrical), in this plane the fluid circulates around an annulus defined by an inner closed curve provided by the intersection of the plane and the inner torus and an outer closed curve provided by the intersection of the plane and the outer torus. Considering a circle inscribed between these two curves and touching both of them, the requirement that the velocity component of the fluid in the plane of section should be constant means that the product of the radius of such a circle, and the distance of its center from the axis of the toruses, must be constant for all positions of the circle around the annulus. This condition has always heretofore been maintained as a basic design constraint for torque converters.
However, the present invention derives from the realization that perhaps this condition does not have to be applied strictly. The point is that in an actual torque converter the fluid flow is not altogether in the plane of section as described above. There is a certain amount of deflection of the fluid around the axis of the toruses, caused by the vanes. Consequently, if the conditions within the vane wheels of an actual torque converter are evaluated, the annular shape according to the simple and geometric condition above may require some modification.
Considering a simple vane arrangement as viewed end on, as seen in FIG. 1, if the vanes are of the same thickness throughout their length, it is clear that the width of the fluid passage formed between the vanes, which is expressed by the diameter G of circles inscribed between two adjacent vanes, increases from their inlet portion to their middle portion, and then decreases again from there on to their portion, and in fact this width corresponds to the curvature of the vanes, being greater, the greater is the curvature. When fluid is flowing along this fluid path, being an actual fluid rather than an ideal one, it cannot keep up with the speed changes necessary to maintain its flow in proper correspondence to the varying width of this flow path, and therefore, as illustrated in FIG. 1, in practice turbulence is created at the parts of the flow path which have a tighter curvature, and a loss of efficiency is caused. This problem is in general solved by the thickness of the vanes being made different at different portions, as shown in FIG. 2, so that the flow path formed between the vanes is of constant width. However, if it is desired to manufacture the vanes of the torque converter out of standard steel plate of constant thickness, in view of cheapness and ease of assembly, this solution cannot be adopted.
Now, for a hydraulic torque converter used in a vehicle transmission, the times when it is called upon to transform the torque are substantially limited to the times when the vehicle is either moving off from rest, or accelerating. At other times there is no need to convert or multiply the torque, and it is desirable that as far as possible the operation of the torque converter should be an operation of direct connection, with minimum slipping. That is, it is a desirable characteristic of such a torque converter that in the low-speed driving range a large amount of slipping should occur, and therefore the torque ratio should be comparatively high; while in the high-speed driving range the slipping between the impeller and the turbine should be as small as possible, and hence the torque ratio should approach unity. In accordance with this desirable characteristic, it has been proposed, in U.S. Pat. No. 4,044,556, which was assigned to the same assignee as the present application, to construct a torque converter of a non-conventional shape, wherein this high-speed range slipping is minimized. In this proposed torque converter the slippage at high speed is so low that its operation approaches to direct connection, and therefore, if a lock-up clutch is further incorporated into the system, when this clutch is engaged or disengaged, very little torque shock is caused. Thus the above-identified patent proposes a torque converter which is particularly suitable for use with a lock-up clutch.
The non-conventional shape of the torque converter of the above-identified invention is as follows. Considering the annulus defined by a section by a plane which contains the axis of the two toruses, as defined above, which is delimited by an inner and an outer closed curve, the invention contemplated to provide a torque converter wherein this annulus was compressed in the axial direction, so that the dimension of the outer closed curve in the direction parallel to the axis of the toruses was smaller than its dimension in the direction perpendicular to that axis. Such a torque converter can schematically be seen in FIG. 3. In the above-identified prior patent, the ratio of the axial to the radial dimension of the outer delimiting closed curve is defined as being substantially in the range 0.64-0.8; and, further, the ratio of the distances from the axis of the toruses of the innermost portion of the outer delimiting curve, and of its outermost portion, is defined substantially to be in the range 0.4-0.33; and, finally, the ratio of the total cross-sectional area of the output of the impeller vane wheel (which is an area of an annular shape, in a plane perpendicular to the axis of the toruses) to the area of the circle outlined around the axis of the toruses by the outermost portion of the outer delimiting curve is defined substantially to be in the range 0.18-0.23. In such a torque converter it is found that the slippage rate at high speed is very low, and in fact such a torque converter is particularly suited for use in a transmission which includes a lock-up clutch.
However, it is found that in such a torque converter according to the aforementioned prior invention the lengths of the fluid circulation flow paths within the impeller vane wheel, the turbine vane wheel, and the stator vane wheel are smaller than in a conventional torque converter. Since the angle through which the flow velocity of the fluid has to be altered is the same, this means that the curvature of the vanes must be tighter, particularly at portions of the belowmentioned point B and in its vicinity. Accordingly, the above-outlined problem of turbulence at the portions of the fluid path where the flow direction of the fluid is changing sharply is aggravated.
SUMMARY OF THE INVENTION
The present invention turns its attention to the above-described type of turbulence in the flow in a hydraulic-type torque converter, and seeks to provide a converter in which the occurrence of such turbulence is minimized or altogether averted.
In accordance with the present invention, this object is accomplished by a hydraulic torque converter which comprises an impeller, a stator, and a turbine, each of which is provided with vanes, wherein the space through which fluid circulates is of the form of the space between an inner and an outer torus which are coaxial, wherein a section through the toruses by a plane containing their axis consists of an annulus which is defined by an inner closed curve provided by the intersection of the plane and the inner torus and an outer closed curve provided by the intersection of the plane and the outer torus, wherein the dimension parallel to the axis of the toruses of the outer closed curve is smaller than its dimension in the direction perpendicular to this axis, and wherein, considering a circle inscribed between the inner and outer closed curves and touching both of them and passing round the annulus, the value which is the product of the radius of such a circle and the distance of its center from the axis of the toruses alters, as the center of the circle passes around at least the portion of the annulus which corresponds to the turbine, from a maximum value at the inlet of the turbine to a minimum value which is substantially smaller than this maximum value, so that, for example, said minimum value is approximately in the range of 0.95-0.65 times said maximum value.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings, which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a schematic illustration to show two-dimensionally the flow paths outlined by a row of vanes and the change of cross-sectional area within the flow paths, and the accompanying generation of eddies and turbulence;
FIG. 2 is a schematic illustration of the same kind as FIG. 1, showing two-dimensionally a row of vanes in which the change in cross-sectional area of the flow paths is removed by making the intermediate portions of the vanes thicker than their end portions;
FIG. 3 is a partial longitudinal cross-sectional diagram showing an embodiment of a hydraulic torque converter according to the present invention; and
FIG. 4 is a perspective view of an in-plane-developed arrangement of the vanes of the torque converter of the present invention, made for the sake of convenience, illustrating the gist of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3 is a partial longitudinal section, showing an example of an embodiment of a hydraulic torque converter of a flattened type, as particularly proposed in the above-mentioned previous patent, and further employing the present invention. In the figure, 1 designates the engine output shaft end portion to which is fixed a drive plate 2 by bolts 3. This drive plate 2 is coupled by bolts 4 to a housing indicated as a whole by 5. The engine output shaft 1, the drive plate 2, and the housing 5 all rotate as one about the axis X--X. An impeller 6 is formed at the right hand side portion as seen in the drawing of the housing 5, which is the rear portion of it, as it is fitted to the vehicle. The impeller 6 is formed of an outer shell 6a which constitutes a portion of the housing 5, a number of vanes 6b disposed circumferentially around the inside of the outer shell and supported thereby, and an inner shell 6c supported by the vanes. A turbine 7 is provided with its inlet portion 7i disposed in juxtaposition with the outlet portion 6e of the impeller, in front of it. The turbine 7 is composed of an outer shell 7a, a plurality of vanes 7b disposed circumferentially around the inside of this outer shell, and an inner shell 7c supported by these vanes. The outer shell 7a is supported, through a hub member 8, by the turbine shaft 9, and thus the turbine 7 rotates about the same axis X--X as the impeller. A stator 10 is provided between the turbine 7 and the impeller 6 with an inlet portion 10i arranged in juxtaposition with the turbine outlet portion 7e and an outlet portion 10e arranged in juxtaposition with the impeller inlet portion 6i. The stator 10 is again formed of an outer shell 10a, a plurality of vanes 10b disposed circumferentially around the inside of this outer shell, and an inner shell 10c supported by the vanes. The outer shell 10a is supported by a fixed annular shaft 12 through a one-way clutch 11 so that it is free to rotate around the axis X--X in one direction only. 13 designates a housing including the impeller, the stator, and the turbine, and it incorporates an oil pump 15 driven by an annular shaft 14 extending rearwards from the housing 5. The turbine shaft 9 is coupled with the input shaft of a gearbox disposed behind the torque converter to the right in the diagram, which is not shown. Thus the drive is transmitted from the engine to the gearbox.
The impeller 6, turbine 7, and stator 10 form in conjunction a flow path for the transmission fluid which fills the entire torque converter. In this connection, the fluid which is inside the space delimited by the inner shells 6c, 7c, and 10c performs no important flow function, and its movement will hereinafter be ignored. Therefore, the flow path of the transmission fluid is between an inner torus which is defined by the inner shells 6c, 7c, and 10c, and an outer torus which is defined by the outer shells 6a, 7a, and 10a. These toruses are of course coaxial, both having the axis X--X. The circulation of fluid around this flow path is rather like the circulation of a smoke ring, and in the figure, which shows a partial longitudinal section of the toruses by a plane which contains the axis X--X, this circulation is anti-clockwise. That is, the fluid is forced by the impeller 6 out of its outlet 6e and into the inlet 7i of the turbine 7. After flowing through the turbine 7, past its vanes, the fluid leaves the outlet 7e of the turbine and flows into the stator 10 through its inlet 10i. After flowing through the stator, past its vanes, the fluid leaves the stator outlet 10e and enters into the impeller 6 through its inlet 6i. In a conventional torque converter the above-outlined conventional condition for continuous flow demands that, considering the points A, B, and C, which are the centers of circles inscribed inside the annulus T defined by the sections of the toruses by the plane of the paper, if the radii of these circles are d1, d1x, and d2, respectively, and the distances of the points A, B, and C from the axis X--X are respectively R1, R1, and R2.
R1×d1=R1×d1x=R2×d2=C (constant)
But, as is clear from the difference between d1 and d1x in FIG. 3, the present invention provides for a construction such that at the point B the width of the annulus T is rather smaller, so that at this portion R1×d1x is less than C.
To make the concept of the present invention more clear, reference should be made to FIG. 4. In this, the arrangement of the vanes is shown in a somewhat distorted manner. The lower X-Y plane in FIG. 4 corresponds to the curved surface of the outer shell 7a, and the upper X-Y plane in FIG. 4 corresponds to the curved surface of the inner shell 7c. Therefore a distortion has been introduced in flattening out these two surfaces. A further distortion is introduced in that the height of the turbine vanes at the inlet portion 7i of the turbine is shown as being the same as their height at the outlet portion 7e of the turbine, but in fact, of course, as is clear from FIG. 3, their height is substantially greater at the portion 7e than at the portion 7i. The vanes as illustrated in FIG. 4 have been normalized in height by being modified from their actual shape so as to incorporate the factor of their distance from the axis of the toruses, which in FIG. 3 is X--X.
It will therefore be apparent that in FIG. 4 the X-axis is parallel to the circumference of circle Do in FIG. 3, the Y-axis is along the curvature of the annulus T in FIG. 3, and the Z-axis is in the direction normal to the outer defining curve of the annulus in FIG. 3. Thus the Y--Z plane in FIG. 4 corresponds to the plane of the paper in FIG. 3, and the shape of the vanes in the Y--Z plane in FIG. 4 corresponds to their shape in the annulus of FIG. 3, distorted as explained above.
According to the above-explained distortion, if the conventional condition is satisfied, the vanes in FIG. 4 will have a rectangular shape, and their height (i.e., their dimension in the Z-direction) will be the same, E, along their length. However, in accordance with the present invention, the height of the vanes in their middle portions is somewhat reduced to Emin, which is substantially in the range of 0.95-0.65 times the value, E, at the inlet portion 7i and the outlet portion 7e. This is expressed schematically, but, transferring this idea back to the actual torque converter shown in FIG. 3, this means that the value which is the product of the radius of a circle inscribed in the annulus T and touching both the inner defining curve and the outer defining curve of the annulus, and the distance of the center of said circle from the axis X--X, is not constant as the said circle moves around the portion of the annulus T which corresponds to the turbine, as in conventional designs of torque converters, but is reduced from a maximum value at the inlet of the turbine, to a minimum value which is substantially in the range of 0.95-0.65 times this maximum value.
As explained above, it is further beneficial to arrange the shape of the vanes so that at their portions which correspond to tighter curving of the flow path of the fluid this aforesaid product of the radius of the circle inscribed in the annulus T and the distance of the center of said circle from the axis X--X is least, and to arrange this value to vary roughly as the radius of curvature of the fluid flow path.
It may also be practiced to apply the construction of the present invention to the vanes of the impeller and/or the stator, as well as to the vanes of the turbine. Generally, however, it is the turbine, rather than the impeller or the stator, which has the shape of a row of vanes which is more prone to generate eddies and turbulence. Hence the present invention is primarily to be considered as to be applied to the turbine.
In the torque converter shown in FIG. 3, the ratio L/H of the axial dimension L and the radial dimension H of the annulus T, the ratio Di/Do of the inner and outer radii of the outer torus, and the ratio a/A of the area a of the total cross-sectional area of the output of the impeller vane wheel to the area of the circle outlined around the axis of the toruses by the outermost portion of the annulus T, are such as to satisfy the conditions proposed in the aforementioned prior patent. In fact, however, research since the date of that application has raised the upper limit on the ratio L/H somewhat, so that this limit is now substantially in the range 0.64-0.87. The ratio Di/Do is substantially to be in the range 0.4-0.33, and the ratio a/A is substantially to be in the range 0.18-0.23. When, with these conditions, is incorporated the above-defined concept of reducing the value which is the product of the radius of the inscribed circle to the annulus T and the distance of the center of said circle from the axis X--X, a torque converter of truly remarkable efficiency results, which is particularly adapted to be used together with a lock-up clutch.
Although the invention has been shown and described with respect to a preferred embodiment thereof, it will be apparent that to one skilled in the art various changes and modifications are possible in the form of the embodiment, without departing from the spirit of the invention, and therefore it is not intended that the scope of the present invention is to be limited by any details of the embodiment shown, or of the drawings, which are given for the purposes of illustration only, but only by the accompanying claims.
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A torque converter is proposed where the height of the vanes on at least the turbine wheel is reduced somewhat compared with conventional designs at their middle portions, so that the generation of eddies and turbulence in the flow of transmission fluid past those portions which are the most sharply curved portions of the vanes is avoided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 11/224,537, filed Sep. 12, 2005, which claims priority to U.S. Provisional Application Ser. No. 60/609,391 filed Sep. 13, 2004. U.S. application Ser. No. 11/224,537 and U.S. Provisional Application Ser. No. 60/609,391 are incorporated herein by reference in their entirety for all purposes.
TECHNICAL FIELD
Applicant's invention relates to roofing for buildings, and more specifically to a slate roofing system and method of installation.
BACKGROUND
Slate roofs are appreciated for their aesthetic and durable qualities. Slate is one of the finest roofing materials available and has several advantages over asphalt shingle roofs. For example, state roofing is fireproof, resists hail damage, and often has a service life of 100 years or more. However, slate is a rigid natural stone product which unfortunately can be damaged by stress. Stress can be introduced into slate in several ways, but the most common cause of stress to slate is nails used to attach the slate to the roof deck. With nail installation, the nails need to be fastened so the slate hangs on the nail. If the nail is inserted too tightly, the nail will pinch the slate. On the other hand if the nail is not inserted deep enough, the overlapping piece of slate may crack from the hidden pressure point. Environmental effects on the wood decking and nails may also contribute to the stress. Environmental changes such as swings in temperature and humidity can cause the decking to expand and contract. If the nails are in a bind in this situation, the slate can crack or fall.
Furthermore, slate roofs are quite expensive (typically two to three times more expensive than composition asphalt roofing), and the weight of the slate is quite high compared to composition shingles (which may require additional support for the roof, further adding cost). Slate materials are expensive themselves, so any reduction in the amount of slate necessary for effective roofing would lead to both a decrease in cost and weight of a roof.
A good background for slate roofing and the method for installing the same may be found in the NRCA Roofing and Waterproofing Manual—4th Edition, pp. 1179-1227, that document being incorporated herein by reference. Typical slate roofs are constructed such that a wood roof is first covered with an underlayment layer, typically asphalt felt paper. Overlapping slate courses are then applied with slate covering the roof in two plies except where there is overlap, in which case there are three plies of slate. Through joints should not occur from the slate roof surface to the felt. So using the conventional slate roofing technique, slate tiles must be elongated sufficiently to allow for three-ply overlap (and two plies of slate on the exposed portions of the roof) in order to ensure that water cannot penetrate the roof between the seams between slate tiles. Accordingly, the conventional slate roofing technique requires the use of a great deal of slate material, due to the need for double ply coverage and three-ply overlap for water resistance, greatly increasing the cost and weight of a slate roof.
Slate roofs may be improved by reducing the amount of slate used to create a waterproof roofing surface, and by eliminating the use of nails (or any other penetration or system requiring a hole in the slate) to secure the slate tiles in place on the roof. This may allow for a more durable, but less expensive and heavy, slate roof. Furthermore, the slate roof would be more durable if there was some means of resisting uplift forces generated by winds on the slate tiles. High winds may catch under the leading edge of the slate tiles, applying a lifting force to the slate. In this manner, wind may increase stresses on the slate tiles. In addition, the wind may actually lift the slate tiles, exposing the underlying roof to the elements. Thus, an improved slate roofing system would attach the slate tiles to the rook deck using some means that would resist wind uplift forces, providing a more durable and weather resistant roof.
SUMMARY
The embodiments of the present disclosure include a roof having slate members attached by battens and hangers. The slate tiles are typically attached to the roof in overlapping rows. Underlayment may be attached to the roof, positioned below the battens. In some embodiments, battens are attached to the roof, stretching across the length of the roof and spaced vertically at regular intervals upon the roof. The hangers may then attach to the battens in order to support slate tiles, thereby affixing the slate tiles to the roof. Generally, the hangers could either be removably secured to the battens and/or secured to the battens in such a way as to be repositionable along the length of the battens. In some embodiments, the hangers are generally tension sprung to resist uplift. Accordingly, the hangers help the slate tile they support to resist uplift forces generated by wind. Additionally, the hangers may help the slate tiles of the lower row to resist uplift by pressing down across the top portion of the slate tiles (on the overlap section). In essence, the overlapping nature of the slate rows allows the hangers to maximize resistance to uplift.
The roof may further include interlayment material (often referred to as “slate liner”) underlying the slate. Generally, slate liner associated with each row of slate underlies the slate tiles of a row. Typically, the slate liner for a row of tile would be positioned atop the hangers associated with that row, and the slate tiles would then be placed in the hangers atop the slate liner. In addition, the roof may include valley metal, gable/rake edge metal and drip edge metal positioned on the roof deck. Generally, the slate roof may be installed by positioning and attaching the battens to a roof deck. The hangers would then be secured to the battens, positioned on the battens in order to properly support slate tile across the roof. In one embodiment, the battens would have regularly spaced hanger holders or slots along their length, shaped and sized to accept the hangers. The hangers are operable to fit securely within the hanger holders, such that the hangers could be securely attached as necessary along the length of the battens to affix slate tiles to the roof. By providing hangers that are removably secured to the battens, the hangers may be appropriately positioned, regardless of an edge or a valley in the roof. An alternative embodiment might have hangers that are repositionable along the length of the battens, so that the hangers may be properly positioned, regardless of an edge or valley. Once the hangers have been appropriately placed on the battens, the state liner would be positioned atop the hangers before placing down the slate. In addition, underlayment may be placed below the battens, with a self-adhering membrane placed below the underlayment.
By underlaying each course of slate with an interlayment material layer, the interlayment material acts as a base to the through joints, preventing water penetration to the underlying roof through seams in the slate tiles. This can reduce the amount of slate used to form a waterproof roof by approximately 40% to 50% (since the interlayment material blocks water seepage through seams between slate tiles, less slate overlap is required to provide a waterproof roof. Rather than two plies of exposed slate and three-plies of slate at areas of overlap, the present embodiments use only a single ply of exposed slate with two-plies of slate at areas of overlap). Generally, heavy-duty, weatherproof interlayment material layer would be used, typically plastic 20 to 60 mil in thickness. Moreover, where slate meets side to side (the through joint), the underlaying interlayment material provides sufficient waterproofing to protect the roof. The interlayment material is also less expensive and lighter weight than the slate it replaces. Thus, disclosed embodiments improve upon prior art slate roofs by providing for a markedly improved weather barrier, lighter weight, and more economical slate roof.
Disclosed hanger embodiments do not require nails to mount the slate on the roof, improving the durability of the slate tiles by reducing stresses. The disclosed embodiments allow a plurality of hangers to be installed at one time. Since damage can also be caused during roof construction, the installation of a plurality of hangers at one time allows the slate to be installed from the top down. In addition, the nature of the hangers allows the roof to be easily repaired without tools. The metal used in some embodiments of the hangers can also be a more durable means of attachment of slate tiles to the roof, since the hanger shape provides for strong, durable attachment. The hangers are also generally spring tempered, which helps them spring against the roof deck. By being tension-sprung, the hangers may provide superior wind uplift protection.
While examples in this application make specific reference to slate and slate installation, the invention and techniques provided herein apply to tile and tile installation regardless of material, and any sort of shingle, as well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a roof deck.
FIG. 2 is a top view of the roof deck illustrating valley preparation and drip edge installation.
FIG. 3 is a top view of the roof deck illustrating placement of underlayment.
FIG. 4 is a top view of the roof deck illustrating placement of valley metals and rake edge metals.
FIG. 5 is a top view of the roof deck illustrating preparation of all valleys, hips, ridges, walls and roof penetrations.
FIG. 6 is a top view of the roof deck illustrating the installation of slate.
FIG. 7 is a perspective view of the roof deck illustrating installation of slate.
FIG. 8 is a perspective view of the roof deck illustrating slate installation at the valley.
FIG. 9A is a top view of a batten with exemplary hangers used according to the present disclosure.
FIG. 9B is a top view of a batten with exemplary hangers used according to the present disclosure.
FIG. 9C is a top view of a batten with exemplary hangers used according to the present disclosure.
FIG. 9D is a perspective view of a batten with exemplary hanger used according to the present disclosure.
FIG. 9E is a perspective view of a batten with exemplary hanger used according to the present disclosure.
FIG. 10 is a front view of the roof deck illustrating hip installation of slate.
FIG. 11 is a top view of the roof deck illustrating the ridge.
FIG. 12 is a side view of the roof deck illustrating ridge installation of slate.
FIG. 13 is a detailed view of slate installation step 1 .
FIG. 14 is a detailed view of state installation step 2 .
FIG. 15 is a detailed view of state installation step 3 .
FIG. 16 is a perspective view of the roof deck illustrating flashing at siding.
FIG. 17 is a perspective view of the roof deck illustrating flashing at sidewall/chimney.
FIG. 18 is a perspective view of the roof deck illustrating plumbing vent details with installation.
FIG. 19A is a side view of the hanger according to one aspect of the present disclosure.
FIG. 19B is a plan view of the hanger of FIG. 19A .
DETAILED DESCRIPTION OF EMBODIMENTS
In FIG. 1 a top view of a roof deck 102 is shown. In the present methodology, the initial step is to inspect and prepare the roof deck 102 . In one embodiment, the roof deck 102 has a valley 104 , eave 114 , gable/rake 116 and ridge 118 . In this exemplary roof deck 102 inspection step, the existing roof sheathing is inspected for structural integrity. The roof deck 102 should be preferably minimum 15/32 inch plywood or code approved oriented strand board (OSB). All roof deck 102 nails should be driven flush with the roof deck 102 . The roof deck 102 should be inspected for protrusions which may damage felt underlayment 110 (See FIG. 3 ).
FIG. 2 is a top view of the roof deck 102 illustrating valley 104 preparation and drip edge 108 installation. In this step of the present methodology, the user installs peel and stick membrane 106 in the valleys 104 while overlapping membrane 106 seams a preferred minimum of six inches. The membrane 106 used is preferably a self-adhering poly(styrene-butadiene-styrene) (SBS) type. For example, the membrane 106 used in the preferred embodiment is Tarco™ Leak Barrier Ice and Water Armor. However, it is to be appreciated that any equivalent membrane can be utilized. The membrane 106 is preferably 36 inches wide. All drip edge 108 metals are then installed. The drip edge 108 is preferably D style No. 26 gauge galvanized or 16 ounce copper metal. On new construction, if the exterior fascia board has not been painted, the drip edge 108 may be delayed and installed after the underlayment 110 (See FIG. 3 ) is installed. The underlayment 110 (See FIG. 3 ) should extend over the drip edge 108 metal.
In FIG. 3 a top view of the roof deck 102 illustrating placement of underlayment 10 is shown. In this step of the present methodology, the user installs underlayment 110 , which is preferably a poly(styrene-butadiene-styrene) (SBS) multipurpose or Type 30 per ASTM D226. During this step, the user will roll the underlayment 110 over the gable/rake edge 112 a preferred minimum of one inch. There is a preferred minimum headlap of two inches for the underlayment 110 . This may be increased to a minimum of four inches in wet or snow areas. Headlap for purposes of this application is defined as the portion of slate 130 (See FIG. 6 ) overlapped by two layers of slate 130 (See FIG. 6 ) from the next two rows. Headlap facilitates making the roof watertight. Indeed, failure to adhere to the recommended headlap can lead to interior water damage. There is a preferred minimum six inch sidelap for the underlayment 110 . For purposes of this application, sidelap is defined as side edges of adjoining pieces of underlayment. Nails (not shown) may be used to secure the underlayment 110 and have a pattern of preferably 12 inches on center at the headlap and preferably 36 inches on center at the center of the underlayment roll.
FIG. 4 is a top view of the roof deck 102 illustrating placement of valley metals 120 and rake edge metals 154 . In the present methodology, the user may install valley metal 120 over membrane 106 (See FIG. 2 ). This valley metal 120 is preferably 26 gauge galvanized, 24 inch “W”, or 16 ounce copper metal. It is preferably installed with a one inch splash diverter (not shown) and preferably fastened with 1.25 inch roof nails or 1.25 inch copper slating nails one inch from the edge. The user may also install gable/rake edge metals 154 at gable/rake edge 112 . The gable/rake edge metal 154 is preferably 26 gauge galvanized or 16 ounce copper metal. Next the user may install vertical wall flashings (See FIGS. 16 and 17 ) and plumbing stack and vent flashings (See FIG. 18 ). The vertical wall flashings (See FIGS. 16 and 17 ) are preferably 26 gauge galvanized or 16 ounce copper. At the next step, the user may install peel and stick membrane 106 over ridge 118 . The membrane 106 used is preferably a self-adhering poly(styrene-butadiene-styrene) (SBS) type. The membrane 106 is preferably 12 inches wide having three inch endlaps.
In FIG. 5 a top view of the roof deck 102 illustrating preparation of all valleys 104 , hips 156 , ridges 118 , walls and roof penetrations is shown. Peel and stick membrane 106 is applied over valley metal 120 (See FIG. 4 ) leaving preferably three inches from the center line of valley 104 uncovered. The membrane 106 should cover valley metal 120 a preferred minimum of 11 inches on each side of the center line and cover nails a preferred minimum of three inches. With a utility knife, the user may cut preferably ten inch wide strips from the roll of peel and stick membrane 106 . The user may install peel and stick membrane 106 over the gable/rake edge metal 154 being sure to cover all fasteners. The membrane 106 should extend a preferred minimum of six inches beyond the gable/rake edge metal 154 over the underlayment 110 . This gable/rake edge metal 154 membrane 106 may also extend over the valley 104 membrane 106 . The membrane 106 on the valley metal 120 and the gable/rake edge metal 154 may be self-adhered, instead of nailed. The membrane 106 should also be installed over all other flashings and roof penetrations a preferred minimum of six inches past all flashings. Next the user may install the hip spacer 126 and the ridge spacer 122 using preferably 1.5 inch roofing nails or coated decking screws. These fasteners are preferably placed at 24 inches on center on each side of the nailer. Spacer flashing 124 is cut from slate liner 140 (See FIG. 6 ) and placed over the ridge spacer 122 and should preferably overlap 12 inches at sidelaps.
FIG. 6 is a top view of the roof deck 102 illustrating the installation of slate 130 . In the slate installation step, the roof deck 102 is outlined with slate 130 . The hips 156 , ridges 118 and valleys 104 are outlined first. Next the user wilt locate and mark the bottom batten row 172 at the drip edge 108 . The bottom row 174 (See FIG. 7 ) of hangers 134 (See FIG. 7 ) should extend to the drip edge 108 . The user may then use a chalk line and measuring tape to locate the remaining rows for battens 132 . Battens 132 should be preferably installed at 10 inch intervals. The battens 132 are preferably galvanized or stainless steel. Stainless steel is generally used where coastal salt water corrosion is a concern. It is to be appreciated that batten 132 spacing may be increased or decreased to accommodate fraction spacing. The user may begin at the hips 156 and valleys 104 and work up the roof deck 102 installing a full batten 132 , slate liner 140 , and 2-3 slates 130 at each row, leaving the field clear to walk. Next, the user may locate and install top row battens 132 , slate liner 140 , and top row of slates 130 (ridge row 178 ), then install ridge slates 150 . The ridge slates 150 should overlap and lock in the ridge row 178 of slates 130 . The user may trim off any exposed slate liner 140 with a utility knife.
In one embodiment, beginning four rows down from the ridge row 178 of slates 130 , the user may install batten 132 . Hangers 134 may or may not be preinstalled on battens 132 . The user may then lay slate liner 140 on hangers 134 (See FIG. 7 ) and drop slate 130 onto hangers 134 (See FIG. 7 ). The hangers 134 (See FIG. 7 ) are preferably spring tempered stainless steel. The user is cautioned to confirm that the keyways or joints line up with the ridge row 178 of slate 130 . Next the user may install the next row of battens 132 locking in the row of slate 130 below and repeating the process. In one embodiment, the user offsets the keyways ½ slate 130 every other row. The last row may be “shoehorned” in by the user. The user may then come down the roof four rows and repeat the process. A perspective view of this slate installation process is shown in FIG. 7 while FIG. 8 illustrates a perspective view of the slate installation at the valley 104 . Greater detail on the slate 130 installation is show in FIGS. 12-15 .
In FIG. 9A a top view of batten 132 with hangers 134 used in the present methodology is shown. Hangers 134 , which are preferably formed of spring tempered stainless steel, can be easily installed and removed to facilitate proper support for the slate 130 . The hangers 134 provide a convenient way to quickly and easily install and remove individual slate 130 . In one embodiment illustrated in FIG. 9A , the hangers 134 have a short member 158 and a long member 160 . The long member 160 has a curved distal end (upward facing hook 162 at one end) and the remaining end is adjacent to a first outward extending arm 166 . In some embodiments, the long member 160 may be modified to include a wider distal end or two distal ends. The first outward extending arm 166 is adjacent a central connecting member 168 . This central connecting member 168 is adjacent a second outward extending arm 170 . This second outward extending arm 170 is adjacent the short member 158 . While the majority of hanger 134 rests in one plane, long member 160 extends at an angle above the plane of first outward extending arm 166 , curves downward at an angle and ends at a point within the linear plane of the first outward extending arm 166 . This exemplary embodiment is illustrated in more detail in FIGS. 19A and 19B . When installing the hanger 134 , the user will insert the second outward extending arm 170 of the hanger 134 into an opening formed by a first hanger holder 142 . The hanger holder 142 is generally defined by the batten 132 to be a pocket or slot-like receiving portion for receiving a portion of the hanger 134 . The hanger holder 142 may be formed as an integral portion of the batten 132 , or as a separable element attached to the batten. The first outward extending arm 166 of hanger 134 will then be inserted into an opening formed by an adjacent hanger holder 142 . When removing the hanger 134 , the user squeezes together the short member 158 and long member 160 to remove the hanger 134 from the first hanger holder 142 and the adjacent hanger holder 142 .
It is to be appreciated that the hanger 134 may take a variety of shapes and configurations for interacting with the battens 132 and retaining the slate members on the roof. Indeed, the hanger holders may be correspondingly altered to take a shape and size corresponding to, or otherwise accommodating, the various hanger shapes and sizes. For example, with reference to FIG. 9B , a head portion 200 of a hanger 234 may take on a circular or substantially circular configuration. A batten 232 may be provided such that a pair of hanger holders 242 are contoured to correspond to the shape of the head portion 200 of the hanger 234 . The hanger 234 may further include a short member 258 and long member 260 to facilitate insertion of the hanger 234 into the hanger holders 242 in a manner similar to that described with reference to FIG. 9A .
In another embodiment depicted in FIG. 9C , a head portion 300 of a hanger 334 may be formed to have a hexagonal or substantially hexagonal shape. Corresponding hanger holders 342 may be provided to correspond to the shape of the head portion 300 of the hanger 334 . Indeed, in some embodiments, the hanger holders 342 may include gaps at the apices of the hanger holders to permit extension of the hexagonal head 300 through the hanger holder when removably secured thereto. The hanger 334 may further include a short member 358 and long member 360 to facilitate insertion of the hanger 334 into the hanger holders 342 in a manner similar to that described with reference to FIG. 9A .
It is to be appreciated that additional embodiments are contemplated in which the head portion of the hanger is sized and shaped to fit into corresponding receiving portions (such as the exemplary hanger holders described above) of the batten, thereby permitting the retention of slate on a roof structure. In such embodiments, the hangers may be removably secured to the battens, thereby permitting hangers to be movable or repositionable along the length of the battens. This provides flexibility in deciding where to establish hangers along the length of the battens. Indeed, larger slate tiles may require a larger number of hangers, whereas smaller slate tiles may require a lesser number of hangers. Accordingly, efficiency of resources can be maximized according to the teachings of the present disclosure. The removably securable relationship between the hangers and the battens also permits quick installation of the roofing system of the present disclosure.
Additional exemplary embodiments are contemplated in which the head portion of the hanger is shaped and sized to fit into, snap into, or otherwise removably attach to, the corresponding receiving portions (e.g., hanger holders) defined in the batten. For example, with reference to FIG. 9D , a head portion 400 of a hanger 434 may include projections 440 shaped and sized to snap-fit into a corresponding grid-like structure 450 (receiving portion) of a batten 432 . Of course, any number of projections 440 are contemplated, so long as they are able to snap-fit, or otherwise attach to, the batten 132 . Still further, in FIG. 9E , a head portion 500 of a hanger 534 may include a pair of projections 540 designed to fit into corresponding receptacles 570 of a batten 532 . In such an embodiment, the projections 540 of the hanger 534 may be substantially L-shaped so as to minimize the distance the projections extend from the head portion 500 . Indeed, the projections 540 may be fixed or actuateable from a first position to a second position. Of course, the projections 540 may take any shape to permit operative engagement of the hanger 534 with the batten 532 .
FIG. 10 is a front view of the roof deck 102 illustrating hip 156 installation of state 130 . The hips 156 of the roof deck 102 are one of the first areas outlined with state 130 . The user will install battens 132 on top of the underlayment 110 . Hangers 134 are inserted into hanger holders 142 of battens 132 . The user will lay slate liner 140 on hangers 134 and drop slate 130 onto hangers 134 . At the hips 156 , hip spacer 126 is applied followed by hip spacer cover 148 . Slate trim pieces 146 are applied and attached to hip 156 by decking screws 144 .
In FIG. 11 a top view of the roof deck 102 illustrating the ridge 118 installation is shown. With the ridge 118 installation step, the user will install ridge spacers 122 by making sure the ridge spacer 122 is preferably evenly spaced over the ridge 118 and fastened at preferably 24 inches on center along each side of ridge 118 with preferably 1.5 inch roofing nails or screws. The user will place preferably 13 inch wide slate liner 140 over the ridge spacers 122 so that the center line of slate liner 140 is centered along the ridge 118 . It is preferred to work with 10-12 foot lengths being sure to preferably overlap end joints 12 inches minimum. Next, the user installs top batten 132 (See FIG. 12 ) along a chalk line using a nail gun and preferably 1.25 inch 0.120 galvanized standard coil fed roofing nails. Hangers 134 (See FIG. 12 ) are inserted into hanger holder 142 (See FIG. 12 ) of battens 132 (See FIG. 12 ). In some embodiments, the batten 132 (See FIG. 12 ) is fastened at the center of the hanger 134 (See FIG. 12 ) except at the gable/rake edges 112 (See FIG. 4 ). The user lays the slate liner 140 along row of hangers 134 (See FIG. 12 ) and tucks under the plastic ridge spacer cover 152 . The ridge spacer cover 152 should preferably overlap top row of slate liner 140 by a minimum of three inches. The user will next lay the first row of slate 130 by placing bottom edge of each slate 130 into top row of hangers 134 (See FIG. 12 ). The hangers 134 (See FIG. 12 ) are preferably preinstalled at six inches center. The slates 130 are preferably twelve inches wide by twelve inches long standard quarried slate. Of course, other spacing dimensions for the hangers 134 and other sized slates 130 are contemplated to fall within the scope of the present disclosure. Also, it is to be appreciated that other tiles other than slate may be used in accordance with the principles of the present disclosure. Indeed, it is contemplated that any roofing or siding members may be used in accordance with the principles herein. The hangers 134 (See FIG. 12 ) are preferably evenly spaced on the slate 130 . Each hanger 134 (See FIG. 12 ) should be preferably three inches from the edge of each full piece of slate 130 . On smaller pieces, it is preferable to have at least two hangers 134 (See FIG. 12 ) are supporting each piece of slate 130 . Hanger 134 (See FIG. 12 ) can be easily removed and replaced to facilitate spacing up to preferably 1.5 inches. In some embodiments, if a measurement calls for a piece of slate 130 less than four inches wide, the adjacent piece should be cut back so that the small piece is preferably a minimum of four inches. The cut edges can be placed side by side so that the cut edge disappears and is not distinguishable. The user preferably ensures that the ridge spacer cover 152 overlaps the top row of slate 130 a preferred minimum of two inches. The top edge of the top row of slate 130 is preferably no more than one inch from the bottom of the ridge spacer 122 . The ridge trim pieces 150 are installed by nailing or screwing each piece of state 130 through two predrilled holes 186 directly through the ridge spacer 122 into the roof deck 102 . The trim pieces 150 are preferably 16 inch.times.7 inch standard quarried slate predrilled. The edge of each trim piece 150 must meet at the top of the ridge 118 and one piece should slightly overlap the other so that a clean, weather resistant joint is formed. If desired, the user may apply a weatherproof caulk of a matching color to the joint. The caulk is preferably a high quality exterior grade silicone. Next, the next ridge trim piece 150 is installed by overlapping the previously installed piece by preferably six inches. If desired, each nail hole can be covered with a weatherproof caulk. The ridge trim pieces 150 should overlap the top of the first row of state 130 by a preferred minimum of two inches. Care should be taken not to overdrive the fasteners on ridge trim pieces 150 . The slates 130 should be able to wiggle slightly. Any plastic ridge spacer cover 152 that is visible after the ridge trim pieces 150 are installed can be carefully trimmed with a utility knife. FIG. 12 is a side view of the roof deck 102 illustrating ridge 118 installation of slate 130 .
In FIG. 13 a detailed view of exemplary slate 130 installation step 1 is shown. In installation step 1 , the user installs battens 132 end to end on a fourth chalk line from the top or ridge 118 . The user fastens each batten 132 with roofing nails 138 at the center of each hanger 134 approximately every six inches. The slate liner 140 is next installed by placing it along the row of battens 132 using the hangers 134 to support the slate liner 140 . It is recommended that each piece of slate liner 140 be preferably a maximum of 25 feet long. The pieces of slate liner 140 should preferably overlap a minimum of twelve inches at side laps. Slate liner 140 should be installed with the dull finish side up or shiny side down. In some embodiments, no nails are driven through the slate liner 140 . Next the user installs slates 130 by placing slates 130 on the hangers 134 being careful to keep hangers 134 centered on the slates 130 . In some embodiments, each slate 130 should have two hangers 134 supporting it preferably evenly spaced from each side edge of the slate 130 . Full slates 130 should have a hanger 134 preferably three inches from each side edge. At the beginning or end of each row a one-half slate offset is recommended and can be achieved by placing additional hangers 134 at the hanger holders 142 provided in the battens 132 . The battens 132 can be cut with tin snips. The user should align the battens 132 end to end preferably maintaining a six inch space between the hangers 134 for slates 130 (or three empty hanger holders 142 in the battens 132 ). Battens 132 should be held back ½ inch from ridge spacers 122 or gable/rake edge metals 154 (See FIG. 5 ).
FIG. 14 is a detailed view of exemplary slate 130 installation step 2 . In this step of installation, the user will install the next row 180 of battens 132 . The battens 132 should lock into the slates 130 below. The user should ensure the hangers 134 are preferably evenly spaced on the states 130 below. The hangers 134 should be preferably three inches from each edge of each slate 130 . Tin snips are used to trim the battens 132 at the ends to facilitate hanger 134 spacing.
In FIG. 15 a detailed view of exemplary slate 130 installation step 3 is shown. In this step of installation, at the top row of each working section an open row 182 is created. To complete the installation of the open row 182 , the user should install slate liner 140 by slipping it under the top row 184 of slate 130 . The bottom edge of the slate liner 140 is held in place by hangers 134 . Next the user installs the slates 130 by slipping the top edge of the slate 130 under the top row 184 until the bottom edge of the slate 130 clears the hangers 134 below. The user pulls or pushes the slate 130 downward slightly until the hangers 134 support the bottom edge of the slate 130 . Preferably an 18 inch wide piece of slate liner 140 can be used as a shoehorn by inserting it first, then the slate 130 slides easier into place. The shoehorn is removed and the process is repeated.
While various embodiments in accordance with the principles disclosed herein have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with any claims and their equivalents issuing from this disclosure. Furthermore, the above advantages and features are provided in described embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages.
Additionally, the section headings herein are provided for consistency with the suggestions under 37 CFR 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the “Brief Summary” to be considered as a characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.
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Systems for assembling and supporting roofing members on a roof structure are described. An exemplary system includes at least one batten extending along a portion of the roof structure. The batten includes receiving portions for removably securing hanger devices along the batten. Related methods for support and assembly are also described.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and is a continuation application of U.S. patent application Ser. No. 12/916,839, which is a divisional application of U.S. patent application Ser. No. 12/154,719, filed May 27, 2008, which claims priority to U.S. Provisional Patent Application No. 60/931,608, filed May 24, 2007, entitled Communication Management in a Virtual Environment, the content of each of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to virtual environments and, more particularly, to a method and apparatus for managing communication between participants in a virtual environment.
[0004] 2. Description of the Related Art
[0005] Virtual environments simulate actual 3-D environments and allow for many participants to interact with each other and with constructs in the environment via remotely-located clients. One context in which a virtual environment may be used is in connection with gaming, although other uses for virtual environments are also being developed.
[0006] In a virtual environment, an actual or fantasy universe is simulated within a computer processor/memory. Multiple players may participate in the virtual environment through a computer network, such as a local area network or a wide area network such as the Internet. Each player selects an “Avatar” which is often a three-dimensional representation of a person or other object to represent them in the virtual environment. Participants send commands to a virtual environment engine that controls the virtual environment to cause their Avatars to move within the virtual environment. In this way, the participants are able to cause their Avatars to interact with other Avatars and other objects in the virtual environment.
[0007] A virtual environment often takes the form of a virtual-reality three dimensional map, and may include rooms, outdoor areas, and other representations of environments commonly experienced in the physical world. The virtual environment may also include multiple objects, people, animals, robots, Avatars, robot Avatars, spatial elements, and objects/environments that allow Avatars to participate in activities. Participants establish a presence in the virtual environment via a virtual environment client on their computer, through which they can create or upload an Avatar and then cause the Avatar to “live” within the virtual environment.
[0008] As the Avatar moves within the virtual environment, the view experienced by the Avatar changes according to where the Avatar is located within the virtual environment. The views may be displayed to the participant so that the participant controlling the Avatar may see what the Avatar is seeing. The participant may control the Avatar using conventional input devices, such as a computer mouse and keyboard. The inputs are sent to the virtual environment client which forwards the commands to one or more virtual environment servers that are controlling the virtual environment and providing a representation of the virtual environment to the participant via a display associated with the participant's computer.
[0009] Depending on how the virtual environment is set up, an Avatar may be able to observe the environment and optionally also interact with other Avatars, modeled objects within the virtual environment, robotic objects within the virtual environment, or the environment itself (i.e. an Avatar may be allowed to go for a swim in a lake or river in the virtual environment). In these cases, client control input may be permitted to cause changes in the modeled objects, such as moving other objects, opening doors, and so forth, which optionally may then be experienced by other Avatars within the virtual environment.
[0010] “Interaction” by an Avatar with another modeled object in a virtual environment means that the virtual environment server simulates an interaction in the modeled environment, in response to receiving client control input for the Avatar. Interactions by one Avatar with any other Avatar, object, the environment or automated or robotic Avatars may, in some cases, result in outcomes that may affect or otherwise be observed or experienced by other Avatars, objects, the environment, and automated or robotic Avatars within the virtual environment.
[0011] A virtual environment may be created for the user, but more commonly the virtual environment may be persistent, in which it continues to exist and be supported by the virtual environment server even when the user is not interacting with the virtual environment. Thus, where there is more than one user of a virtual environment, the environment may continue to evolve when a user is not logged in, such that the next time the user enters the virtual environment it may be changed from what it looked like the previous time.
[0012] Virtual environments are commonly used in on-line gaming, such as for example in online role playing games where users assume the role of a character and take control over most of that character's actions. In addition to games, virtual environments are also being used to simulate real life environments to provide an interface for users that will enable on-line education, training, shopping, and other types of interactions between groups of users and between businesses and users.
[0013] When participants encounter each other in the virtual environment, they may desire to communicate with each other, much as people would like to communicate in the real world. The communication may be a simple wave, nod, or other gesture, a simple hello, or optionally the participants may want to converse with each other.
[0014] Conventionally, the virtual environments have allowed participants to chat with each other by typing text into a chat bar associated with the view of the virtual environment. Communication management in this type of environment was relatively easy, since the participants could choose to ignore typed messages from other participants. As virtual environments are integrated with other forms of communication, such as Voice over Internet Protocol (VoIP) based audio communication, the communication becomes more intrusive. Additionally, as other forms of communication are integrated with and available through the virtual environment, it will become more important to enable participants in a virtual environment to manage how they are able to communicate with other participants and to enable the participant to manage how other participants are able to initiate communication.
SUMMARY OF THE INVENTION
[0015] A method and apparatus for managing communication between participants in a virtual environment enables the participants to elect to automatically connect with each other via a preferred communication mechanism, manually connect with each other, or choose not to connect with each other. The connection may be point-to-point between two participants or may include multiple participants. Establishment of a connection, or the ability to establish a connection, may be based on the proximity of the participants, or the Avatars representing the participants, in the virtual environment. Once the connection is established, the connection may be managed so that the connection is maintained while the Avatars remain proximate each other and is automatically severed once the Avatars move away from each other. Environmental noise and other audio aspects may be included in the connection to simulate a real-world conversation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Aspects of the present invention are pointed out with particularity in the appended claims. The present invention is illustrated by way of example in the following drawings in which like references indicate similar elements. The following drawings disclose various embodiments of the present invention for purposes of illustration only and are not intended to limit the scope of the invention. For purposes of clarity, not every component may be labeled in every figure. In the figures:
[0017] FIG. 1 is a functional block diagram of an example system that may be used to manage communication between participants in a virtual environment according to an embodiment of the invention;
[0018] FIG. 1A is a functional block diagram of another example system that may be used to manage communication between participants in a virtual environment according to an embodiment of the invention;
[0019] FIGS. 2-11 are example representations of several connection scenarios between Avatars representing participants interacting in a virtual environment; and
[0020] FIGS. 12-19 are schematic diagrams showing how proximity between Avatars in a virtual environment may be used to manage communication between the participants in the virtual environment according to an embodiment of the invention.
DETAILED DESCRIPTION
[0021] The following detailed description sets forth numerous specific details to provide a thorough understanding of the invention. However, those skilled in the art will appreciate that the invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, protocols, algorithms, and circuits have not been described in detail so as not to obscure the invention.
[0022] FIG. 1 shows an example system that may be used to manage the communication context of one or more individuals via a virtual environment according to an embodiment of the invention. As shown in FIG. 1 , a virtual environment 12 is generally created by one or more virtual environment servers 14 . A virtual environment is a three dimensional representation of an environment such as the real world or a fantasy world. The virtual environment servers maintain the virtual environment and generate views of the virtual environment to be presented to participants as they navigate their Avatars through the virtual environment. The virtual environment servers keep track of the location of various Avatars and other objects within the virtual environment.
[0023] A virtual environment may be any type of virtual environment, such as a virtual environment created for an on-line game, a virtual environment created to implement an on-line store, a virtual environment created to implement an on-line training facility, or for any other purpose. Virtual environments are being created for many reasons, and may be designed to enable user interaction to achieve a particular purpose. Example uses of virtual environments include gaming, business, retail, training, social networking, and many other aspects.
[0024] A participant (such as user A, B, or C in FIG. 1 ) can use a computer 16 running a virtual environment client 20 and a user interface 22 to access the virtual environment server 14 via a data network 18 . The participant may see a representation of a portion of the computer-generated three dimensional virtual environment on a display 24 and input commands via a user input device 26 such as a mouse or keyboard. The user interface generates the output shown on the display under the control of the virtual environment client, and receives the input from the user and passes the user input to the virtual environment client. The virtual environment client passes the user input to the virtual environment server which causes the user's Avatar or other object under the control of the user to execute the desired action in the virtual environment. In this way the user may control a portion of the virtual environment, such as the person's Avatar or other objects in contact with the Avatar, to change the virtual environment for the other users of the virtual environment.
[0025] In the embodiment shown in FIG. 1 , the virtual environment server 14 is affiliated with a communication server 28 to enable communication sessions to be selectively established between participants in the virtual environment. The communication server may interface with communication clients 30 on the user computers to enable communication sessions to be established between participants. According to an embodiment of the invention, the virtual environment server includes a communication manager 32 that allows participants to manage the establishment, termination, and other aspects of the communication sessions while interacting in the virtual environment. Although the embodiment shown in FIG. 1 has a separate communication server 28 , in another embodiment the functions of the communication server may be performed by the communication manager 32 , so that the virtual environment server 14 may not only control the establishment of communication sessions between participants, but may also participate in the establishment of the communication sessions. Alternatively, as shown in FIG. 1A , the functions of the communication server, communication manager, and virtual environment server may be implemented as a single server 15 . Thus, multiple combinations of functionality may be possible and the invention is not limited to the particular way in which the different functions are allocated between different components of the system.
[0026] FIG. 2 shows an example Avatar 50 that may be used to represent a participant in a virtual environment. As shown in FIG. 2 , the Avatar has a likeness of a human which is common in virtual environments. According to an embodiment of the invention, a partially translucent communication aura 52 may partially surround the Avatar and be superimposed over the background when the participant associated with the Avatar is willing to engage in communication sessions with other participants. For example, the Avatar on the left in FIG. 2 is shown as superimposed over the partially translucent communication aura 52 . The presence of the aura indicates to other participants in the virtual environment that the participant is available for audio communication. The Avatar on the right, by contrast, does not have an aura which indicates to the other participants that the participant associated with the Avatar is not available for audio communication.
[0027] The user may control the aura by setting a preference via their User Interface 22 to instruct the communication manager 32 whether they are willing to engage in audio communication sessions with other participants. This preference will be used by the virtual environment server to superimpose the aura around the participant's Avatar when the participant is available, and to remove the aura when the participant is not available. Optionally the appearance of the Aura may be specified by the participant. For example, when a participant creates an character in the virtual environment the participant may be asked to specify many features of their character, such as height, weight, gender, age, hair color, etc. The color and shape of the user's aura may be a feature that the user is able to specify when creating their Avatar, or when deciding to implement the communication option described herein, so that the various aspects of what the aura look like may be customized by the user.
[0028] The communication manager 32 may enable communication sessions to be established between participants manually or automatically. FIG. 3 shows a scenario where two Avatars, who have both specified that connection should occur automatically, meet in a virtual environment. As shown in FIG. 3 , where both Avatars are set to connect automatically, the distance between the Avatars may be used to control establishment of the audio connection between the participants. The use of distance to enable audio connection simulates the real world, in which people are accustomed to talking with each other while in the same room, but not when separated by a great distance.
[0029] Optionally, the distance between Avatars may be supplemented by other environmental context, such as the location of the Avatars within the virtual environment relative to each other. An example of this is shown in FIG. 6 . Specifically, assume that the virtual environment simulates a house or other building that has multiple rooms 60 A, 60 B. In the real world, people are not generally able to talk to each other through the walls. Thus, in the virtual environment the Avatars may be prevented from establishing an audio connection where the Avatars are on opposite sides of a wall 62 or other barrier in the virtual environment. However, if there is an aperture 64 that would allow voice communication to occur through the wall, such as a door, window, or other aperture (See FIG. 7 ), the Avatars may be allowed to communicate with each other. Thus, the environmental context may be used in addition to proximity to determine whether the communication manager should establish a communication session between the participants in the virtual environment.
[0030] FIGS. 4 and 5 show a process of enabling participants associated with Avatars to communicate manually. As shown in FIG. 4 , when an Avatar such as the Avatar 50 B associated with a first participant (initiating participant) meets an Avatar associated with another participant (responding participant), the initiating participant (user B in this example) will use their user interface to attempt to communicate with the responding participant. For example, the initiating participant may scroll his mouse over the Avatar of the proposed responding participant and right click on the proposed responding participant. Undertaking this sequence of actions or another sequence of events may cause a dialog box 54 to be presented to the initiating participant via which the initiating participant may specify his preference to establish an audio communication session with the responding participant.
[0031] When the initiating participant indicates that a communication session is desired, the responding participant will receive an alert tone or be shown a communication bubble via which the responding participant may accept or decline the proposed audio communication session. If the responding user is set to automatically connect, the responding user will only be provided with an alert tone. Where the user is set to manually connect, the communication bubble may also give the responding participant a way to suggest an alternative communication method such as text/instant messaging option. Although not shown, the communication bubble may also give the responding participant other additional options such as the option of obtaining additional information about the initiating participant. Although a dialog box and a communication bubble were used to show example interfaces that may be provided to the participants, other types of interfaces may be used as well depending on the preferences of the owner running the virtual environment.
[0032] If a communication session is declined, the Avatars may continue their activities in the virtual environment as before. However, where the Avatars are both set to automatically connect or where the participants agree to establish a connection, the communication manager and/or the communication server will cause a communication channel to be set up between the initiating and responding participants.
[0033] Once a communication channel has been established, it may be desirable to allow other participants in the virtual environment know that the two participants are communicating. Thus, as shown in FIG. 8 , once the communication session has been established the virtual environment server may be notified so that the virtual environment server may modify the representation of the Avatars to convey to the other participants in the virtual environment that a conversation is occurring. In the example shown in FIG. 8 , this is represented by extending the partially translucent communication aura 52 to partially surround both Avatars that are associated with the communication session. By unifying the aura around both Avatars other participants in the virtual environment are able to tell that a conversation is occurring.
[0034] During a conversation, either participant may decide that the conversation should be a private conversation to avoid interruption by other participants. If the conversation is private it may be represented differently to the other participants, for example as shown in FIG. 9 . Setting the conversation to private may cause the Avatars may be teleported to a private location/room in the virtual environment where other users can't interrupt them. In FIG. 9 , this is represented by superimposing a bubble 64 on each of the Avatars associated with the communication session, and interconnecting the bubbles 64 via a tube 66 to indicate that the two Avatars are engaged in a conversation.
[0035] Either participant may terminate a communication session to cause the visual representation of the Avatars to revert back to normal (see e.g. FIG. 3 ). Where the participants have set their Avatars to automatically connect, and one of the participants has terminated the communication session, the virtual environment server may impose additional restrictions on establishment of a connection between the two participants. For example, assume that Avatars 50 A and 50 B are within the auto-connect distance, and that the participant associated with Avatar 50 A has just disconnected a previous connection. Since the Avatars are technically within the auto-connect distance and both are set to automatically connect, without the additional restriction the virtual environment server may attempt to re-establish the connection. Thus, for example, where a connection is disconnected the virtual environment server may require the Avatars to move away from each other beyond the disconnect distance and then re-approach each other before allowing a new connection to be established. Alternatively, the virtual environment server may impose a time restriction to prevent a new connection from being established between the two users, for example for several seconds. Still alternatively, the virtual environment server may disable the auto-connect mechanism for the particular Avatars that were previously associated with a communication session to require those Avatars to connect manually with each other for a period of time. Other methods of preventing unintended automatic reconnect may be implemented as well.
[0036] There may be times where a third party may want to join an on-going conversation. An example of this is shown in FIG. 10 . Where the participants are all set to automatically connect and automatically allow others to connect, the third participant may join in the conversation. This may be represented to other participants in the virtual environment by showing the aura to also include the third Avatar as shown in FIG. 11 .
[0037] When the third participant seeks to join an existing conversation, the third participant may indicate that desire to the virtual environment server (e.g. by scrolling over and right clicking on the conversation aura). Optionally, the third participant may be provided with a dialog, such as the dialog box 68 shown in FIG. 10 , to enable the third participant to specify how he would like to join the conversation. For example, the third participant may ask to join the on-going conversation, automatically join the existing conversation, send one or more of the participants an Instant Message, or request a private conversation with one of the users. Other options may be available as well.
[0038] If the third participant is accepted into the conversation, the existing audio channel is moved to a conference bridge with all three parties. The visual representation of the conversation (aura) is also adjusted to include the Avatar associated with the third participant so that other participants in the virtual environment know that a group conversation is occurring. Other users may join the conversation unless the conversation is set to private by one or more of the participants.
[0039] In a multi-party conversation, one user may be allowed to evict another user from the conversation. Alternatively, to prevent one person from dominating and controlling the membership in the conversation, a voting process may be required such that two or more, a majority, or unanimity may be required to evict a participant from a conversation. Once the multi-party conversation has reduced in size such that there are only two remaining participants, then the conference may be moved from the conference bridge to a two-way communication channel.
[0040] FIGS. 12-18 show aspects of how distance may be used, at least in part, to establish and disconnect communications sessions between participants in a virtual environment. FIG. 12 shows a first user (Avatar 1 =A 1 ) located in a virtual environment. A connect distance R 1 may be established for the Avatar A 1 such that another Avatar will need to be within distance R 1 of the first Avatar to establish a connection. In the example shown in FIG. 12 , Avatar A 2 is within R 1 of Avatar A 1 , and thus Avatars A 1 and A 2 may establish a connection. Where they are set to automatically connect, the connection will be established automatically. Where they are set to manually connect, they may need to choose to establish the session with each other. Although not shown, different radii R 1 -a and R 1 -m may be used for establishment of a connection automatically and manually.
[0041] Once a connection is established, the participants may continue talking on the connection while their Avatars are proximate each other. To allow some flexibility on how close the Avatars are required to be with each other, a disconnect distance may be specified such that the connection will automatically be terminated once the Avatars move away from each other. This is shown in FIG. 12 as radius R 2 . Note, in this regard, that radius R 2 is somewhat larger than radius R 1 to provide hysteresis to the connection. In FIG. 12 , if Avatars A 3 and A 2 have established a communication session, then Avatars A 3 and A 2 will continue to be able to talk on the connection even though they are further apart than the connection distance, since the distance between the two Avatars has not yet exceeded the disconnect distance R 2 . Avatar A 4 , in FIG. 12 , would not be allowed to engage in a communication session with Avatar A 1 , however, since Avatar A 4 is outside both the connect and disconnect distances.
[0042] FIG. 13 shows a possible way of calculating connect and disconnect distances where there are multiple parties. As shown in FIG. 13 , where there are multiple parties a logical center of the communication session 70 may be established. The logical center of the communication session may be the center of mass of the various participants, and the connect/disconnect distances may be calculated from that point rather than being calculated from the position of any one of the participants. Although FIG. 13 shows the formation of a logical center of mass of the communication system between three parties, this may also be extended to a situation where there are only two parties. An example of this is shown in FIG. 16 . In a two party conversation, may the connect distance and disconnect distance may be measured as the distance between the parties or, optionally, may be measured from the center of mass of the conversation.
[0043] Referring again to FIG. 13 , the logical center may be thought of as a virtual location of a conference bridge between the participants. As the users move relative to each other, the logical center of the conference bridge will move as well to stay at the center of mass of the various participants to the communication session. In this way the logical center will respond to the movements of the Avatars and track the participants. The logical center may be represented in the virtual environment by a dot or other indicia.
[0044] When a user moves more than the disconnect distance away from the logical center of the conversation, the user will be disconnected from the communication session. This is shown in FIG. 14 . Specifically, in FIG. 14 Avatar A 4 is located initially at time T 1 within the disconnect distance from the logical center. At time T 2 , Avatar A 4 has moved outside of the disconnect distance thus causing the participant associated with Avatar A 4 to be disconnected from the communication session.
[0045] Similarly, if a participant wants to join a communication session, the participant may move their Avatar to get within the connection distance of the logical center of the communication session, e.g. as shown in FIG. 15 . Once the Avatar A 5 is within the connect distance of the logical center, the Avatar A 5 may automatically or manually join the conversation. Since the Avatar A 5 is not part of the communication session at time T 1 , movement of the Avatar A 5 toward the conversation will not cause the logical center to move. However, at time T 2 once the Avatar A 5 has joined the conversation, the location of Avatar A 5 will also be used to calculate the logical center of the conversation.
[0046] FIG. 16 shows a two person conversation in which a center of mass of the conversation is used to calculate the connect and disconnect distances. The connect and disconnect distances may be calculated for the parties to the conversation, and also for other persons seeking to join the conversation. For example, in FIG. 16 , it will be assumed that a conversation is occurring between Avatars A 1 and A 2 . A third Avatar, A 3 , would like to join the conversation. In one embodiment, the third Avatar may be required to get within a connect distance of the center of mass of the conversation. Alternatively, in another embodiment, the third Avatar may seek to join the conversation if he is within a connect distance of either one or both of the participants. Thus, the system may optionally calculate a center of mass between any set of two or more participants to a conversation and use the center of mass to determine whether to enable another participant to join into the conversation.
[0047] The connect distance may change for a given conversation as the number of participants increase. For example, it may be difficult to keep a larger number of Avatars within the disconnect distance than it is to keep two or three people together. Accordingly, the connect/disconnect distance may increase as the number of participants in the conversation grows. Conversely, it may be desirable to reduce the connect distance where there are a large number of people (Avatars) gathered together in a compact manner. For example, if there is a gathering of Avatars, small groups of Avatars may want to have private conversations much like they would at a real-world party. In this instance the connect distance may be set to be rather small to prevent the conversation from being joined by many other Avatars unintentionally. Thus, the connect and disconnect distance may be adjusted based on how populated the virtual environment is, the number of participants, and optionally other factors that may affect how participants would desire to talk with each other.
[0048] FIGS. 17-18 show how the logical center of the conversation moves as participants to the conversation move relative to each other. As shown in FIG. 17 , assume initially at time T 1 that three Avatars A 1 -A 3 are engaged in a communication session. The logical center of the communication session will be calculated at the center of mass of the three Avatars. FIG. 18 shows the center of mass of the conversation at time T 2 . As shown in FIG. 18 , as Avatars A 2 and A 3 move to the left, the center of Mass of the conversation will likewise move to the left. However, since Avatar A 1 has not moved, the center of mass of the conversation will move less than the individual movements of either of the Avatars A 2 , A 3 .
[0049] Where movement of the logical center of the conversation causes an Avatar to be outside the disconnect distance, that Avatar may be disconnected from the conversation.
[0050] It may be desirable to include background noise in a virtual environment. For example, it may be desirable to include music, crowd noise, noise sources such as the sound of a waterfall or fountain, or other background noise source. FIG. 19 shows an example where an environmental audio source has been included in the virtual environment. The environmental audio may be streamed to each of the participants as the participants engage in the virtual environment. The environmental audio may also be overlayed onto the communication session having a direction which is associated with the direction of the environmental noise source to the logical center of the conversation. The virtual relative position of each source contribution can be tracked and positioned for a given user, for example using a Head Related Transfer Function (HRTF). For example, if Avatar A 1 is to the front left relative to Avatar A 2 , audio from Avatar A 1 will be played to Avatar A 2 as if coming from the front left.
[0051] Optionally, one or more of the participants may have the option of turning off the background noise to make it easier for that participant to hear the conversation. The background noise may be turned off on a participant-by-participant basis, or for the communication session as a whole.
[0052] The functions described above may be implemented as one or more sets of program instructions that are stored in a computer readable memory within the network element(s) and executed on one or more processors within the network element(s). However, it will be apparent to a skilled artisan that all logic described herein can be embodied using discrete components, integrated circuitry such as an Application Specific Integrated Circuit (ASIC), programmable logic used in conjunction with a programmable logic device such as a Field Programmable Gate Array (FPGA) or microprocessor, a state machine, or any other device including any combination thereof. Programmable logic can be fixed temporarily or permanently in a tangible medium such as a read-only memory chip, a computer memory, a disk, or other storage medium. All such embodiments are intended to fall within the scope of the present invention.
[0053] It should be understood that various changes and modifications of the embodiments shown in the drawings and described in the specification may be made within the spirit and scope of the present invention. Accordingly, it is intended that all matter contained in the above description and shown in the accompanying drawings be interpreted in an illustrative and not in a limiting sense. The invention is limited only as defined in the following claims and the equivalents thereto.
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A method and apparatus for managing communication between participants in a virtual environment enables the participants to elect to automatically connect with each other via a preferred communication mechanism, manually connect with each other, or choose not to connect with each other. The connection may be point-to-point between two participants or may include multiple participants. Establishment of a connection, or the ability to establish a connection, may be based on the proximity of the participants, or the Avatars representing the participants, in the virtual environment. Once the connection is established, the connection may be managed so that the connection is maintained while the Avatars remain proximate each other and is automatically severed once the Avatars move away from each other. Environmental noise and other audio aspects may be included in the connection to simulate a real-world conversation.
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BACKGROUND
The subject of the invention is a cooling device for a motor vehicle, comprising a cooling circuit capable of cooling an engine unit using a liquid coolant circulated by at least one variable flow rate pump. The invention applies advantageously to electric motor vehicles.
In an internal combustion engine, the repeated combustions overheat the contact parts, such as the pistons, cylinders and valves, and are diffused throughout the mechanical parts of the engine. Consequently, these parts need to be cooled to prevent damage. To work properly, combustion engines therefore require a suitable, constant temperature.
In electric-drive vehicles, it is also necessary to cool the various elements of the power train.
It is known to use a cooling system comprising one or more pumps to circulate a liquid coolant around the engine, as well as a radiator, which is a heat exchanger used to cool the liquid. In this case, the flow rate of the liquid coolant depends on the engine speed and is in particular zero when the engine is stopped.
BRIEF SUMMARY
It would be desirable to have a cooling device that optimized operation of the pumps and in particular limited the wear and energy consumption thereof.
The device according to the invention enables this objective to be achieved.
The subject of the invention is therefore a cooling device for a motor vehicle, comprising a cooling circuit capable of cooling an engine unit using a liquid coolant circulated by at least one variable flow rate pump, the flow rate of each pump being commanded by a command system.
In the device according to the invention, the command system is capable of adjusting the flow rate of each pump so that the temperature of the liquid coolant does not exceed a fixed set point temperature.
The command system may be capable of adjusting the flow rate of each pump at all times so that the temperature of the liquid coolant does not exceed the fixed set point temperature.
The command system is advantageously able to establish a flow rate set point as a function of a variable set point temperature.
The variable set point temperature is for example a function of the fixed set point temperature, the temperature of the liquid coolant and a temperature of the liquid coolant estimated as a function of the flow rate set point.
The variable set point temperature may be equal to the difference between the temperature of the liquid coolant and the estimated temperature, subtracted from the fixed set point temperature.
The motor vehicle may be an electric vehicle and the engine unit may include an electronic piloting system.
The electric vehicle may include a battery charger unit and the cooling circuit is advantageously able to cool the charger unit and the engine unit.
The command system is preferably able to establish the flow rate set point as a function of the variable set point temperature, the temperature outside the vehicle, the speed of the vehicle, the thermal losses of the electronic piloting system and the thermal losses of the battery charger.
The command system is preferably able to establish the estimated set point temperature as a function of the flow rate set point, the temperature outside the vehicle, the speed of the vehicle, the thermal losses of the electronic piloting system and the thermal losses of the battery charger.
The device may include a first pump able to supply liquid coolant selectively to the engine unit and a second pump able to supply liquid coolant selectively to the charger unit.
The device may include a first valve able to stop liquid coolant from entering the charger unit and a second valve able to stop liquid coolant from entering the engine unit.
The device may include a hydraulic restriction enabling a minimum flow rate of liquid coolant to be maintained in the engine unit.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the present invention are set out in greater detail in the description below, given by way of non-limiting example and in reference to the attached drawings, in which:
FIG. 1 is a block diagram of a cooling device according to the invention, built into an electric vehicle,
FIGS. 2 to 16 are diagrams used to explain the invention.
DETAILED DESCRIPTION
The cooling device 1 , as shown in FIG. 1 , includes a first electric pump 2 , a second electric pump 3 , a battery charger 4 , an engine unit 5 , and a radiator 6 , as well as a first solenoid valve 7 and a second solenoid valve 8 . The first electric pump 2 , the second electric pump 3 , the first solenoid valve 7 and the second solenoid valve 8 are connected to a command device 9 .
The first electric pump 2 is designed to be used when the vehicle is moving, while the second electric pump 3 is designed to be used when recharging the battery. The flow rate of the first pump 2 and the flow rate of the second pump 3 may be adjusted using a command signal.
When the vehicle is stationary, the charger 4 enables the electric drive battery, not shown, to be recharged from the domestic electricity network.
The first solenoid valve 7 enables the second pump 3 and the charger 4 to be short-circuited when the vehicle is moving, while the second solenoid valve 8 enables the engine unit 5 to be short-circuited when charging the battery, if cooling of the engine unit 5 is not deemed to be necessary. The second solenoid valve 8 may be connected to a hydraulic restriction 10 that enables a pressure drop to be effected, thereby maintaining a flow rate of liquid coolant in the engine unit 5 , even if the second solenoid valve 8 is open.
The engine unit 5 includes an engine 11 and an electronic piloting system 12 designed in particular to transform the DC voltage from the battery into AC voltage.
The radiator 6 makes it possible to cool the liquid coolant, similarly to the cooling device of an internal combustion engine. It is fitted with an electric fan, not shown.
It is necessary to cool the engine unit 5 when the vehicle is moving, and the charger 4 when the vehicle is stationary. The cooling strategy is managed by the command device 9 . The command device 9 is a processor connected to sensors in the cooling circuit, in particular liquid coolant temperature sensors. The processor 9 pilots the pumps 2 , 3 , the solenoid valves 7 , 8 , and the electric fan unit of the radiator 6 . The processor 9 is also advantageously connected to other processors in the vehicle, for example via a controller area network (CAN) bus, in order to obtain other measurements required for the cooling strategy. The processor 9 hosts the strategy for preparing the liquid coolant flow rate command.
A possible solution is to slave the flow rate of each pump 2 , 3 in an adjustment system in a closed loop including a proportional-integral (PI) corrector.
The PI corrector does not react, i.e. it does not change the flow rate, unless the output temperature of the water exceeds the set point temperature. The cooling system is a system with a potentially significant overall inertia: the calories in the electrotechnical system are generated in the metal masses of the electronic piloting system and it may take time before they are evacuated to the water. Consequently, a PI corrector may react too late if it waits for variations in the temperature of the cooling water.
FIGS. 2 and 3 illustrate the problem posed through a cooling test. The conditions of this test are as follows.
The loss power to be dissipated from the electrotechnical system is stepped up to 7.5 kW for 400 s, before being dropped to a stabilized 1.5 kW.
Arbitrarily, vehicle speed is set to 30 km/h, external temperature to 30° C., and constant water flow rate to 150 l/h.
The first test, shown in FIG. 2 , is performed with an open loop, with no corrector, the water flow rate being constant.
The upper part of the figure shows the losses from the electronic piloting system to be cooled, and the lower part shows the response of the water temperature over time. It can be seen that at t=400 s, the temperature of the water is only 42.8° C., and that it will reach more than 60° C., but not for 33 minutes.
The second test, as shown in FIG. 3 , is performed under the same conditions, but this time, the PI corrector is activated: this is what will modify the flow rate. It can be seen that the PI corrector only reacts when the temperature of the water exceeds the 50° C. set point, which is too late.
To remedy this, the inputs and the output of a command strategy block A according to the invention are shown in FIG. 4 .
The inputs of block A are as follows:
TF_mes: Temperature of the liquid coolant, which can be obtained by a single sensor or obtained by merging several sources (for example: the electric engine or the electronic piloting system may themselves be fitted with water temperature sensors), V_VH: Vehicle speed, usually calculated by the ABS processor and available on the vehicle CAN, Temp_Ext: External temperature obtained from the vehicle CAN, Losses_PEB: Signal generated by the electronic piloting system representing an estimate of the losses generated in the electronic piloting system and the electric machine. Indeed, the electronic piloting system at all times knows the currents in the engine phases, and it also has a temperature sensor (and often several) and is therefore able to provide a reasonably precise estimate of the losses from the unit {electronic piloting system, engine}, Losses_BCB: Signal generated by the battery charger representing an estimate of the losses generated in the battery charger. Indeed, the battery charger at all times knows the charging current, and it also has a temperature sensor (and often several) and is therefore able to provide a reasonably precise estimate of the losses from the battery charger.
The output from block A is:
PWM_WEP_CN: Flow rate command for the electrotechnical system comprising the electronic piloting system, the battery charger and the electric drive motor. It is a signal between 0 and 100 expressing a percentage of the maximum flow rate deliverable by the pump.
Depending on the operating method, either the first pump or the second pump will be commanded by this signal.
The objective is to automatically adjust the flow rate command between a minimum value and a maximum value as a function of the temperature of the cooling circuit.
The principle is as follows: a maximum desired set point temperature is selected and then, using an explicit internal model and closed-loop control, a flow rate is determined to obtain this set point temperature. The looped signal is the difference between the temperature measurement of the liquid coolant and the temperature produced by this explicit internal model.
FIG. 5 shows the operating principle of this approach.
The control device is made up of two blocks:
Block B, known as the corrector block, receives an input of a water temperature TF_Req to be reached. Using different measurements (such as outside temperature, powers to be dissipated, and vehicle speed), block B is used to determine the flow rate required to achieve this target water temperature TF_Req in steady-state, Block C, known as the model block, receives as an input the set point flow rate calculated by block B and generates in real-time a water temperature ym on the basis of a dynamical model of the system.
The set point flow rate is also sent to a block D corresponding to the real system, and a water temperature yp may be measured.
The principle is that the target water temperature TF_Req is not always equal to the set point CONS_TF, it is corrected once the actual temperature differs from the temperature estimated by the internal model.
The remainder of the description contains details on obtaining blocks B and C.
Firstly, a fine model of the cooling system is prepared using a finite element model. Secondly, a simplified model based on physical equations is produced.
FIG. 6 illustrates the principle used. The simplifying hypotheses used are as follows:
Conveyance conditions disregarded: all of the water in the cooling circuit is treated as an immobile mass of water, The members (electronic piloting system PEB, electric drive motor and battery charger BEB) are treated as metal masses. The heat (losses from the electrotechnical system) is generated in these metal masses, then flows into the mass of water, The heat flows then flow through the radiator. The exchange characteristics of the radiator are provided by the manufacturers.
The dynamical equations are as follows:
M PEB C PEB ⅆ T PEB ⅆ t = P PEB - hiS PEB ( T PEB - T f ) ( eq 1 ) M BCB C BCB ⅆ T BCB ⅆ t = P BCB - hiS BCB ( T BCB - T f ) ( eq 2 ) M f C f ⅆ T f ⅆ t = hiS PEB ( T PEB - T f ) + hiS BCB ( T BCB - T f ) - φ radiator ( eq 3 )
In which:
M PEB =Metal mass equivalent to the unit {electronic piloting system+engine}, C PEB =Specific heat capacity of the unit {electronic piloting system+engine}, T PEB =Average temperature of the unit {electronic piloting system+engine}, hiS PEB =Exchange ratio between the water and the unit {electronic piloting system+engine}, M BCB =Equivalent metal mass of the battery charger, C BCB =Specific heat capacity of the battery charger, T BCB =Average temperature of the battery charger, hiS BCB =Exchange ratio between the water and the battery charger, M f =Fluid mass, C F =Specific heat capacity of the fluid, T f =Water temperature, Φradiator=Heat flow evacuated by the radiator, given using a map,
The power evacuated by the radiator depends on three magnitudes:
φradiator=f (Flow rate, Tair, Tf, V_AIR)
The flow rate passing through the radiator (Flow rate), The temperature of the fluid (Tf) and, The speed of the air passing through the radiator (V_AIR).
The radiator manufacturers supply the power evacuated by the radiator in the form of a two-dimensional map:
The two inputs for the map are:
Flow rate in l/h, Air speed in m/s.
The power evacuated by the radiator is given for a fixed water/air temperature difference ATref (for example: ATref=10°).
The following applies to any water/air temperature difference:
Power_radiator
=
(
Twater
-
Tair
)
10
·
Power_radiator
_DTref
This therefore gives a non-linear transfer as a function of flow rate and air speed.
Air speed is the sum of two sources:
Air speed attributable to vehicle speed. This is a fraction of vehicle speed, and Additional wind speed provided by the electric fan unit of the radiator. This air flow is dependent on vehicle speed.
To obtain the corrector block B, the objective is to obtain the static gain of the flow rate to water temperature transfer in the radiator, i.e. the required flow rate must be determined for a given power to be evacuated.
This problem can be resolved through linearization of the maps of the power of the radiator as a function of flow rate. It can be seen that the mapping can be approximated by an equation of the form:
Prad_lin
=
λ
1
·
(
Vair
Vair_ref
)
Flow
rate
(
Δ
T
Δ
Tref
)
(
eq
4
)
Prad_lin represents the power evacuated approximated by a law proportional to flow rate, air speed and ATref.
Vair_ref is set arbitrarily at 90 km/h (air speed equivalent to this vehicle speed).
ATref=10° C. is retained.
λ 1 is calculated for example for the flow rate point=800 l/h, giving a power of 26210 W, so λ 1 =26210/800 W/(l/h).
The flow rate is therefore written as follows:
Flow
rate
=
Pradiator
λ
1
·
(
Vair
Vair_ref
)
·
(
Δ
T
Δ
Tref
)
of
the
form
:
Flow
rate
=
Pradiator
λ
R
(
eq
5
)
The embodiment of the control module A shown in FIG. 2 is shown in detail in FIG. 7 . The inputs are described above.
The command Flow rate cons generated by the corrector block B is saturated between [Flow_Max] and [Flow_Min] which are the flow rate ranges supported by the pump. The command PWM is calculated using a simple table and provides the control output.
This command is also saturated between [Flow_Max] and [Flow_Min] before being re-injected into the dynamical model. These two parameters constitute the two adjustment parameters of the invention. The third parameter is “CONS_TF”, which is the maximum desired set point temperature.
FIG. 8 shows a possible embodiment of block B. It is the embodiment of the equation (eq 5).
FIG. 9 shows a possible embodiment of block C. Block C includes numerical integrations. It is realized at each sampling period, which is typically around 1 second.
As can be seen, the model is broken down into four blocks C 1 to C 4 , the operations of which are performed successively in the following order:
Block C 1 (‘Flux_radiator_linear’), Block C 2 (‘PEB_ME’), Block C 3 (‘BCB’), Block C 4 (‘WATER’).
Block C 1 (‘Flux_radiator_linear’) is used to calculate the power evacuated by the radiator to the outside air. A possible embodiment of this block is shown in FIG. 10 .
The inputs of block C 1 are as follows:
TF_MDL 1 : Water temperature calculated by the model at the previous sampling instant, Temp_Ext: Air temperature outside the vehicle, measured by the passenger compartment processor, V_VH: Vehicle speed, Flow rate: Flow rate measurement.
The output from the block C 1 is Flux_Rad, the flow of the radiator. Block C 1 is the embodiment of the equation (eq 4).
Block C 2 is used to calculate the power exchanged between the unit {electronic piloting system+engine} to the water, as well as the temperature of the unit {electronic piloting system+engine}. A possible embodiment of this block is shown in FIG. 11 .
The inputs of block C 2 are as follows:
Losses_PEB: Losses dissipated by the unit {electronic piloting system+engine},
TF_MDL 1 : Water temperature calculated by the model at the previous sampling instant, Temp_Ext: Air temperature outside the vehicle, measured by the passenger compartment processor, TP_PEB_MDL 1 : Temperature of the unit {electronic piloting system+engine} calculated by the block “PEB_ME” at the previous sampling instant.
The outputs from block C 2 are as follows:
Flux_PEB: Flow exchanged between the unit {electronic piloting system+engine} and the water, TP_PEB_MDL 1 : Temperature of the unit {electronic piloting system+engine}.
Block C 2 is the embodiment of the equation (eq 1).
Block C 3 is used to calculate the power exchanged between the battery charger and the water, as well as the temperature of the battery charger. A possible embodiment of this block is shown in FIG. 12 .
The inputs of block C 3 are as follows:
Losses_BCB: Losses dissipated by the battery charger, TF_MDL 1 : Water temperature calculated by the model at the previous sampling instant, Temp_Ext: Air temperature outside the vehicle, measured by the passenger compartment processor, TP_BCB_MDL 1 : Temperature of the battery charger calculated by the block “BCB” at the previous sampling instant.
The outputs from block C 3 are as follows:
Flux_BCB: Flow exchanged between the battery charger and the water, TP_BCB_MDL: Temperature of the battery charger. Block C 3 is the embodiment of the equation (eq 2).
Block C 4 is used to calculate the temperature of the water. A possible embodiment of this block is shown in FIG. 13 .
The inputs of block C 4 are as follows:
Flux_PEB: Flow exchanged between the unit {electronic piloting system+engine} and the water, Flux_BCB: Flow exchanged between the battery charger and the water, Flux_Rad: Flow exchanged between the radiator and the outside air, Temp_Ext: Air temperature outside the vehicle, measured by the passenger compartment processor.
The output from block C 4 is TF_MDL, the water temperature generated by the internal model.
Block C 4 is the embodiment of the equation (eq 3).
It should be noted that the parameters in blocks C 1 to C 4 are parameters having a physical meaning.
FIG. 14 shows the development of the temperature of the water and of the water flow rate as a function of time, obtained using the device according to the invention. The test conditions are identical to those described for FIGS. 2 and 3 .
It can be seen that the intended objective is achieved: from the beginning of the test, the corrector is able to predict that the flow rate required to obtain a water temperature of 50° C. is a high flow rate (the command is saturated at the maximum flow rate of 800 l/h). Subsequently, when the losses to be dissipated are dropping, the corrector rapidly readjusts the flow rate command to the required value. The water temperature therefore remains below 50° C. throughout the test.
A second test showing the correct operation of the invention is shown in FIGS. 15 and 16 .
The conditions of this test are as follows. Firstly, losses of 1500 W are injected. The vehicle speed is set at 30 km/h, with an outside temperature of 30° C.
At t=10000, losses of 2000 W are injected.
FIG. 15 illustrates operation of the PI corrector. The corrector does not change the flow rate, unless the water temperature exceeds the set point temperature of 50° C. As a result, the reaction occurs when the set point is passed.
As shown in FIG. 16 , the corrector according to the invention immediately calculates, in a sampling period, the static flow rate required for cooling. It can be seen here that when the power step varies, the water flow rate is recalculated instantly, which prevents the set point from being exceeded, unlike the PI corrector.
The invention therefore makes the system safer. When a maximum set point temperature is set, the corrector ensures that the flow rate is commanded optimally so that this set point is not exceeded.
If the cooling requirement is too great to be met by simply increasing the flow rate, the electric fan unit is then activated to increase this cooling. With the internal-model corrector according to the invention, the electric fan unit is only activated if everything that could have been done using the flow rate command has been done.
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A cooling device for a motor vehicle, including a cooling circuit configured to cool an engine assembly using a liquid coolant circulated by at least one variable delivery pump, the delivery output by each pump being controlled by a control system. The control system is configured to regulate the delivery of each pump so that the temperature of the liquid coolant does not exceed a fixed datum temperature.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 61/921,331, filed Dec. 27, 2013, for “Rapid Free Space Optical Link Acquisition with Moving Focal Plane Containing an Array of Detectors.” Such application is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present invention relates to the field of optical wireless communications, and in particular to acquisition, tracking, and pointing (ATP) systems for free space optical (FSO) communications.
[0003] FSO systems employ light propagating in free space to transmit data without using a connecting cable or transmission line. An FSO system typically consists of a set of two transmitting terminals and receiving terminals or transceiver terminals. Electrical communication signals are converted to optical signals, and then transmitted from the telescope of the transmitting optical terminal. The receiving terminal receives the incoming optical signal into a receiving telescope, which focuses the signal into an optical focal plane for coupling into a photodetector, which then converts the light energy back into an electrical signal.
[0004] In order for a receiving terminal to receive an optical signal from a transmitting terminal, the terminal telescopes must be properly aligned. ATP components provide the beam steering necessary for optical telescopes in FSO systems. ATP components act to steer a transmitting telescope or receiving telescope, or both, to point in a desired direction.
[0005] Beam steering in optical systems may be accomplished by changing the refractive index of the medium through which the beam is transmitted, or by the use of mirrors or lenses. One existing beam-steering solution is motorized gimbals. A gimbal is a mechanical apparatus to allow a suspended object to rotate freely along two simultaneous axes, within a defined angle of view. A gimballing system used for the alignment of an optical transmitter or receiver typically moves the entire transmitting or receiving telescope through the required field of view. Often, the transmitter and receiver telescopes are mechanically coupled so that the transmitted beam is in the exact direction of an incoming optical beam for collection by the receiving telescope, and thus the two telescopes operate with a common gimballing system.
[0006] Gimbal-based FSO systems may be quite heavy due to the weight of the mechanical components, motors, and servos. Gimbal-based systems may also be bulky due to the required mechanical components. Finally, mechanical gimballing systems may require the use of a great deal of electrical power, far more power than is typically consumed by the electronics associated with an optical receiver or transmitter system.
[0007] As an alternative to gimbal-based FSO systems, U.S. Pat. Nos. 7,224,508, 7,612,317, 7,612,329, and 8,160,452 teach beam steering by moving an optical fiber in the x-y focal plane of the receiver telescope, including, for example, the use of micro-electro-mechanical systems (MEMS) components to position the optical fiber.
BRIEF SUMMARY
[0008] The present invention is directed to an FSO system and ATP components for an FSO system using a multi-element array of photo-detectors positioned in the focal plane of an optical transmitter, receiver, or transceiver telescope. As an optical signal is received in the telescope, that signal is detected on certain elements of the multi-element focal plane detector array. In response, the focal plane detector array may be repositioned within the focal plane of the telescope. In certain implementations, a high-speed optical detector, an optical transmitter diode, an optical fiber, or other optical communications element may be positioned at the center of the multi-element detector array. The detector array is manipulated such that the light signal input maximum is aligned with the optical communications element. In this way, the telescope may be aligned without the use of traditional “beam steering” techniques.
[0009] By noting the x-y position of the incoming signal on the telescope focal plane based on the elements of the multi-element detector array that receive that signal, the angle of a remote incoming optical signal may be detected, and that information may be used to control the movement of the optical communications element to the location of the arriving remote terminal optical signal. The invention simplifies FSO systems by eliminating the need for beam splitters and prisms that would be required if a multi-element array detector were employed as a wavefront detector and implemented remotely from the transmitter. In contrast to the present invention, this alternative approach would require two separate optical paths and relatively complex optical component design, and could require mirrors for 90-degree turns.
[0010] These and other features, objects and advantages of the disclosed subject matter will become better understood from a consideration of the following detailed description, drawings, and claims directed to the invention. This brief summary and the following detailed description and drawings are exemplary only, and are intended to provide further explanation of various implementations without limiting the scope of the invention, which is solely as set forth in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates a side and end view of an optical telescope with a focal plane array receiving an optical signal at an edge of the focal plane array.
[0012] FIG. 2 illustrates a side and end view of an optical telescope with a focal plane array translated such that an optical transmission element is at the optical signal maximum.
[0013] FIG. 3 illustrates three different incoming beam angles to an optical telescope and the corresponding locations where an optical signal strikes a focal plane array.
[0014] FIGS. 4 a , 4 b , and 4 c each illustrate a front view of a focal plane array showing the location of an optical fiber, an incoming optical signal in FIG. 4 b , and the position of the focal plane array after translation with respect to the optical signal in FIG. 4 c.
[0015] FIG. 5 shows a close-up view of an optical signal received at the focal plane array, with a three-dimensional graph of the optical signal intensity on the focal plane array in top and side perspective view.
[0016] FIG. 6 illustrates an implementation with a separate receiver and transmitter telescope using a focal plane array in the focal plane of the telescope.
[0017] FIG. 7 illustrates an implementation with a single transceiver telescope using a focal plane array in the focal plane of the telescope.
DETAILED DESCRIPTION
[0018] With reference to FIGS. 1 through 7 , an implementation of the present invention may now be described. A laser communications transceiver incorporating the rapid acquisition, tracking and pointing (ATP) system is described herein, but the invention is not so limited, and in fact may be put to other applications where the ATP function is desired. The optical system of FIGS. 1 through 7 consists of beam expansion optics and focusing optical design that provides angle of arrival direction measurement and controlled motion in the focal plane that provide immediate alignment of the incoming optical beam. Additionally, for a transmitter telescope, it provides controlled motion in the focal plane that aligns precisely the outgoing transmitted beam in the direction of an incoming optical beam from a remote optical terminal.
[0019] The focal plane contains an array of photo-detectors of precise size to provide a correspondingly precise measurement of the position of a focused optical beam spot that strikes the detectors, yielding various optical signal photocurrent amplitudes in the vicinity of the beam's focused spot. Each detector array element that receives its relative part of the beam spot's energy provides positional information to the focal plane's translational system. This information from each element of the multi-element detector array is transferred to the control system, which uses the information to calculate a maximum beam spot. The controller moves the optical communications element at the center of the multi-element detector array to the maximum beam spot in the focal plane, thereby aligning the optical communications element at the maximum optical intensity location, and therefore synchronizing the FSO link.
[0020] FIG. 1 illustrates the operational design of an implementation of the free space optical communications transceiver telescope and focal plane components described in this invention with a high speed photo-receiver 5 as the optical communications element. A side view is shown to the left of FIG. 1 , with an end view on the right. The telecentric telescope contains five optical elements 1 and its wide angle input lens shows an entering beam 2 from an angle 3 that is focused onto the focal plane at a spot 4 , illuminating several of the detectors in the focal plane array (FPA) 10 in the focal plane near the bottom edge of the array. These detectors send signals to the control electronics identifying the optical spot's location, which in turn commands the movement of the focal plane assembly to align the high speed photo-receiver 5 at the center of the FPA with the exact position of the focused optical spot 4 .
[0021] FIG. 2 shows the FPA focal plane moved to its new position so that the high speed photo-receiver has been moved and is located at the optical beam spot location. In FIG. 2 , the focal plane assembly is moved down to the position aligning the center of FPA 10 , at the high speed photo-receiver 5 , with the arriving optical beam spot. FPA 10 has been moved by the positioning motors 7 and 9 and actuators in the Y-direction 6 and in the X-direction 8 to align the photo-receiver 5 to exactly overlap the focused spot 4 ; it converts the optical signal to an electrical signal connected by wire to the motion control electronics.
[0022] The connecting wires to photo-receiver 5 can in certain implementations be replaced with an optical fiber matched for maximum optical power coupling and be used for both receiving and transmitting optical signals from remotely located electronics. This requires that a polished optical fiber flat surface for input and output be placed and aligned precisely within the focal plane at the center of the FPA 10 .
[0023] In certain implementations, for use in an FSO transmitter telescope, the diode in the center of the FPA 10 is replaced by an optical emitter such as a laser diode that transmits from the center of FPA 10 and its focal plane of an identical telecentric telescope. The FPA 10 detectors in this implementation function by identifying the direction and location of a remote FSO terminal's arriving signal beam using the same technique as described above with respect to the high speed photo-detector 5 . The location of the focused spot arriving from a remote FSO terminal would identify its direction of arrival via its beam spot X-Y position on the FPA 10 , and command the FPA assembly to move to the X-Y position for transmission in the direction of the arriving beam from the remote FSO terminal.
[0024] The telecentric optical design is illustrated in FIG. 3 by viewing it from the side for an example for various angles landing in the focal plane along the Y-axis. The simple five-lens system 1 converts the beam arrival angles into a corresponding optical spot in the X-Y focal plane 4 . In this illustration, only the Y-axis is shown. Three different input beam angles are depicted ( 2 a , 2 b , 2 c ) arriving from the left and transformed to an X-Y location in the focal plane on the right side where the beam spots are focused 4 . The optical design is spherical providing linearity in the X-Y plane.
[0025] FIG. 4 depicts an end view of the focal plane with the FPA 10 and its centered high speed photo-detector 5 . The first position ( 4 a ) shows the original centered focal plane assembly position without any beam illumination; the second shows the same position with a beam spot 4 landing in the upper left corner onto the nearby FPA detectors. The center of the spot will provide a strong photocurrent to the detectors near the center of the beam, while the detectors further from the center radially will record lower photocurrents. The 3D beam spot is depicted in the lower right corner of FIG. 4 illustrating the center of the spot with the strongest optical signal and the radial reduction in optical power that is measured by the group of detectors. All of the detectors receiving light energy provide an electrical signal to the control electronics, which employs a relative location algorithm to calculate the distance and direction from the centered high speed photo-detector receiver 10 (or optical fiber).
[0026] FIG. 5 shows a close up illustration of the FPA detectors in the vicinity of the high speed photodetector 5 after having been moved to the optical beam spots position. The photographs on the right side show a beam profile measurement of an optical spot.
[0027] After the movement of the FPA assembly 10 to this receiving location, a tracking algorithm is employed that sustains the optimum alignment for the highest optical signal arriving to the photo-detector. The algorithm in certain implementations uses quad-detector centroiding. The position of the photo-receiver is actively and rapidly updated and provides tracking of remote moving FSO terminals. The adjacent four detectors are used for quad-detector signal balancing centroiding. Second-order signals from detectors that are the next neighbors to the four adjacent detectors may also be used in the algorithm. The short term average optical power received at the high speed photo-detector 5 is used in the control calculations.
[0028] For an FSO transmitter telescope with an LED or laser diode as an optical communications element, with the beam spot tracking of a beam arriving from a remote FSO terminal, the alignment with the remote terminal can use the same quad-detector signal balancing as the receiver to maintain the beam alignment with the remote FSO terminal for link synchronization.
[0029] FIG. 6 illustrates an optical telescope system that may utilize the ATP components described above with a separate transmitter and receiver. Two sets of lenses 1 transmit beam 2 into and out of the device. Two FPA detectors 10 are used, with connecting components 11 to transmit the signals received and to be sent.
[0030] Illustrated in FIG. 7 , using an optical fiber at the location of the photo-detectors or transmitters, both transmit and receive signals can use the same centered fiber within the same telescope. This implementation requires optical isolation techniques applicable to FSO systems. A transmission optical fiber 12 is connected to a fiber optic coupler/splitter 13 to separate (and combine) the two separate optical paths from receiver 14 and transmitter 15 . This system is significantly more complicated and includes more fiber optic components than the implementation of FIG. 6 .
[0031] The FPA detector elements rapidly determine the incoming angle of arrival and therefore the focal plane position of the beam spot then send this information to the ATP control loop to move the receiver (or fiber) to the incoming angle of the beam. The high sensitivity detectors measure the optical strength at each of the different detectors and send this information matrix to the control algorithm that determines the spot's exact location. To first order, four of the detectors provide the largest signals and provide position (angular) information. The surrounding detectors will provide the 2nd and 3rd order accuracies that provide the most precise information on the location of the spot, thereby sending this information through the position (angular) detection signal processing and algorithms.
[0032] During an acquisition scan for a terminal to terminal FSO link, contact is made with the array at first pass in the scan. The beam spot is measured in the matrix position, and with multiple detectors illuminated, and with their respective positions known, this single pass measurement is processed and the focal plane array is moved over so that the centered device (or fiber) is aligned with the beam spot. Each element's position, and its measured optical power level, can be collectively integrated algorithmically and precisely determine the position of the illuminating spot. However, the measurement is immediate and simultaneous, so the signal to the motion control system for the focal plane translation stages is immediate, thereby providing an automatic alignment at high speed.
[0033] The pattern of signals incident upon the elements that make up multi-element FPA 10 may be represented as a two-dimensional array. The array provides the location on the focal plane where the most optical power is incident. The coordinates of this location can be represented in a 2-dimensional vector R.
[0034] The FPA component is movable about the defined XY-plane, with the defined origin being at the center of the optical fiber or diode (0, 0). The optical power measurements seen by the detectors in the vicinity of the focused optical spot are stored in an n×n matrix, which we will call P, with each array element represented as P ij . For the “missing” elements, that is, those elements in P that correspond to locations where the fiber is, the value is stored as (0, 0).
[0035] To find the horizontal component of R, we create a vector, Ph, of the values of the sums of the sensor values in each column of P.
[0000]
Ph
j
=
Σ
l
=
1
m
P
ij
[0036] Ph′ is created from Ph by the following normalization process.
[0000]
Ph
j
′
=
{
Ph
j
/
∑
j
=
1
n
Ph
j
,
when
∑
j
=
1
n
Ph
j
≠
0
Ph
j
,
when
∑
j
=
1
n
Ph
j
=
0
[0037] The vertical coordinate of each row of the sensor array is stored in a vector d row . The dot product of Ph′ and d row yields the horizontal component of R, which we denote as R x .
[0000]
R
x
=
Ph
′
·
d
row
.
[0038] The vertical component is found in an analogous manner. We create a vector, Pv, of the values of the sums of the sensor values in each row of P.
[0000]
Pv
i
=
∑
j
=
1
n
P
ij
[0039] Pv′ is created from Pv by the following normalization process.
[0000]
Pv
i
′
=
{
Pv
i
/
∑
i
=
1
n
Pv
i
,
when
∑
i
=
1
n
Pv
i
≠
0
Pv
i
,
when
∑
i
=
1
n
Pv
i
=
0
[0040] The horizontal coordinate of each column of the sensor array is stored in a vector d col . The dot product of Ph′ and d col yields the vertical component of R, which we denote as R y .
[0000]
R
y
=
pv
′
·
d
col
[0041] We now have the vector, R, which points to the location, relative to the FPA center with the optical fiber, transmitter diode, or receiver diode, where the peak optical power is found.
[0000]
R
=
[
Rx
,
Ry
]
[0042] The control system of the free space optical communications system is then commanded to move to the location indicated by R, which places the peak of the optical power in the center of the FPA 10 .
[0043] Since the above method allows for the detection of the peak power location any time observable optical power is seen anywhere on the sensor array, the acquisition process becomes simple. One or both terminals begin a search by moving the stage in a scanning pattern. Both terminals monitor their sensor arrays, and, if at any time any of the sensors report a value greater than a minimum threshold power level, the peak power location is determined by the previously explained method. The terminal then translates the fiber (or active transmitter or receiver) to the location indicated by the vector R. At this point, the beam is pointed directly at the other terminal. Since it is pointed directly at the other terminal, it will be seen by that terminal's sensor array, and it will move its fiber (or diode) to the location of the peak optical power. At this point, both terminals are aimed at each other, and the acquisition process is complete. Having acquired the location of the other terminal, each terminal tracks the other by utilizing quad-detector centroiding algorithms and by monitoring the power received into the optical fiber or by the high speed detector diode.
[0044] It may be understood that this simplified, single-step alignment of certain implementations of the present invention does not require the conventional internal “beam steering” techniques of many optical telescope systems; instead, it moves the communications detector to the location of the beam spot, thereby requiring smaller mass movement and high precision. Additionally, the high-speed photo detector at the center of the focal plane array can, in certain implementations, be an optical fiber that precisely matches the optical design of the telescope for maximum optical power coupling efficiency; this optical fiber is connected to the receiver and/or the optical transmitter devices remotely inside the electronics systems of the FSO device.
[0045] The present invention in various implementations may be used for purposes such as beam stabilization during FSO communications. The fast-moving actuators that control position of the focal plane array and optical communications element may compensate for vehicle movements and vibrations when the associated optical telescope is mounted on a vehicle. In one implementation, accelerometers send the frequencies and directions of the vibrations of the vehicle to the focal plane array motion controller. In this way, the response and compensation to vibration is controlled directly in the X-Y plane of the focal plane array.
[0046] The present invention has been described with reference to the foregoing specific implementations. These implementations are intended to be exemplary only, and not limiting to the full scope of the present invention. Many variations and modifications are possible in view of the above teachings. The invention is limited only as set forth in the appended claims. All references cited herein are hereby incorporated by reference to the extent not inconsistent with the disclosure herein. Unless explicitly stated otherwise, flows depicted herein do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the following claims. Any disclosure of a range is intended to include a disclosure of all ranges within that range and all individual values within that range.
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An acquisition, pointing, and tracking (ATP) apparatus for free space optical (FSO) communications systems incorporates a multi-element detector array positioned at a focal plane of an optical telescope. An optical communications element lies at the center of the detector array. In lieu of traditional beam steering, the apparatus performs pointing and tracking functions internally by first calculating a position of an optical maximum on the detector array, and then translating the detector array within the focal plane of the telescope such that the optical communications element lies at the optical maximum for transmitting and/or receiving optical communications signals.
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FIELD OF THE INVENTION
[0001] The field of this invention is generally plugs and packers for downhole use and more particularly packers that have a sealing element that swells and retains boost forces when subjected to pressure differentials.
BACKGROUND OF THE INVENTION
[0002] Packers and plugs are used downhole to isolate zones and to seal off part of or entire wells. There are many styles of packers on the market. Some are inflatable and others are mechanically set with a setting tool that creates relative movement to compress a sealing element into contact with a surrounding tubular. Generally, the length of such elements is reduced as the diameter is increased. Pressure is continued from the setting tool so as to build in a pressure into the sealing element when it is in contact with the surrounding tubular.
[0003] More recently, packers have been used that employ elements that respond to the surrounding well fluids and swell to form a seal. Many different materials have been disclosed as capable of having this feature and some designs have gone further to prevent swelling until the packer is close to the position where it will be set. These designs were still limited to the amount of swelling from the sealing element as far as the developed contact pressure against the surrounding tubular or wellbore. The amount of contact pressure is a factor in the ability to control the level of differential pressure. In some designs there were also issues of extrusion of the sealing element in a longitudinal direction as it swelled radially but no solutions were offered. A fairly comprehensive summation of the swelling packer art appears below:
[0000] I. References Showing a Removable Cover Over a Swelling Sleeve
[0004] 1) Application US 2004/0055760 A1
[0005] FIG. 2 a shows a wrapping 110 over a swelling material 102 . Paragraph 20 reveals the material 110 can be removed mechanically by cutting or chemically by dissolving or by using heat, time or stress or other ways known in the art. Barrier 110 is described in paragraph 21 as an isolation material until activation of the underlying material is desired. Mechanical expansion of the underlying pipe is also contemplated in a variety of techniques described in paragraph 24 .
[0006] 2) Application US 2004/0194971 A1
[0007] This reference discusses in paragraph 49 the use of water or alkali soluble polymeric covering so that the actuating agent can contact the elastomeric material lying below for the purpose of delaying swelling. One way to accomplish the delay is to require injection into the well of the material that will remove the covering. The delay in swelling gives time to position the tubular where needed before it is expanded. Multiple bands of swelling material are illustrated with the uppermost and lowermost acting as extrusion barriers.
[0008] 3) Application US 2004/0118572 A1
[0009] In paragraph 37 of this reference it states that the protective layer 145 avoids premature swelling before the downhole destination is reached. The cover does not swell substantially when contacted by the activating agent but it is strong enough to resist tears or damage on delivery to the downhole location. When the downhole location is reached, pipe expansion breaks the covering 145 to expose swelling elastomers 140 to the activating agent. The protective layer can be Mylar or plastic.
[0010] 4) U.S. Pat. No. 4,862,967
[0011] Here the packing element is an elastomer that is wrapped with an imperforate cover. The coating retards swelling until the packing element is actuated at which point the cover is “disrupted” and swelling of the underlying seal can begin in earnest, as reported in Column 7 .
[0012] 5) U.S. Pat. No. 6,845,322
[0013] This patent has many embodiments. The one in FIG. 26 is foam that is retained for run in and when the proper depth is reached expansion of the tubular breaks the retainer 272 to allow the foam to swell to its original dimension.
[0014] 6) Application US 2004/0020662 A1
[0015] A permeable outer layer 10 covers the swelling layer 12 and has a higher resistance to swelling than the core swelling layer 12 . Specific material choices are given in paragraphs 17 and 19 . What happens to the cover 10 during swelling is not made clear but it presumably tears and fragments of it remain in the vicinity of the swelling seal.
[0016] 7) U.S. Pat. No. 3,918,523
[0017] The swelling element is covered in treated burlap to delay swelling until the desired wellbore location is reached. The coating then dissolves of the burlap allowing fluid to go through the burlap to get to the swelling element 24 which expands and bursts the cover 20 , as reported in the top of Column 8 .
[0018] 8) U.S. Pat. No. 4,612,985
[0019] A seal stack to be inserted in a seal bore of a downhole tool is covered by a sleeve shearably mounted to a mandrel. The sleeve is stopped ahead of the seal bore as the seal first become unconstrained just as they are advanced into the seal bore.
[0000] II. References Showing a Swelling Material under an Impervious Sleeve
[0020] 1) Application US 2005/0110217
[0021] An inflatable packer is filled with material that swells when a swelling agent is introduced to it.
[0022] 2) U.S. Pat. No. 6,073,692
[0023] A packer has a fluted mandrel and is covered by a sealing element. Hardening ingredients are kept apart from each other for run in. Thereafter, the mandrel is expanded to a circular cross section and the ingredients below the outer sleeve mix and harden. Swelling does not necessarily result.
[0024] 3) U.S. Pat. No. 6,834,725
[0025] FIG. 3 b shows a swelling component 230 under a sealing element 220 so that upon tubular expansion with swage 175 the plugs 210 are knocked off allowing activating fluid to reach the swelling material 230 under the cover of the sealing material 220 .
[0026] 4) U.S. Pat. No. 5,048,605
[0027] A water expandable material is wrapped in overlapping Kevlar sheets. Expansion from below partially unravels the Kevlar until it contacts the borehole wall.
[0028] 5) U.S. Pat. No. 5,195,583
[0029] Clay is covered in rubber and a passage leading from the annular space allows well fluid behind the rubber to let the clay swell under the rubber.
[0030] 6) Japan Application 07-334115
[0031] Water is stored adjacent a swelling material and is allowed to intermingle with the swelling material under a sheath 16 .
[0000] III. References Which Show an Exposed Sealing Element that Swells on Insertion
[0032] 1) U.S. Pat. No. 6,848,505
[0033] An exposed rubber sleeve swells when introduced downhole. The tubing or casing can also be expanded with a swage.
[0034] 2) PCT Application WO 2004/018836 A1
[0035] A porous sleeve over a perforated pipe swells when introduced to well fluids. The base pipe is expanded downhole.
[0036] 3) U.S. Pat. No. 4,137,970
[0037] A swelling material 16 around a pipe is introduced into the wellbore and swells to seal the wellbore.
[0038] 4) US Application US 2004/0261990
[0039] Alternating exposed rings that respond to water or well fluids are provided for zone isolation regardless of whether the well is on production or is producing water.
[0040] 5) Japan Application 03-166,459
[0041] A sandwich of slower swelling rings surrounds a faster swelling ring. The slower swelling ring swells in hours while the surrounding faster swelling rings do so in minutes.
[0042] 6) Japan Application 10-235,996
[0043] Sequential swelling from rings below to rings above trapping water in between appears to be what happens from a hard to read literal English translation from Japanese.
[0044] 7) U.S. Pat. No. 4,919,989 and 4,936,386
[0045] Bentonite clay rings are dropped downhole and swell to seal the annular space, in these two related patents.
[0046] 8) US Application US 2005/009363 A1
[0047] Base pipe openings are plugged with a material that disintegrates under exposure to well fluids and temperatures and produces a product that removes filter cake from the screen.
[0048] 9) U.S. Pat. No. 6,854,522
[0049] FIG. 10 of this patent has two materials that are allowed to mix because of tubular expansion between sealing elements that contain the combined chemicals until they set up.
[0050] 10) US Application US 2005/0067170 A1
[0051] Shape memory foam is configured small for a run in dimension and then run in and allowed to assume its former shape using a temperature stimulus.
[0000] IV. Reference that Shows Power Assist Actuated Downhole to Set a Seal
[0052] 1) U.S. Pat. No. 6,854,522
[0053] This patent employs downhole tubular expansion to release potential energy that sets a sleeve or inflates a bladder. It also combines setting a seal in part with tubular expansion and in part by rotation or by bringing slidably mounted elements toward each other. FIGS. 3, 4 , 17 - 19 , 21 - 25 , 27 and 36 - 37 are illustrative of these general concepts.
[0054] The various concepts in U.S. Pat. No. 6,854,522 depend on tubular expansion to release a stored force which then sets a material to swelling. As noted in the FIG. 10 embodiment there are end seals that are driven into sealing mode by tubular expansion and keep the swelling material between them as a seal is formed triggered by the initial expansion of the tubular.
[0055] What has been lacking is a technique for automatically capturing applied differential pressures to a set element, particularly when set by swelling in reaction to exposure to well fluids, and retaining that force in the element to retain or/and boost its sealing capabilities downhole. The present invention offers various embodiments that capture boost forces from differential loading in the uphole or downhole directions and various embodiments to accomplish such capture in a single element or multiple elements on a single or multiple mandrels. Those skilled in the art will more readily appreciate the scope of the invention from a review of the description of the preferred and alternative embodiments, the drawing and the claims that appear below and define the full scope of the invention.
SUMMARY OF THE INVENTION
[0056] A packer assembly features one or more elements that preferably swell when in contact with well fluids and have a feature in them that responds to an applied load in a given direction by retaining such a boost force with a locking mechanism. A single element can have two such mechanisms that respond to applied forces from opposed directions. Friction force for adhering the element to the mandrel is enhanced with surface treatments between them that still allow the locking mechanisms to operate.
BRIEF DESCRIPTION OF THE DRAWING
[0057] FIG. 1 is a section view showing a sealing element that is fixed on one end and has the locking feature for capturing a boost force in one direction at the opposite end and shown in the run in position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0058] FIG. 1 will be used to illustrate a variety of variations of the present invention. What is illustrated in the Figure is a mandrel 10 for a packer P. Mounted to the mandrel 10 is an element 12 that preferably is of the type that swells in contact with well fluids using materials described in the patents and applications discussed above. A covering (not shown) can also be applied to the element 12 to provide a time delay to allow the packer P to be positioned close to where it needs to be set. The materials that accomplish this delay using a cover that goes away after a time exposure to well fluids and predetermined temperatures are also discussed in the patents and applications above.
[0059] In the Figure, the element assembly 12 has an uphole end 14 and a downhole end 16 . In one variation that is shown, the uphole end 14 is abutting a block 18 and is further secured to it and between itself and mandrel 10 with an adhesive or some type of bonding material 20 compatible with well materials and temperatures. Block 18 can be a ring welded to the mandrel 10 or can be attached with adhesive or threads or can be integral to the mandrel. While the element 12 can swell radially along its length, differential loading from the uphole end 14 toward the downhole end 16 will not budge the element away from block 18 due to the presence of bonding material 20 . In the embodiment of the Figure, any net downhole force from such loading will not add an additional sealing force into the element 12 because the upper end of the embodiment in the Figure is bonded and stationary, unlike the opposite end that has a ratchet feature, as will be described below. However, if there is differential loading after the element 12 swells to a sealing position the result will be that pressure applied in that direction will cause the downhole end 16 to ride toward uphole end 14 thus shortening the length of the element 12 while increasing its internal pressure. This increase in internal pressure will enhance the sealing force of the element to allow it to withstand even greater differentials going from the downhole end 16 to the uphole end 14 . To lock in that boost force that comes from loading due to increasing pressure conditions near the downhole end 16 , it is desirable to lock in such boost forces when they occur. To accomplish this, the mandrel 10 has a series of serrations or other rough surface treatment 22 adjacent downhole end 16 . The element 12 has an undercut 24 where ring 26 is secured with an adhesive or other bonding material 28 adjacent a ring 30 with an interior serrated surface 32 . Surfaces 22 and 32 ride over each other in one direction like a ratchet but lock upon relative movement in an opposed direction. Ring 30 is also bonded to element 12 with adhesive such as 28 . Rings 26 and 30 can be separate or unitary. In this version, the central section 34 is not bonded to mandrel 10 . This allows the length of the element 12 to decrease in response to a net force when the element 12 is set and compressed from an uphole directed force. Such a force results in ratcheting between surfaces 22 and 32 to lock in a greater force into the swelled element 12 against a surrounding tubular or an open hole (neither of which are shown).
[0060] Those skilled in the art will appreciate that the design shown in FIG. 1 can be inverted so that net forces in the downhole direction or toward the right in FIG. 1 will result in locking in a greater sealing force in the element 12 .
[0061] Another variation is to use two packers P mounted adjacent each other with opposed orientations for the locking device so that net forces in an uphole or downhole direction will each result in capturing a greater sealing force in the element 12 . Alternatively, a single mandrel 10 can house two elements of the type shown in FIG. 1 except that they are in mirror image orientation to allow capturing additional sealing force in the element 12 regardless of the direction of the net applied force. In yet another alternative, the assembly shown in undercut 24 can be disposed on opposed ends of the same element with a binder such as 20 being disposed only in the middle portion 34 . In that manner, a net force in either direction will cause a ratcheting action that retains a greater sealing force in the element 12 .
[0062] While a ratchet based system for locking in additional sealing force has been illustrated other mechanisms that permit unidirectional compression of the element from applied differential pressure loads on a set element 12 downhole are well within the scope of the invention.
[0063] Referring again to FIG. 1 an additional feature can be added to deal with the issue of relative movement during delivery to the packer P to the desired location for setting. Portions of the mandrel 10 can receive a roughening surface treatment in the form of grooves or adhered particles that will enhance the grip on element 12 . Of course, the location of such treatment of the mandrel 10 need to be placed in locations where longitudinal compression of the element 12 from pressure loading will not be impaired. For example, in the embodiment literally shown in FIG. 1 the block 18 will adequately resist shifting of the element 12 during run in. The middle section 34 will need to permit sliding to allow the ratcheting movement between teeth 22 and 32 . To prevent premature ratcheting during run in, a ring 36 can retain end 16 during run in and can be made of a material that dissolves or goes away over time to let the ratcheting or other pressure enhancing device hold in the greater sealing force from pressure loading on the set element 12 . This can be in the form of a coated threaded ring where the coating only dissolves after a time exposure at a given temperature. After that the well fluids attack the ring to the point of failure and the swelling of the element 12 can begin to set the packer P. Alternatively, the swelling of the element 12 can defeat the retainer 36 as could simply swaging the mandrel 10 .
[0064] However, if the version shown in FIG. 1 is revised so what is depicted at end 16 is also at end 14 in a mirror image, then it would make sense to surface treat the mandrel 10 in the middle section 34 as that section would not be moving during normal operation of the packer P. The surface treatment on the mandrel 10 can also act to hold the boost force from pressure loading that is anticipated once the packer P goes in service. Alternatively the element 12 itself can have a surface treatment where it contacts the mandrel 10 or both can be treated in the area of contact. Surface treatment on the mandrel can be multiple grooves, for example.
[0065] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below:
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A packer assembly features one or more elements that preferably swell when in contact with well fluids and have a feature in them that responds to an applied load in a given direction by retaining such a boost force with a locking mechanism. A single element can have two such mechanisms that respond to applied forces from opposed directions. Friction force for adhering the element to the mandrel is enhanced with surface treatments between them that still allow the locking mechanisms to operate.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. §119(e) of copending provisional application No. 60/370,194, filed Apr. 5, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an applicator roller having a roller jacket formed with a jacket surface for receiving a liquid thereon and for at least partly transferring the liquid. The invention also relates to an applicator roller and rotating element assembly, as well as to a dryer, a cooling roller stand and a printing press having the applicator roller.
[0004] Furthermore, the invention relates to a method of coating material webs with a liquid, in particular silicone oil emulsion, which is applied to the material web via an outer circumferential surface of a roller jacket of an applicator roller.
[0005] In web-fed rotary printing, for example in web-fed rotary offset printing, a material web is unwound from a supply reel in a reel changer, guided vertically or horizontally through a plurality of successively disposed printing units in order to print it, then guided through a dryer, for example, a hot air dryer, in order to dry it. The material web is finally guided over cooling rollers of a cooling roller stand in order to cool down the material web heated in the dryer. Thereafter, the material web can be cut and folded into signatures in a folder, and the signatures thus produced can be fed to a distribution system, as well. The material web is normally printed on both sides thereof and in many colors by the printing units. The use of dampening solution is necessary in conventional offset printing, due to which the material web has to be dried initially, and consequently cooled down before further processing.
[0006] Cooling roller stands of the prior art usually have a plurality of cooling rollers over and between which a cooling medium flows. The material web is guided through the cooling roller stand and around the cooling rollers on a meandering web path.
[0007] It is furthermore known to apply a liquid coating medium, for example silicone oil emulsion, to the entire area of the material web by an applicator roller. The applicator roller is able to be disposed within the cooling roller stand. Coating the printed material web with the silicone oil-water emulsion in the form of a thin film prevents the products from being smeared in the region of turner bars or in the folder of the printing press. Furthermore, setting off the printing ink lying under the silicone layer to deflection elements, for example to turner bars, is prevented.
[0008] German Published, Non-prosecuted Patent Application DE 197 43 741 A1 discloses an installation for coating substrate webs with a coating medium, which includes applicator rollers for respectively picking up and scooping up the coating medium, in particular silicone oil emulsion, from a respective dip trough or bath. The jacket or circumferential surfaces of the applicator rollers which are wetted with the coating medium are disposed in contact with the substrate web.
[0009] The composition of the surface of the respective applicator roller is not described in further detail in that German application, so that it must be assumed that that roller surface is a usually smooth and closed surface.
[0010] Furthermore, U.S. Pat. No. 3,923,936 describes a roller having regularly distributed and comparatively small openings formed in the surface thereof. The described roller can serve either for transferring a liquid to a surface or for picking up a liquid from a surface. The roller can, moreover, be constructed as a dip roller together with a dip trough or bath or as a hollow roller having an interior which is acted upon by a liquid or by a vacuum or negative pressure. Furthermore, the roller can serve for dehydrating or dewatering paper, for example a paper web being guided through a gap between the described roller and a further counterpressure or back-pressure roller. In that regard, the liquid absorbed by the described roller due to capillary action of the openings is forced out of the sponge-type surface of the described roller in a further gap to a further counterpressure roller.
[0011] The absorbent surface, therefore, picks up liquid in order either to transfer it to the web or remove it from the web. A strict distinction is drawn between those two possibilities in the aforementioned U.S. Pat. No. 3,923,936.
[0012] Furthermore, German Published, Non-prosecuted Patent Application DE 29 34 005 A1 describes a device for removing liquid from moving strip material, wherein a hollow roller rolls on the surface of the strip material, for example cold-rolled, high-speed metal strips, and the surface of the hollow roller is covered with at least one layer of absorbent material. Furthermore, the hollow roller has a perforated circumferential jacket under the absorbent material. The perforations or holes formed in the jacket are provided for the passage of liquid, which is taken up by the at least one layer of absorbent material, into the interior of the hollow roller, which is under vacuum or negative pressure.
[0013] However, the hollow roller with the absorbent surface described in the last-mentioned reference is not used for applying a liquid to the strip material.
[0014] German Patent DE 199 57 453 C1 discloses a method for applying highly viscous ink in an offset printing press. A hollow roller is employed having a surface formed by a netlike structure, through which the printing ink guided into the interior of the hollow roller can travel to the outside and, therefore, transfer to a further roller. Excess and non-transferred ink is entrained or carried around for a complete revolution of the roller and is forced back into the netlike structure by the contact pressure between the netlike roller and the following further roller in the contact gap between the netlike roller and the further roller.
[0015] However, the roller disclosed in the last-mentioned reference does not have a surface for applying the ink. Instead, the surface is reduced as much as possible so that, due to the netlike structure, a large number of openings are made available through which the ink application or transfer takes place.
[0016] U.S. Pat. No. 4,188,882 discloses a dampening device for offset printing presses. In that device, a dampening solution is picked up by a dip roller in a dip trough and transferred to a netlike surface of a further roller, which is acted upon from the inside with blast air in such a manner that the transferred dampening solution is sprayed from the netlike surface in a direction towards an element to be dampened.
[0017] A problem arises during the application of a liquid by an applicator roller to, for example, a material web or a further roller disposed downstream. The problem is that excess liquid can accumulate in the form of a reservoir in the inlet wedge or pocket between the applicator roller and either the material web or the further roller.
[0018] A further problem arises during coating of a material web. The further problem is that the material web can have reduced contact with the applicator roller during transport, for example as a result of fluttering of the material web, and that in such cases excess liquid from the reservoir formed in the inlet wedge or pocket can escape through the gap between the material web and the applicator roller and thus, in a nonuniform distribution, can form a coating on the material web. Those irregularities in the coating are detectable in the final product, for example a printed product, and consequently reduce the quality thereof in an unacceptable manner.
SUMMARY OF THE INVENTION
[0019] It is accordingly an object of the invention to provide an applicator roller having a roller jacket, an applicator roller and rotating element assembly, a dryer, a cooling roller stand and a printing press having the applicator roller and a method for coating a material web, which overcome the herein-aforementioned disadvantages of the heretofore-known devices and methods of this general type and with which a uniform application, transfer or coating of a liquid is possible.
[0020] It is a further object of the present invention to provide such an applicator roller which prevents an accumulation of excess liquid.
[0021] It is also an object of the invention to provide an alternative applicator roller or an alternative transfer roller to those rollers heretofore known from the prior art.
[0022] It is yet another object of the invention to provide a method for coating material webs which avoids an accumulation of excess liquid.
[0023] Moreover, it is an object of the invention to rectify or at least reduce the aforedescribed problems during the application or transfer of a liquid or during coating with a liquid.
[0024] With the foregoing and other objects in view, there is provided, in accordance with the invention, an applicator roller comprising a roller jacket having an outer cylindrical surface for picking up a liquid and, at least to some extent, for transferring the liquid. The roller jacket is formed with at least one perforation through which excess liquid is guidable into a hollow interior of the applicator roller.
[0025] With the objects of the invention in view, there is also provided a combination of an applicator roller and a rotating element disposed downstream therefrom in a liquid travel direction. The applicator roller comprises a roller jacket having an outer cylindrical surface for picking up the liquid and, at least to some extent, for transferring the liquid. The roller jacket is formed with at least one perforation through which the excess liquid is guidable into a hollow interior of the applicator roller. The rotating element is a roller, a cylinder or a continuously onward moving element such as a material web or a paper web. The liquid is water, dampening solution, silicone oil emulsion or ink. The excess liquid is guidable into the interior of the applicator roller from an accumulation thereof in an inlet wedge formed between the applicator roller and the rotating element.
[0026] In accordance with a further feature of the invention, the applicator roller serves for scooping up the liquid from a dip trough by the outer cylindrical surface of the roller jacket or for picking up the liquid from a rotating element disposed upstream therefrom in a travel direction of the liquid.
[0027] In accordance with an added feature of the invention, the excess liquid guidable into the interior of the applicator roller is at least to some extent feedable to the dip trough through the at least one perforation.
[0028] In accordance with an additional feature of the invention, the applicator roller is formed with a plurality of axial active regions, and the roller jacket is formed with a plurality of perforations in addition to the at least one perforation. Each of the plurality of axial active regions has at least one of the perforations.
[0029] In accordance with yet another feature of the invention, the perforations are formed in the roller jacket so as to be offset in circumferential direction and in axial direction. Some of the perforations at least partly overlap common axial regions.
[0030] In accordance with yet a further feature of the invention, the perforations are linear perforations.
[0031] In accordance with yet an added feature of the invention, the perforations have a length of less than 50 mm and a width of less than 1 mm.
[0032] In accordance with yet an additional feature of the invention, the interior of the applicator roller has absorbent material therein.
[0033] In accordance with still another feature of the invention, the absorbent material is sponge-type material or a sponge body.
[0034] With the objects of the invention in view, there is additionally provided a cooling roller stand integrated into a dryer, comprising an applicator roller. The applicator roller includes a roller jacket having an outer cylindrical surface for picking up a liquid and, at least to some extent, for transferring the liquid. The roller jacket is formed with at least one perforation through which excess liquid is guidable into a hollow interior of the applicator roller.
[0035] With the objects of the invention in view, there is further provided a cooling roller stand disposed immediately downstream of a dryer, comprising an applicator roller. The applicator roller includes a roller jacket having an outer cylindrical surface for picking up a liquid and, at least to some extent, for transferring the liquid. The roller jacket is formed with at least one perforation through which excess liquid is guidable into a hollow interior of the applicator roller.
[0036] With the objects of the invention in view, there is also provided a printing press, comprising an applicator roller. The applicator roller includes a roller jacket having an outer cylindrical surface for picking up a liquid and, at least to some extent, for transferring the liquid. The roller jacket is formed with at least one perforation through which excess liquid is guidable into a hollow interior of the applicator roller.
[0037] In accordance with a further feature of the invention, the printing press is a web-fed rotary printing press or a web-fed rotary offset printing press.
[0038] In accordance with an added feature of the invention, the printing press includes a cooling roller stand having integrated therein at least one applicator roller, including a roller jacket having an outer cylindrical surface for picking up a liquid and, at least to some extent, for transferring the liquid. The roller jacket is formed with at least one perforation through which excess liquid is guidable into a hollow interior of the applicator roller.
[0039] In accordance with an additional feature of the invention, the printing press includes a dryer having a cooling roller stand integrated therein or a cooling roller stand disposed immediately downstream from the dryer. The cooling roller stand has at least one applicator roller including a roller jacket having an outer cylindrical surface for picking up a liquid and, at least to some extent, for transferring the liquid. The roller jacket is formed with at least one perforation through which excess liquid is guidable into a hollow interior of the applicator roller.
[0040] In accordance with yet an additional feature of the invention, the dryer is a hot air dryer.
[0041] With the objects of the invention in view, there is additionally provided a method for coating a material web, which comprises applying a liquid to the material web by the outer circumferential surface of a roller jacket of an applicator roller, and guiding excess liquid into the interior of the applicator roller via at least one perforation formed in the roller jacket.
[0042] In accordance with another mode, the method of the invention further includes providing the material web as a paper web in web-fed rotary printing or web-fed rotary offset printing.
[0043] In accordance with a further mode, the method of the invention further includes providing the liquid as a silicone oil emulsion.
[0044] In accordance with a concomitant mode, the method of the invention further includes guiding the excess liquid from a location thereof in an inlet wedge formed between the applicator roller and the material web into the interior of the applicator roller via the one perforation and a plurality of additional perforations formed in the roller jacket.
[0045] Thus, an applicator roller according to the invention, having a roller jacket, the outer circumferential surface of which serves for picking up a liquid and transferring it at least to some extent, is distinguished by the fact that the roller jacket is formed with at least one perforation through which excess liquid is led away into the interior of the applicator roller.
[0046] Through the use of the applicator roller according to the invention, a uniform application and/or transfer of liquid can advantageously be achieved. The outer circumferential surface of the roller jacket of the applicator roller picks up the liquid and transfers it at least to some extent, but at the same time the applicator roller is prevented from picking up and transferring too much and, therefore, excess liquid.
[0047] According to the invention, such excess liquid is led away into the interior of the applicator roller through at least one perforation, i.e., through one or more openings formed in the roller jacket.
[0048] The applicator roller according to the invention thus has a circumferential surface which, according to the invention, carries out two functions, namely picking up and transferring the liquid, and guiding excess liquid away into the interior of the applicator roller. In this way, it is advantageously possible to achieve a uniform application/transfer or a uniform coating with a single applicator roller that is configured relatively simply in terms of construction.
[0049] Furthermore, irregularities on the element to be coated, for example a material web, produced by excess liquid or by excess coating medium can advantageously be avoided and, as a result, the quality of the element can be increased considerably.
[0050] In a further refinement of the invention, the perforation of the outer circumferential surface of the roller jacket of the applicator roller can guide away into the interior of the applicator roller excess liquid, in particular water, dampening solution, silicone oil-water emulsion or ink, which is located in an inlet wedge or pocket formed between the applicator roller and a rotating element disposed downstream, in particular a roller or a cylinder, or an element moving continuously onward, in particular a material or paper web.
[0051] In this way, an accumulation of liquid in the inlet wedge or pocket can advantageously be prevented, or liquid already accumulated in the inlet pocket can be dissipated again. The interior of the applicator roller can additionally be formed as a hollow space, and therefore the applicator roller as a hollow roller, so that the liquid passing into the interior through the at least one perforation can be guided away unimpededly.
[0052] It is further possible for the applicator roller to receive the liquid scooped up from a dip trough or supply trough by the outer circumferential surface of the roller jacket or picked up or transferred from a rotating element disposed upstream, in particular a roller.
[0053] The interaction of the applicator roller with a dip or supply trough, from which the liquid used for the coating is scooped, also serves for the uniform application of the liquid, it being possible in particular for interruptions in the supply of liquid to be avoided, because the applicator roller is always adequately wetted with liquid. However, it is also conceivable for the rotating element disposed upstream to be constructed as a dip roller, and to transfer the liquid to the applicator roller in a transfer gap.
[0054] Furthermore, the surface of the applicator roller can also be sprayed with the liquid, or supplying the liquid can be carried out by a chambered doctor blade which is operatively connected to the roller.
[0055] Furthermore, provision can be made for the liquid led away into the interior of the applicator roller to be supplied to the dip trough again, at least to some extent, through the perforations in the circumferential surface of the roller jacket of the applicator roller. The liquid level in the dip trough and the liquid level in the interior of the applicator roller are at the same height, because the perforations provide for the dip trough and the interior of the applicator roller to form a system of communicating tubes. During rotation of the applicator roller, however, the liquid level in the interior of the roller can fall and, with a sufficiently small opening ratio at the same time (ratio between open area and total area), for example less than 10%, the liquid level can also fall virtually completely.
[0056] The coating medium or the liquid led away into the interior of the applicator roller through the perforations can thus likewise advantageously flow through the perforations into the supply trough again and can be used again for wetting the outer circumferential surface of the applicator roller.
[0057] The perforations of the applicator roller advantageously make unnecessary any further equipment for leading away the liquid led away into the interior, for example in the axial direction through the bearing journals of the applicator roller, i.e., it is advantageously possible to dispense with such equipment, which leads to a further reduction in costs and work during the operation and maintenance of the applicator roller.
[0058] It is also conceivable, however, for the interior of the applicator roller to be subject to vacuum, for example a slight vacuum, applied thereto in order to pick up the liquid through the perforations, for example from the reservoir in the inlet wedge or pocket. In this regard, for example a pump can be used, with which the suction power through the perforations of the roller jacket can be adjusted.
[0059] In order to prevent liquid from being sucked up, which is located in the lower region, and therefore at the same level as the liquid level in the dip trough, the interior of the applicator roller can also be divided into, for example, two chambers, vacuum being applied only to the upper chamber. In this regard, the upper chamber can in particular apply vacuum to that section of the applicator roller which forms the inlet wedge or pocket. This advantageously makes it possible to increase the action of guiding excess liquid away through the perforations.
[0060] In a further embodiment of the applicator roller according to the invention, the perforations can be formed in such a way that each axial active region of the applicator roller has at least one perforation or opening.
[0061] In this regard, the axial active region of the applicator roller is understood to be every axial section of the applicator roller which is formed for applying or transferring liquid. For example, the end sections of the applicator roller need not belong to the active region of the applicator roller. Providing at least one perforation opening in every axial active region of the applicator roller, i.e., at least one perforation or opening in the outer circumferential surface at any desired point in the circumferential direction within the active region, advantageously ensures that both the application and transfer of the liquid and the action of picking up excess liquid by the applicator roller takes place uniformly, as viewed in the axial direction. Thereby, in particular, visible irregularities, for example the formation of stripes, on a printed product can be avoided.
[0062] Furthermore, the action of picking up excess liquid, for example from an inlet wedge or pocket, as viewed in the axial direction, is carried out with high uniformity, so that for example when highly viscous liquids are used, accumulated liquid is dissipated uniformly as viewed in the axial direction.
[0063] Furthermore, the perforations can be formed in such a way or can be formed as a linear perforation in such a way that perforation openings disposed to be offset in the circumferential direction and in the axial direction partly overlap common axial regions.
[0064] A perforation formed as a linear perforation in the roller jacket of the applicator roller, individual lines or slits of the perforation partly overlapping joint axial regions, is additionally used for the uniform application or transfer of liquid and therefore the uniform coating of material to be coated.
[0065] For example, it is of particular advantage to configure the applicator roller in such a way that the perforations or openings have a length of less than 50 mm, or 8 mm to 50 mm, and a width of less than 1 mm, or 0.1 mm to 1 mm, for example 0.25 mm. The perforations or openings can be cut into the roller jacket of the applicator roller by a laser device, for example.
[0066] An applicator roller according to the invention can also have a drive, in particular a separate drive or motor.
[0067] In a further refinement of the invention, the applicator roller can likewise be driven in oscillation, i.e., oscillating in the axial direction.
[0068] An applicator roller according to the invention can preferably be disposed upstream of the first and/or upstream of the second cooling roller of a cooling roller stand. For example, an applicator roller according to the invention can apply silicone oil-water emulsion to a paper web in a section of the web path running vertically from top to bottom between the first and the second cooling roller of a cooling roller stand. In this regard, the applicator roller can be disposed on that side of the material or paper web whereon the second cooling roller is also located, so that the emulsion is applied to the surface of the web before the latter is guided over the following cooling roller, and smearing, set-off or condensation of printing ink on the cooling roller is avoided.
[0069] In a further embodiment of the invention, provision can be made for constructing the interior of the applicator roller in such a way that the interior has an increased absorbency, for example a sponge-type material or a sponge body can be disposed in the interior of the applicator roller. In this way, liquid is advantageously sucked inwardly from the perforations or openings, so that an undesirably high application of liquid or nonuniform application does not occur. The use of absorbent material is advantageous in particular in conjunction with circular perforations or openings.
[0070] Provision can further be made for a cooling roller stand, in particular a cooling roller stand integrated into a dryer or disposed immediately downstream of a dryer, to be distinguished by an inventive applicator roller as described hereinabove. Furthermore, a printing press, in particular a web-fed rotary printing press or web-fed rotary offset printing press, can be distinguished by an applicator roller as described hereinabove or by a cooling roller stand having such an applicator roller or by a dryer having such an applicator roller.
[0071] A method according to the invention for coating material webs, in particular paper webs in web-fed rotary printing or web-fed rotary offset printing, a liquid, in particular silicone oil emulsion, being applied to the material web by the outer circumferential surface of the roller jacket of an applicator roller, is distinguished by the fact that excess liquid, in particular such liquid as is located in an inlet wedge or pocket formed between the applicator roller and the material web, is guided away into the interior of the applicator roller by at least one perforation formed in the roller jacket.
[0072] The advantages indicated above in conjunction with the applicator roller according to the invention as described also result when implementing the method according to the invention of coating material webs, in particular uniform coating of the material web can advantageously be brought about, and the accumulation or build-up of excess liquid can be reduced or even avoided.
[0073] The excess liquid is guided away through the perforations for example by the capillary action of the perforations or openings, by the force of gravity acting upon the liquid, by the pressure of the liquid resulting from the height of the reservoir built up, by the contact pressure in the gap between applicator roller and a following roller or material web or by the suction action of a pump or vacuum source operatively connected to the interior of the applicator roller.
[0074] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0075] Although the invention is illustrated and described herein as embodied in an applicator roller having a roller jacket, an applicator roller and rotating element assembly, a dryer, a cooling roller stand and a printing press having the applicator roller and a method for coating a material web, 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.
[0076] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0077] [0077]FIG. 1 is a diagrammatic, side-elevational view of an applicator roller according to the prior art, with a material web being guided vertically upwardly from below, the applicator roller being operated so as to run in the same direction as that of the material web;
[0078] [0078]FIG. 2 is a side-elevational view of an applicator roller according to the prior art, with a material web being guided vertically upwardly from below, the applicator roller being operated so as to run in a direction opposite to that of the material web;
[0079] [0079]FIG. 3 is a side-elevational view of an applicator roller according to the prior art, with a material web being guided vertically downwardly from above, the applicator roller being operated so as to run in a direction opposite to that of the material web;
[0080] [0080]FIG. 4 is a side-elevational view of an applicator roller according to the prior art, with a material web being guided vertically downwardly from above, the applicator roller being operated so as to run in the same direction as that of the material web;
[0081] [0081]FIG. 5 is a side-elevational view of an applicator roller according to the prior art, with a material web being driven horizontally from the left-hand to the right-hand side of the figure, and the applicator roller being operated so as to run in the same direction as that of the material web;
[0082] [0082]FIG. 6 is a side-elevational view of an applicator roller according to the prior art, with a material web being driven horizontally from the left-hand to the right-hand side of the figure, and the applicator roller being operated so as to run in a direction opposite to that of the material web;
[0083] [0083]FIG. 7 is a side-elevational view of two applicator rollers according to the prior art disposed after one another, with a paper web being guided horizontally from the left-hand side to the right-hand side of the figure, one of the applicator rollers being operated so as to run in the same direction as that of the paper web, and the other of the applicator rollers being operated so as to run in a direction opposite to that of the paper web;
[0084] [0084]FIG. 8 is a side-elevational view of an applicator roller according to the invention, with a paper web being guided vertically downwardly from above, and the applicator roller being operated so as to run in the same direction as that of the paper web;
[0085] [0085]FIG. 9 is a side-elevational view of an applicator roller according to the invention, with a material web being guided vertically downwardly from above, the applicator roller being operated so as to run in a direction opposite to that of the material web;
[0086] [0086]FIG. 10 is a side-elevational view of an applicator roller according to the invention, with a material web being driven horizontally from the left-hand to the right-hand side of the figure, and the applicator roller being operated so as to run in a direction opposite to that of the material web;
[0087] [0087]FIG. 11 is a perspective view of a roller jacket of an applicator roller according to the invention, which is formed with perforations;
[0088] [0088]FIG. 12 is an enlarged, fragmentary view of FIG. 11 showing a portion of the circumferential jacket surface of the roller jacket of an applicator roller according to the invention;
[0089] [0089]FIG. 13 is a side-elevational view of an assembly of a perforated applicator roller according to the invention in conjunction with a following roller;
[0090] [0090]FIG. 14 is a side-elevational view of an assembly of a perforated applicator roller according to the invention in conjunction with a roller disposed upstream therefrom and a roller disposed downstream therefrom; and
[0091] [0091]FIG. 15 is a view similar to that of FIG. 13, with a discharge element disposed in the interior of the applicator roller according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0092] Referring now to the figures of the drawings in detail and first, particularly, to FIGS. 1 to 7 thereof, there are seen applicator rollers according to the prior art, which have different configurations, namely material and paper web travel or running directions which are different, and rotation directions of the applicator rollers which are different. The various illustrated configurations lead to different relationships with respect to the transport path of the liquid to be applied, which are described in greater detail hereinbelow.
[0093] FIGS. 1 to 10 each illustrate at least one respective applicator roller 1 having a rotational axis 2 , a direction of rotation represented by a curved arrow 4 , a roller jacket 6 and an outer cylindrical or jacket surface 8 . Due to the rotation of the applicator roller 1 , a liquid 10 , for example a silicone oil-water emulsion, is scooped up from a dip trough 12 by the jacket surface 8 . The outer cylindrical jacket surface 8 of the applicator roller 1 , which is wetted with the liquid 10 , rolls on the surface of a transported material web 14 and, in this regard, transfers the liquid 10 , which is scooped up from the dip trough 12 , to the surface of the material web 14 in the form of a closed liquid film.
[0094] [0094]FIG. 1 illustrates an example wherein the material web 14 is guided vertically from the bottom to the top of the drawing, and the applicator roller 1 is operated so as to run or rotate in the same direction.
[0095] In this regard, the term “run in the same direction” is intended to indicate that the material web 14 and the applicator roller 1 have surface speeds directed in the same direction in the contact region 16 between one side of the surface of the material web 14 and the outer cylindrical or jacket surface 8 of the applicator roller 1 . The magnitude of the surface speeds of the material web 14 and the applicator roller 1 may be different, however, in this regard. In contrast therewith, the term “run in the opposite direction” is intended to indicate that the directions of the surface speeds of the material web 14 and of the outer cylindrical or jacket surface 8 are opposed to one another in the contact region 16 , it being possible here for the magnitudes of the surface speeds to be of different values, too.
[0096] As is ascertainable from FIG. 1, a liquid film 18 forms on the outer cylindrical or jacket surface 8 of the roller jacket 6 and, starting from the surface of the liquid 10 stored in the dip trough, extends as far as the contact region 16 between the jacket surface 8 and the material web 14 . This liquid film 18 is entrained or carried along together with the cylindrical jacket surface 8 in accordance with the rotation of the applicator roller 1 and has the effect of coating the material web 14 with a liquid film 20 . Excess liquid which does not pass the contact region 16 and thus does not contribute to producing the liquid film 20 runs back into the dip trough 12 in the form of a liquid film 22 on the liquid film 18 transported along by the applicator roller 1 . Thus, in this configuration of material web guide direction and applicator roller rotation, there is no problem with excess liquid accumulating on the applicator roller or in the inlet wedge or pocket 24 formed between the applicator roller 1 and the material web 14 .
[0097] In comparison with FIG. 1, FIG. 2 shows the relationships when the rotational direction 4 of the applicator roller 1 is reversed. In this case, a liquid film 18 is likewise formed on the surface 8 of the roller jacket 6 of the applicator roller 1 and is transferred as a liquid film 22 to the material web 14 in the inlet wedge or pocket 24 . Because, in this case, the applicator roller 1 is operated so as to run in a direction opposite to that of the material web 14 , the latter picks up completely the liquid transported into the inlet wedge or pocket 24 in the form of the liquid film 22 , so that there is no accumulation of excess liquid in the inlet wedge or pocket 24 . Furthermore, an excessive quantity of scooped-up liquid 10 is returned to the dip trough 12 in the form of a liquid film 20 which runs on the liquid film 18 under the influence of the force of gravity.
[0098] [0098]FIG. 3 shows the relationships in contrast with FIG. 1 for the case wherein the rotational direction 4 of the applicator roller 1 is maintained, whereas the running or travel direction of the paper web 14 , however, is reversed. In this case, too, there is no build-up and accumulation, respectively, of excess liquid in the inlet wedge or pocket 24 formed between the applicator roller 1 and the material web 14 .
[0099] [0099]FIG. 4 shows an applicator roller 1 operated so as to run in the same direction as that of the material web 14 , however, in contrast with the example of FIG. 1, the transport direction of the material web 14 of FIG. 4 runs in vertical direction from the top to the bottom of the figure. As can be readily ascertained from FIG. 4, in this case, a reservoir 26 of excess liquid builds up in the inlet wedge or pocket 24 , and is supplied by the liquid film 18 . Consequent to the transport of the material web 14 , fluctuations occur in the contact pressure between the material web 14 and the applicator roller 1 in the contact region 16 , so that an at least time-variant additional quantity of liquid 28 is transferred to the material web 14 from the reservoir 26 . This coating of the material web 14 , which is formed, for example, as stripes, considerably reduces the quality of a produced printed product.
[0100] As shown in FIG. 5 and FIG. 7, the problem of accumulating liquid in the inlet wedge or pocket 24 formed between the applicator roller 1 and the material web 14 can also occur when the material web is guided horizontally.
[0101] [0101]FIG. 5 shows an applicator roller 1 which is operated so as to run in the same direction as that of the material web 14 and which revolves at such a rotational speed that more liquid is transferred into the inlet wedge or pocket 24 from the dip trough 12 than is conducted away through the contact region 16 in the form of the liquid coating film 20 . In this case, the reservoir 26 could be avoided or dissipated by a lower rotational speed of the roller 1 , but it may be possible that, at reduced rotational speed, the liquid film 20 on the material web 14 does not have the necessary depth and layer thickness, respectively, or, for example, becomes irregular, so that those skilled in the art would refrain or turn away from reducing the rotational speed.
[0102] In FIG. 6, the applicator roller 1 of FIG. 5 is shown as operating so as to run in a direction opposite to that of the material web 14 , due to which there is no accumulation of liquid in the inlet wedge or pocket 24 .
[0103] The roller 1 shown at the right-hand side of FIG. 7 is operated so as to run in a direction opposite to that of the material web 14 , thus in a manner corresponding to that of the roller 1 shown in FIG. 6, but revolves at a higher rotational speed than the latter roller, so that, in this case, a reservoir 26 is formed in the inlet wedge or pocket 24 .
[0104] [0104]FIG. 8 shows an applicator roller 1 ′ according to the invention, having a roller jacket 6 ′ and an outer cylindrical or jacket surface 8 ′ for picking up a liquid film 18 ′ and transferring it at least to some extent in the form of a liquid film 22 ′ to a material web 14 in a contact region 16 . According to the invention, the roller jacket 6 ′ is formed with perforations 30 through which excess liquid which, as shown in FIG. 4, could accumulate in the inlet wedge or pocket 24 as a reservoir 26 , is guided away into the interior 32 of the applicator roller 1 ′ and there, for example in the form of a liquid film 34 , is guided back to the stored liquid 10 in the dip trough 12 .
[0105] Since the stored liquid 10 in the dip trough 12 outside the applicator roller 1 ′ and within the applicator roller 1 ′ forms a system of communicating tubes, the liquid level is equalized inside and outside the applicator roller 1 ′. If necessary or desirable, excess liquid may be fed back into the dip trough 12 .
[0106] Due to the contact pressure prevailing in the contact region 16 between the applicator roller 1 ′ and the material web 14 , excess liquid is forced through the perforations 30 into the interior 32 of the applicator roller 1 ′.
[0107] In the embodiment of the applicator roller 1 ′ according to the invention which is shown in FIG. 8, a liquid film 20 ′ also forms on the liquid film 18 ′ that is entrained or carried along with the applicator roller 1 ′ and, as a consequence of the force of gravity, runs back into the dip trough 12 .
[0108] Prevention of the build-up of a reservoir 26 in the inlet wedge or pocket 24 (note FIG. 4) can be influenced or even controlled, for example, by a suitable selection of the perforations. In other words, the prevention of the build-up is influenced or controlled by the number and configuration and arrangement of the respective perforations or openings formed on the surface of the roller 1 ′, or else by the rotational speed of the applicator roller 1 ′. In this regard, the rotational speed can also be prescribed by a control unit.
[0109] As can further be concluded from FIG. 8, the inner cylindrical or jacket surface 36 of the roller jacket 6 ′ likewise entrains a liquid film 38 from the liquid supply 10 . However, this liquid film 38 is guided around with the applicator roller 1 ′, without reaching the outer surface, i.e., without reaching the outer cylindrical or jacket surface 8 ′ of the roller jacket 6 ′, and is guided back to the stored liquid 10 again. At current maximum rotational frequencies of the applicator roller 1 ′ of about 50 to 200 revolutions per minute, it is not possible for the liquid to pass through the perforations 30 from the inside to the outside due to the centrifugal force produced by the rotation of the applicator roller 1 ′.
[0110] It should be mentioned herein that the rotational frequency of the applicator roller is advantageously selected in such a way that the surface speed thereof assumes a prescribed percentage of the material web speed. In other words, in the event of changes in the speed of the material web, for example when starting up a printing press, the rotational frequency of the applicator roller is also changed. This percentage normally lies in the range of from 1% to 10%, for example between 2% and 5% or, for example, below about 3%. An advantageous applicator roller in conjunction with vertical web guidance can have, for example, a maximum rotational frequency of less than 100 revolutions per minute, in particular, 75 revolutions per minute.
[0111] [0111]FIG. 9 shows the applicator roller 1 ′ from FIG. 8, however, now running in a direction opposite to that of the material web 14 . In this case, too, the surface 8 ′ of the roller jacket 6 ′ entrains or carries along therewith a liquid film 18 ′ from the supply trough 12 , which is of sufficient thickness that a liquid coating film 22 ′ of desired thickness can be formed or built up on the material web 14 . It is thus possible without difficulty to operate the applicator roller 1 ′ so that it runs in a direction that is the same direction as or the opposite direction from that of the material web 14 , and possibly to alternate between these two operating states.
[0112] It should further be noted that the problem of ink build-up on the applicator roller in the situations shown in FIGS. 2, 3 and 6 exists in the situation of FIG. 9, because the web 14 and the surface of the applicator roller 1 ′ are not coated with liquid in the contact region 16 . In contrast therewith, this problem is solved by the use of the applicator roller according to the invention in the situation shown in FIG. 9, because the roller surface 8 ′ of the applicator roller 1 ′ is wetted by the capillary action of the perforations or openings 42 .
[0113] A further disruptive effect of the applicator rollers according to the prior art should be described here. If a conventional applicator roller is operated so as to run in a direction opposite to that of the material web, then more liquid is transferred than during the operation of the applicator roller so as to run in the same direction as that of the material web, because in the latter case the liquid has to pass the contact region.
[0114] On the other hand, an applicator roller according to the invention is able to transfer sufficient liquid, for example to a material web, even when the applicator roller is running in the same direction as that of the material web, because, in this operating mode, liquid can be drawn out of the perforations after the contact region has been passed. The operator can therefore advantageously choose the operation wherein the applicator roller is running in the same direction as that of the material web, just as well as the operation wherein the applicator roller is running in the opposite direction from that of the material web, and therefore prevent the build-up of ink on the applicator roller.
[0115] Furthermore, FIG. 10 shows how, by using an applicator roller 1 ′ according to the invention, it is possible to prevent a reservoir 26 from building up or forming in the inlet wedge or pocket 24 (note FIG. 7, right-hand roller) in the case of horizontal web guidance. Excess liquid is led away into the interior 32 of the applicator roller 1 ′ through the perforations 30 in the region of the inlet wedge or pocket 24 or of the contact region 16 and, in the interior, is led back in the form of a liquid film to the liquid circuit in the liquid supply 10 contained in the dip trough 12 . An advantageous applicator roller in conjunction with horizontal web guidance can, for example, have a diameter between 30 mm and 50 mm, in particular about 38 mm, and a maximum rotational frequency between 150 and 200 revolutions per minute.
[0116] In a departure from the illustration of FIG. 10, the applicator roller 1 ′ according to the invention can also advantageously be operated for running in the same direction as that of the material web in the case of horizontal web guidance (note FIG. 7, left-hand roller).
[0117] [0117]FIG. 11 shows the roller jacket 6 ′ of an applicator roller 1 ′ according to the invention with a rotational axis 2 , the perforations 42 of the roller jacket 6 ′ being illustrated in a region 40 . The perforations 42 are formed as linear perforations or slits disposed at least approximately parallel to the axis of rotation, and being offset axially and in circumferential direction.
[0118] Also derivable from FIG. 11 is that the axial active region 46 defined by the two broken circumferential lines has at least one perforation or opening, although two are actually shown. Although not illustrated in FIG. 11, an applicator roller according to the invention can be formed with perforations, as shown in region 40 , over the entire active surface of the roller jacket and can therefore be formed so that each axial active region 46 , i.e., each axial region provided for the transfer of liquid, has at least one perforation or opening 43 .
[0119] [0119]FIG. 12 shows the region 40 in an enlarged diagrammatic view, it being possible to see the offset configuration of the perforations or openings 42 both in the axial direction Y and in the circumferential direction X. The individual perforations or openings 42 a to 42 d , respectively, have a length L and a width B, the length L extending in the axial direction, and the width B in the circumferential direction. FIG. 12 further reveals that the perforations or openings 42 a to 42 d overlap a common axial region C. For the case wherein all the end sections of the perforations or openings 42 overlap in this way, assurance is offered that there are no axial regions of the applicator roller 1 ′, which do not have at least one perforation or opening or at least one part of a perforation or opening, and thereby prevent the formation of the stripes by excess liquid that has not been led away.
[0120] As shown in FIG. 12, the two perforations or openings 42 b and 42 d have an axial offset of Δ-Y and an offset in the circumferential direction of Δ-X. The surface of the applicator roller 1 ′ between the perforations or openings 42 is sufficiently large, according to the invention, that adequate scooping of liquid and picking up and transferring of this liquid in the desired and necessary amount is assured. For example, provision can advantageously be made for selecting the ratio of the total area of the openings 42 to the total surface of the applicator roller 1 ′ in the range between 1% and 50%. In order to dissipate or prevent the formation of reservoirs 26 , a ratio of less than 5%, in particular less than 3% or more particularly about 1% will advantageously be selected. In order to achieve a rewetting of a dried material web with the applicator roller 1 ′, in addition to the application of, for example, silicone oil emulsion, a ratio of more than about 10% will advantageously be selected.
[0121] Besides a linear perforation or slit, every other type of perforation is also conceivable, for example an at least approximately circular hole, it being possible for the perforations or openings, for example, advantageously to have a diameter of 1 mm to 10 mm, in particular about 2 mm or about 4 mm.
[0122] Furthermore, FIG. 13 shows that the applicator roller 1 ′ may also transfer the liquid film 18 ′ to a roller 48 disposed downstream and, in this regard, can be used with advantage for preventing the production of a liquid reservoir in the inlet wedge or pocket 24 between the applicator roller 1 ′ and the roller 48 disposed downstream. It is thus possible, for example, also to use the applicator roller 1 ′ according to the invention in an inking-roller or dampening-roller train within an inking or dampening unit of a printing press.
[0123] As FIG. 14 shows, the applicator roller 1 ′ according to the invention may also be used between a roller 50 disposed upstream and a roller 48 disposed downstream for transferring a liquid from the upstream roller 50 to the downstream roller 48 . In this regard, the applicator roller 1 ′ according to the invention, which in this case can also be referred to as a transfer roller, prevents the production of a reservoir in the inlet wedge or pocket 24 between the roller 48 disposed downstream and the applicator roller 1 ′, and also the production of a reservoir in the inlet wedge or pocket 52 between the roller 50 disposed upstream and the applicator roller 1 ′. Excess liquid, for example water, ink, dampening solution or silicone oil emulsion, is led away into the interior 32 of the applicator roller 1 ′ through the perforations 30 formed in the roller jacket 6 ′ of the applicator roller 1 ′.
[0124] The excess liquid can then be guided out of the applicator roller 1 ′ in the axial direction (as shown in FIG. 15) or again, as shown in FIG. 14, fed through the perforations, due to the force of gravity, to a collecting region 54 , for example in the form of a curved sheet, and fed back therefrom to the liquid supply 10 again, in particular by a pump 56 .
[0125] By contrast, FIG. 15 reveals that the amount of liquid led away into the interior 32 of the applicator roller 1 ′ through the perforations 30 can also be collected in the interior by a suitable receptacle 58 which, for example, rests on the inner cylindrical or jacket surface 36 ′ of the applicator roller 1 ′. The liquid 60 contained in the receptacle 58 can then be led away, for example in the axial direction, from the interior 32 of the applicator roller 1 ′, for example through the end sections or the bearing journals of the applicator roller 1 ′, and in particular fed to a liquid circuit again.
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An applicator roller includes a roller jacket having an outer cylindrical surface for picking up a liquid and, at least to some extent, for transferring the liquid. The roller jacket is formed with at least one perforation through which excess liquid is guidable into a hollow interior of the applicator roller. An assembly of an applicator roller and a rotating element disposed downstream therefrom in a liquid travel direction, a cooling roller stand integrated into a dryer and having the applicator roller, a cooling roller stand disposed immediately downstream from a dryer and having the applicator roller and a printing press having the applicator roller, are also provided. A method is provided for coating a material web.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a supercharged internal combustion engine of a motor vehicle, which has a cooling circuit, in which a working medium is recycled, which at least partially is conveyed in a vaporous or gaseous physical condition. In this connection, at least one expander unit is provided which is operatively connected with an output shaft of the internal combustion engine, in which the at least partially vaporous or gaseous working medium is expanded and the kinetic energy of the vapor or the gas is converted into kinetic energy.
[0002] With the development or further development of internal combustion engines, the main focus of the work recently, on the one hand, has been on the reduction of pollutants and on the other hand, on increasing efficiency of the assembly. In this connection, a possibility exists of increasing the efficiency of modern internal combustion engines by optimally using the heat occurring in the area of the respective internal combustion engine. By providing appropriate features, it is possible to limit the dimensions of the required cooling assembly as well as also make useable the heat loss for other applications in the area of the motor vehicle which otherwise is merely released to the environment. Until now, incidental heat in motor vehicles in the area of the internal combustion engine is used primarily for heating the interior of the vehicle. A problem with this, however, is that the heat required by the vehicle occupants varies, primarily, however, only in exceptional cases with the output provided from the combustion engine. In addition, in particular in the summer months, cooling rather than heating is required, whereby the cooling of the vehicle interior is realized with the aid of a corresponding cooling assembly.
[0003] In order to improve engine cooling, recently combustion engines, in particular, vehicle engines, were further developed, such that the corresponding systems enable a use of the incidental heat in the area of the internal combustion engine in the most effective manner. In this connection, on the one hand the possibility exists of using the incidental heat for other heat sinks provided in the vehicle or of converting the heat energy with the aid of corresponding circuit processes into mechanical energy, in particular, kinetic energy.
[0004] DE 197 45 758 A1 discloses a cooling assembly for internal combustion engines of motor vehicles, which are to make possible an optimal cooling of the combustion engine using proportionally smaller heat exchanger surfaces. The system described in this reference has an evaporative cooling system, in which the cooling water used, preferably a water-anti-freeze passes through a phase transition liquid-vapor-liquid during operation of the cooling system. In this connection, the effect is utilized that the heat transfer coefficients from the warm wall on the boiling liquid as well as from the vapor on the cold wall are higher than with the convection between liquid or gas and one wall. The use of the described evaporative cooling therefore should eventually ensure that heat exchangers can be used with relatively small heat exchanger surfaces compared to common convection heat exchangers. This leads to a substantial minimizing of the space required fro the cooling assembly, in particular the heat exchanger.
[0005] In addition to evaporative cooling, in which a substance, primarily water, which is mixed only with an additive for preventing freezing, is used in a coolant circuit, a cooling system for an internal combustion engine is disclosed for example in JR 09072255, which provides two cooling circuits, whereby in one of the two cooing circuits, a two-substance mixture is used as the working medium. In this connection, first incidental excess heat in the area of the internal combustion engine is conducted via a first cooling circuit and with the aid of a heat exchanger, transferred to the working medium supplied in the second cooling circuit. The working medium in the form of the two-substance mixture located in the second cooling circuit is a water-ammonia mixture. This mixture demonstrates in particular that the mixture components have different evaporation temperatures with the same pressure ratios. This type of system offers the advantage that already at a low temperature level, vapor is produced, which is available for a subsequent use.
[0006] In the described technical solution, essential components are provided in the second cooling circuit; a generator, in which the ammonia of the water-ammonia mixture is evaporated; a phase separator, in which the liquid phase is separated from the vapor phase; a condenser, in which the ammonia is again fluidized; a choke valve with a downstream evaporator; and finally an absorber, in which the gaseous ammonia is dissolved in water with heat output. In the described cooling system, the heat to be dissipated from the area of the internal combustion engine is transferred in the area of the generator to the water-ammonia mixture and finally used primarily with the help of the condenser for fuel preheating. Also in this case, based on the occurring phase transition, relatively small heat exchanger surfaces are used.
[0007] In addition, “BMW Power aus dem Abgas; in Auto Motor Sport from Dec. 8, 2005 (see also internet side http://www.auto-motor-sport.de/d/98231)” discloses a cooling system of a motor vehicle, in which heat energy is removed from exhaust and cooling water, which subsequently is converted in an expander unit into kinetic energy. The expander unit that is used has two steam-axial piston engines, which are coupled via a belt drive with the output shaft of the actual internal combustion engine. Also, this system has two separate cooling circuits for steam production, in which on the one hand water is heated to over 500° C. and on the other hand, ethanol is heated up to 105° C. Both media exist with the above-noted temperatures in the corresponding cooling circuits in the form of superheated steam, which is supplied respectively to one of the two steam-axial piston engines. The kinetic energy stored in the steam is converted in this manner into kinetic energy, which is transferred via the belt drive onto the output shaft of the internal combustion engine in order to achieve an increase in efficiency of the internal combustion engine.
SUMMARY OF THE INVENTION
[0008] From the known state of the art, in which in a cooling circuit of an internal combustion engine, first steam is provided and then next, using an expander unit for producing kinetic energy is again expanded, the present invention is based on the object of providing a technical solution, with which the energy conversion in the area of the internal combustion engine is realized using economically sensible components, which require only minimal space. The solution to be provided should hereby have simple constructive structure, in particular, and without substantial expense, be capable of being integrated in the periphery of an internal combustion engine. In addition, it should be noted that the essential structure of an internal combustion engine as well as the arrangement of the mounting assembly must not be changed fundamentally based on the use of an additional expander unit.
[0009] According to the present invention, a supercharged internal combustion engine of a motor vehicle is provided, which has a cooling circuit in which a working medium is converted, which is conveyed at least partially in a vaporous or gaseous physical state, whereby at least one expander unit that is connected operatively with an output shaft of the internal combustion engine via a power train is provided. In the expander unit, by means of a conversion from the energy contained in the at least partially vaporous or gaseous working medium, an output shaft of the expander unit is moveable. In addition, the expander unit is embodied as a two-cycle reciprocating engine, preferably as a radial engine, which is connected operatively directly or indirectly via the power train with the output shaft of the internal combustion engine.
[0010] In this connection, it is contemplated that the two-cycle reciprocating engine is disposed either within a housing surrounding the internal combustion engine or outside of the internal combustion engine housing. In a very specialized further embodiment of the invention, the two-cycle reciprocating engine is disposed within the housing of the internal combustion engine in the region of the oil pan. In this manner, it is possible to attach the two-cycle reciprocating engine in a particularly space-savings manner in the area of the internal combustion engine.
[0011] Based on the embodiment of the expander unit as a radial engine according to the present invention, it is possible to provide a supercharged internal combustion engine, in which the conversion of kinetic energy contained in a working medium into additional kinetic energy in the most compact space is achievable. In this connection, the radial engine is characterized primarily by its radial construction, in particular by the arrangement of the at least two cylinders in one plane, which is arranged advantageously perpendicular to the output shaft of the supercharged internal combustion engine. The vapor producing unit as well as the radial engine preferably is designed, such that a maximum power is achievable on the output shaft of the radial engine of up to 40 kW, with a long-distance commercial vehicle engine. In this connection, the use of a radial engine is suitable, in particular, whose cylinder has an inner diameter of 55 to 65 mm, preferably 60 mm.
[0012] With the proposed technical solution according to the present invention, steam is produced at least intermittently in at least one cooling circuit, via which heat from the supercharged internal combustion engine is conducted, preferably from the engine block. The steam is conveyed to the radial engine. There the steam puts the pistons into motion in the individual cylinders and in this manner, also puts an output shaft of the radial engine into rotation. The rotation energy of the output shaft of the radial engine in turn is transferred to the output shaft of the supercharged internal combustion engine. In this connection, it is contemplated to couple the output shafts of the radial engine and the internal combustion engine either directly or indirectly to one another, for example the radial engine is disposed directly on the output shaft of the internal combustion engine, or a direct connection between the output shafts, perhaps via a belt or gear wheel drive or even via a gear, is provided.
[0013] In an advantageous embodiment of the invention, the radial engine is provided in the area of a fan wheel of the supercharged internal combustion engine. In this connection, it should be considered that the fan wheel typically is connected operatively with the output shaft, in particular the crankshaft of the internal combustion engine or is disposed directly on it. With the aid of a fan wheel disposed in this manner, normally an air/water heat exchanger and/or the outer wall of the internal combustion engine is impinged with cool air. Advantageously, the radial engine is disposed between a housing of the internal combustion engine, primarily the crankcase, and the fan wheel is disposed so that an extremely space-saving arrangement of an additional expander unit is possible.
[0014] A specialized design of the internal combustion engine of the invention contemplates that the output shaft of the internal combustion engine is a crankshaft, with which the radial engine is connected operatively. Advantageously, the radial engine is attached to the output shaft, on which also a fan of the internal combustion engine is provided. With this type of embodiment, therefore, the radial engine and a fan wheel are attached to an output shaft of the internal combustion engine, in particular the crankshaft. In this connection, it is contemplated on the one hand that the output of the radial engine acts directly on the corresponding output shaft of the internal combustion engine or an appropriate gear for example in the form of a sun gear, is interposed.
[0015] A further particular embodiment of a supercharged internal combustion engine in contrast has a separate output shaft, on which the radial engine is secured, whereby the output shaft of the radial engine in turn is connected via a gear wheel drive with the output shaft, in particular the crankshaft of the internal combustion engine. An alternative embodiment further contemplates that instead of the gear wheel drive, a belt drive, preferably a cogged belt drive, is disposed between the crankshaft of the engine and the output shaft of the radial engine. Also in this case, it is possible by all means to provide a gear between the output shaft of the radial engine and the crankshaft. For the sake of completeness, it is noted that with the above-described embodiment of the invention, it is immaterial whether the radial engine is arranged with the corresponding working connection with the output shaft of the radial engine and the crankshaft of the internal combustion engine within the crankcase or outside of the crankcase. Nevertheless, attaching of the radial engine as well as the element for creating a working connection between the radial engine and crankshaft of the internal combustion engine outside of the crankcase offers substantial advantages for maintenance as well as for mounting of a drive unit.
[0016] The radial engine preferably has at least one intake as well as one discharge valve, which can be regulated as needed with the aid of a cam valve control or corresponding disc valve control. The working medium vapor produced in a vapor production unit is conveyed into the working chamber of the cylinder of the radial engine via a valve mechanism embodied in this manner, so that the piston subsequently executes a linear movement. As soon as the piston has achieved the lower dead center, the discharge of the steam through the discharge valve begins. In a so-called drive mode of the radial engine, the discharge of the steam, the movement of the piston, as well as the discharge of the expanded steam through the discharge valve is repeated in a cyclical sequence, so that the output shaft of the radial engine is put into rotation.
[0017] With a specialized embodiment of the invention, as a supplement to the drive mode, it is provided that the radial engine also is convertible in a braking mode. For the design of the braking mode, essentially three alternative technical embodiments are contemplated.
[0018] In a first variation of the braking modes the steam is conducted through the cylinder of the radial engine in a reverse order compared to the drive mode, so that the vapor or the gas flows through the cylinder chambers of the individual cylinders in the reverse direction. In this connection, the valves operating in the drive mode as the discharge valve are used as intake valves and the valves operating in the drive mode as intake valves are used as discharge valves. In this manner, the output shaft of the radial engine is in a reverse rotation compared to the drive mode.
[0019] A second advantageous technical variation of the braking mode contemplates a variable control of the valves, so that the intake as well as the discharge valves are impinged with vapor or gas depending on the respective operating mode. In a very specialized embodiment in this connection, the opening and closing points or the respective opening and closing time periods are regulated depending on the respective operating mode. With the previously described valve control, therefore, it is possible to conduct vapor or gas into the cylinder chambers of the radial engine, such that the radial engine acts in a braking manner on the crankshaft driven by the supercharged internal combustion engine.
[0020] In a third variation of a radial engine according to the present invention, different cams are provided on a camshaft, specifically drive and brake cams, which actuate the valves directly or indirectly. In an advantageous embodiment, the cams are connected operatively with the valves via corresponding driver rods and rocker arms. In this connection, it is contemplated further that the previously mentioned to driver rods are embodied separately, in order to operate in a preferable manner the radial engine in the drive or braking mode.
[0021] With a radial engine, which has a braking mode as previously described, it is possible advantageously to slow down the crankshaft of a supercharged internal combustion engine.
[0022] The regulation of the vapor supply in the radial engine in order to activate the drive and/or the braking mode is done with the help of a central regulating and control unit. Preferably, such a control and regulating unit is integrated in the central vehicle computer or the internal combustion engine or engine control unit. A further specialized embodiment of the invention contemplates further corresponding sensors within the cooling circuit, in which a working medium is conveyed at least partially in a vaporous or gaseous phase. With the sensors, the pressure, the temperature and/or the vapor or gas content of the working medium is detectable and is transferable to the control and regulating unit.
[0023] A very particular design of the radial engine provided on a supercharged internal combustion engine according to the present invention contemplates an actuating mechanism for the intake and discharge valves, which is arranged on the outside of the radial engine and can be placed in a translatory movement with the different slide valves based on the rotation of the output shaft of the radial engine. This translatory movement is initiated, such that the intake and discharge valves of the radial engine are opened and closed as required.
[0024] A further advantageous embodiment of the radial engine contemplates that at least three cylinders with the corresponding intake and discharge valves are provided. In this connection, each cylinder preferably has an intake and discharge valve, as previously mentioned. Of course, it also is possible to provide each cylinder with a higher number of intake and/or discharge valves. In this connection, the designation intake or discharge valve relates to the flow direction of the vapor or gas in the drive mode.
[0025] In a further specialized design, the radial engine or at least components of the radial engine are made from a temperature-resistance material. In this connection, it is contemplated, especially with regard to the weight of the radial motor, to make the pistons or also other components, such as the valves, drive rods, rocker arms, connecting rod or even the crankshaft of the radial engine from an appropriately resistant plastic.
[0026] Next, the invention will be described in greater detail with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows a side view of the installation of an internal combustion engine with an additional radial engine, whose output shaft is coupled with a fan drive shaft arranged within the radial engine crankcase;
[0028] FIG. 2 shows a sectional view of a radial engine, whose output shaft is coupled with a fan drive shaft arranged within the radial engine crankcase;
[0029] FIG. 3 shows a side view of the installation of an internal combustion engine with an additional radial engine, whose output shaft is coupled with a shaft arranged outside of the fan drive shaft of the radial engine crankcase, which is operatively connected with the internal combustion engine; and
[0030] FIG. 4 shows a sectional view of a radial engine, whose output shaft is coupled with a shaft arranged outside of the radial engine crankcase, which is operatively connected with the internal combustion engine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] FIG. 1 shows in a side view the positioning of an internal combustion engine 1 with a radial engine 2 and a fan wheel 3 . Essential with regard to the represented solution is that the radial engine 2 is connected operatively via a power train with an output shaft of the internal combustion engine 1 , normally connected with the crankshaft of the internal combustion engine 1 . The radial engine 2 is supplied during operation of the internal combustion engine with a working medium vapor that is under pressure, which places the pistons arranged in the cylinders as well as the crankshaft 4 of the radial engine 2 connected with the pistons into motion and in this manner, the vapor is expanded. It is important that the crankshaft 4 of the radial engine 2 is connected operatively with the fan drive shaft 6 . In this connection, with the embodiment of a supercharged internal combustion engine 1 according to the present invention as shown in FIGS. 1 and 2 , the fan drive shaft 6 is disposed within the crankcase 11 of the radial engine, so that the axial distance between the fan drive shaft 6 and the crankshaft 4 of the radial engine 2 is minimized.
[0032] The fan wheel 3 is driven via a fan drive shaft 6 and a cooling air flow during operation of a motor vehicle, with which an air/water heat exchanger and/or the outer wall of the internal combustion engine is cooled. The fan drive shaft 6 is connected via gear wheel drive (see FIGS. 2 , position 8 ) with the crankshaft (not shown) of the internal combustion engine 1 . The mounting of the radial engine to the crankcase of the internal combustion engine 1 takes place with the aid of the radial engine flange 5 , whereby the radial engine flange 5 has corresponding recesses 7 , in which screws are insertable, which subsequently are screwed into the crankcase.
[0033] FIG. 2 shows a sectional representation of a radial engine 2 provided in addition to an internal combustion engine 1 . The crankshaft 4 of the radial engine 2 is connected directly via the fan drive shaft 6 with the crankshaft of the internal combustion engine. In this connection, a chain drive 9 creates the working connection between the crankshaft 4 of the radial engine 2 and the fan drive shaft 6 and the gear wheel drive 8 mentioned above creates a corresponding connection between the fan drive shaft 6 and the crankshaft of the internal combustion engine 1 . It is important with regard to the integration of an additional radial engine 2 in the power train of an internal combustion engine 1 as shown in FIG. 2 that the operation of the fan wheel 3 and the expander unit formed as a radial engine 2 can take place independently from one another. For this purpose, a coupling or clutch 10 is provided between the chain drive 9 and the crankshaft 4 of the radial engine 2 , through whose actuation, the :S crankshaft 4 of the radial engine 2 and the fan drive shaft 6 selectively are couplable or uncouplable. In this manner, in can be ensured in particular that instead of providing an additional vapor circuit with the radial engine 2 in each operating point of the internal combustion engine 1 , a reliable cooling of the drive unit takes place. In addition, also in dynamic operating phases of the internal combustion engine 1 , for example with continuous acceleration processes of the driven vehicle, the internal combustion engine 1 will not drive the radial engine 2 , although the additionally provided vapor circuit reacts relatively inactively with the radial engine 2 .
[0034] In connection with the embodiment shown in FIG. 2 , the clutch 10 is embodied as a so-called freewheel clutch (also overriding clutch). In this case, the freewheel has a clamping body, which ensures that the rotational movement of the fan drive shaft 6 and the crankshaft 4 of the radial engine are uncoupled as soon as the load ratio changes.
[0035] In addition, with the embodiment described in connection with FIG. 2 , it is provided that the radial engine is driven in the drive mode as well as in the braking mode. For this reason, the freewheel is embodied to be lockable, so that by reversing the valve, operation in the drive mode as well as in the braking mode can be possible
[0036] As already mentioned above, the output shaft 4 of the radial engine 2 connected via a chain drive 9 and the fan drive shaft 6 are disposed in the crankcase 11 of the radial engine 2 . The through drive of the fan drive wheel 6 to the fan wheel 3 takes place in this connection through the crankcase 11 in an area located between the two connecting rods 12 of the radial engine 2 in this manner, the axial distance between the fan drive shaft 6 and the crankshaft 4 of the radial engine 2 is maintained relatively small.
[0037] The intake as well as the discharge valves of the radial engine 2 are in the form of seat valves, which permits a high impermeability in the closed position. The actuation of the intake and discharge valves takes place with the aid of cam discs, which are provided on the crankshaft 4 of the radial engine 2 .
[0038] With the described design of a vapor-driven radial engine 2 , the air drive shaft 6 is operated with a higher rotary speed than the crankshaft of the internal combustion engine. Based on the high operating rotary speed of the fan drive shaft 6 , it is thereby possible to design the radial engine with a relatively small cubic capacity, since the crankshaft 4 of the radial engine 2 is operated in a rotary speed range that is at least similar to the operating rotary speed of the fan drive shaft 6 .
[0039] In addition, the arrangement of the radial engine directly behind the fan wheel 3 or between the fan wheel 3 and the internal combustion engine 2 offers a very space-saving arrangement possibility for the additional expander unit.
[0040] The supplying of the vapor from the vapor production unit (not shown) to the valves takes place via working medium lines 15 , which preferably are embodied as flexible tubes.
[0041] FIG. 3 shows first the installation of an additionally provided, vapor-driven radial engine 2 on an internal combustion engine 1 . In contrast to the embodiment described in connection with FIGS. 1 and 2 , the fan drive shaft 6 is disposed outside of the crankcase of the radial engine. The fan drive shaft 6 runs outside of the crankcase between two cylinders of the radial engine 2 to the fan wheel 3 and is connected operatively with the crankshaft of the internal combustion engine 1 on the side opposite the fan wheel via a gear wheel drive.
[0042] In FIG. 4 , a sectional representation of the installed radial engine shown in FIG. 3 is represented. In this case, the crankshaft 4 of the radial engine 2 is coupled via a spur gear step 13 and a corresponding flange connection with the crankshaft of the internal combustion engine 1 . Depending on the placement of the spur gears used for the spur gear step 13 the spur gear step 13 also can be embodied as a step-up spur gear. In addition, a freewheel, which equalizes the varying difference in rotary speed between the crankshaft 4 of the radial engine and the crankshaft of the internal combustion engine as a function of the load ratio is integrated directly in the spur gear step.
[0043] The intake and discharge valves of the cylinder of the radial engine 2 in turn are embodied as seat valves, which are actuated by cam discs arranged on the crankshaft 4 of the radial engine 2 . The embodiment shown in FIGS. 3 and 4 of a supercharged internal combustion engine with an additional radial engine offers the advantage that with the external fan drive shaft 6 , the radial engine 2 itself can be designed to be smaller. In addition, with this constructive design, the fan coupling 14 can be flange-mounted in the area of the fan wheel 3 between two cylinders of the radial engine 2 . In this manner, the fan wheel 3 is disposed directly in front of the radial engine 2 .
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A supercharged internal combustion engine of a motor vehicle has a cooling circuit, in which a working medium is recycled, which is conveyed at least partially in a vaporous or gaseous physical state. At least one expander unit is provided which is operatively connected with an output shaft of the internal combustion engine via a power train. Via a conversion of energy contained in the at least partially vaporous or gaseous working medium in the expander unit, an output shaft of the expander unit is moveable. The expander unit is embodied as a two-cycle reciprocating engine, which is operatively connected directly or indirectly via the power train with the output shaft of the internal combustion engine.
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This is a division, of application Ser. No. 07/211,627, filed June 27, 1988 now U.S. Pat. No. 4,835,045.
FIELD OF THE INVENTION
This invention relates to fiber glass boards. More particularly, it relates to a fiber glass board adapted for use as a form board capable of supporting liquid loads with minimal deflection.
BACKGROUND OF THE INVENTION
Fiber glass boards are sometimes used as form boards to temporarily support poured lightweight concrete or gypsum. When set, the resulting slab functions as a roofing surface or an interstitial limited-access maintenance floor between main floors in a building such as a hospital. Fiber glass boards are well suited for such use. They are lightweight, fire resistant, easy to handle and can be cut to size to fit around obstacles such as pipes, cables and columns. In addition, their resin bonded fibers are strong, lying generally in a direction perpendicular to the applied load and being capable of transferring and distributing the load uniformly. Fiber glass boards also absorb a portion of the water in the concrete or gypsum slurry and thus aid in the setting of this medium. Such boards typically have a thickness of one to two inches and a density of 8 pcf or more.
Although fiber glass boards of the type described have functioned adequately as a form board, it would be desirable to have available a fiber glass board that does not deflect as much under load. Alternatively, if the amount of deflection of current boards is acceptable, such a board could provide a similar function but at a lower density. A major requirement in the manufacture of such a board is to be able to employ the same basic process utilized in manufacturing the current product in order to continue to derive the economic benefits of the process. Any modification of the process required to produce a board having improved strength and stiffness must therefore be compatible with the basic process.
It is known that loads applied to a fiber glass board are distributed within the board from fiber to fiber through resin bonded junctions. For optimum strength, therefore, each fiber should be long enough to intercept and be bonded to two or more adjacent fibers. At a particular binder level, assuming that the binder is strong enough to accept and transfer the fiber load, coarse fibers are preferable to fine fibers because they are straighter and can individually carry more load than fine fibers. Fine fibers, being present in greater quantity than coarse fibers at a given density, produce a greater number of fiber junctions which require a greater quantity of resin.
It would stand to reason that the process used to produce fiber glass form boards should provide predominantly long fibers. Unfortunately, the most economical processes available produce a mixture of long and short fibers which are not conducive to improved load distribution. For example, in the rotary fiberization process, by which molten glass is attenuated through small orifices in the side of a rapidly spinning metal cylinder to form fibers which are sprayed with binder as they fall to a moving collection conveyor, the reduction in rotational speed of the falling mass of fibers can cause long fibers to become entangled in clusters or bundles. The regions between bundles tend to have relatively low fiber content, resulting in areas of weakness in the board. One way of avoiding such areas is to add additional fiber to the collection conveyor to pack these regions. Another way is to produce very short fibers by use of a different process or by use of an air knife on the rotary process. Adequate fiber-to-fiber contact of short fibers, however, requires high fiber loading on the collection conveyor and relatively high binder content. In addition to being less economical than boards containing long fibers, boards comprised of short fibers tend to irritate the skin more and are less flexible.
The most desirable way of producing fiber glass boards having the strength and stiffness required for use as a form board would be to somehow modify existing processes without having to add fiber or produce boards comprised mainly of short fibers.
SUMMARY OF THE INVENTION
This invention provides a method of manufacture which can be carried out on existing production lines with only minor modification. A moving blanket of relatively long, coarse glass fibers, the average diameters of which are primarily in the range of 3.5-8.0 microns, is subjected to forces causing relative movement between fibers of the moving blanket. This action takes place at a point in the process prior to the compressing of the blanket and the curing of the binder. The relative movement is sufficient to cause the fibers in the blanket to be predominantly oriented generally parallel to the major faces of the board in directions both parallel to and transversely of the direction of movement of the blanket. In addition, a fibrous mat is applied to at least one of the major faces of the blanket so as to be located on a major face of the finished board.
In a preferred embodiment the relative movement between fibers is caused by moving a downstream portion of the blanket at a faster rate than the upstream portion. This produces a drawing action on the blanket, which tends to reorient or realign the fibers to make them more parallel to the faces of the board. It has been found that a rate of movement of the downstream portion of the blanket in the range of 3% -10% faster than the rate of movement of the upstream portion will have the desired effect on blankets comprised of relatively long coarse glass fibers.
The faster downstream rate is caused by utilizing two conveyors, the first being a fiber collection conveyor and the second being the conveyor that carries the blanket through the curing oven. By moving the second conveyor at a faster rate than the first conveyor the drawing action of the blanket and relative movement of fibers is brought about.
The application of the fibrous mat to a face of the blanket increases the stiffness of the board. Preferably, a fiber glass mat is applied to a major face of the blanket at the upstream end of the second conveyor so that the mat will not be subjected to movement at different rates of speed. A board having greater stiffness can be produced by applying mats to both faces of the blanket. Binder or adhesive is applied to the interface of the mat and blanket and is cured in the oven to make the mats an integral part of the final board product.
Other features and aspects of the invention, as well as other benefits of the invention, will readily be ascertained from the more detailed description of the invention which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the process of producing the fiber glass board of the present invention;
FIG. 2 is an enlarged sectional view of the blanket as it is drawn into the downstream conveyors;
FIG. 3 is a pictorial view of the fiber glass board of the present invention;
FIG. 4 is an enlarged transverse sectional view of the board of FIG. 3 taken along line 4--4 of FIG. 3;
FIG. 5 is a view similar to that of FIG. 4, but showing a board with a mat on only one face; and
FIG. 6 is a transverse sectional view of the board of the present invention showing it supporting a layer of liquid cementitious material.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, glass fibers are shown being produced by a rotary process of fiberization. A stream of molten glass 10 from a melter or forehearth, not shown, flows into a rapidly rotating spinner 12 the side wall of which contains a great many small orifices. The centrifugal force of the rotating spinner extrudes the glass through the orifices in the form of fibers 14 which are sprayed with binder from spray nozzles 16 and which are forced downward by air jets 18. The fibers drop to a moving collection conveyor 20 which delivers the resulting blanket 22 to the nip of upper and lower conveyors 24 and 26, respectively, which are comprised of connected hot plates 28. The conveyors 24 and 26 move the blanket through an oven 30 where the binder is set. The spacing between the conveyors 24 and 26 determines the thickness of the resulting board 32, which upon exiting from the oven is transferred to a conveyor 34 located just downstream from the end of conveyors 24 and 26. The board 32 may be slit to the desired width by one or more slitters 36 upon exiting from the oven and may further be cut to length by guillotine cutter 38. The process described thus far is typical of existing processes for the continuous production of fiber glass boards and is well known in the art. The various elements of the process referred to accordingly may be of any suitable available type or design.
The invention provides for two modifications to be made to the board making process just described. According to one modification rolls 40 and 42 of fiber glass mat are mounted for rotation so that the mats 44 and 46, respectively, can be fed over suitable idler rolls 48 and 50 into the nip formed by the blanket 22 and the conveyors 24 and 26. Thus, mat 44 extends over idler roll 48 into the nip between the conveyor 24 and the upper surface of the blanket 22, and mat 46 extends over idler roll 50 into the nip between the conveyor 26 and the lower surface of the blanket. Binder is sprayed from suitable applicators 52 onto the interface between the mats 44 and 46 and the upper and lower surfaces of the blanket. It should be understood that although two mats and spray applicators are illustrated, both major faces of the blanket need not necessarily be faced with a mat. It may very well be that a single mat on one of the faces will be sufficient to provide the desired added stiffness to the product, in which case only a single mat would be applied.
According to the other modification to the basic board making process the conveyors 24 and 26 are run so that their linear speed is greater than the linear speed of the conveyor 20. Thus, as shown further in FIG. 2, when the blanket 22 enters the space between the conveyors 24 and 26 it is not only compressed in thickness but is also subjected to a drawing operation whereby the entangled fibers of the blanket are exposed to forces tending to separate them. The difference in rates of movement is not enough to tear the blanket but is sufficient to cause the bulk of the fibers to become aligned or oriented with the faces of the blanket.
A faced board 54 resulting from the described process is shown in FIGS. 3 and 4 to consist of a main body portion 56 faced with mats 44 and 46. If only a single facing mat is applied the board appears as in FIG. 5, wherein board 54' is shown with only the bottom face covered with a mat 46.
Referring to FIG. 6, the board 54 is typically used as a form board by supporting its side edges on suitable support members such as beams 58. Truss bars and reinforcing screen may also be employed in a manner well known in the art, but have not been shown for the sake of clarity. Light weight concrete or gypsum 60 is then poured over the upper surface of the board and is supported by the board as it cures.
Although the results of these process changes are apparent, as determined in tests run on the product, the manner in which the process changes function is not fully understood. With respect to the facing operation, it is believed that the mat on the board face which serves as the bottom of the board in use reinforces the board in the area of highest tensile loading. It is also believed that the mat on the face which serves as the top of the board in use inhibits fiber separation and buckling due to lateral compression. For the mats to be effective in providing stiffness to the major faces of the board the additional binder or adhesive added to the interface between the mats and the blanket should be in the range of 0.25%-1.0% of the weight of the finished board.
With respect to the drawing operation which causes relative movement of the fibers within the blanket, the fibers tend to be oriented into planes parallel to the board faces, which is believed to minimize the occurrence of low density regions between fiber bundles. The increase in the rate at which the blanket is drawn into the curing oven may vary but should be in the range of 3%-10% greater than the rate of movement of the fiber collection conveyor. The preferred increase should not be less than that which produces fiber orientation parallel with the board faces, as observed visually in the board edges. Any less increase than this produces a more flexible bonded fibrous mass that puts the burden of rigidity on the fibrous mats. A drawing action which is too severe, on the other hand, tends to align the fibers in the direction of processing, which substantially reduces the strength of the board in the cross-processing direction and may reduce the width of the bonded blank from which the boards are cut.
Tests were conducted by supporting one-inch thick boards 5-7 feet in length and 24 or 32 inches in width on a one-inch ledge along their perimeter, and pouring a liquid load of gypsum-cement, gypsum or water on their upper surface. The measured deflection corroborated calculations based on the theory that board deflection, given a standard processing method, board direction and size, is inversely proportional to the product of the modulus of elasticity (E) and thickness cubed (t3). Thus according to the theory any increase in Et3 in all board directions over that of a standard board represents an improvement in board performance under load. Testing indicates that between thicknesses of 0.5 and 2.25 inches the product of Et3 in a given board direction is constant for a particular weight per unit area of board. It also indicates that imposing a slight oven draw on the uncured fiber in the manner described above yields a higher value of Et3 than conveying the fiber blanket into the oven at the same speed as the collection conveyor. Application of a fibrous mat, preferably a chopped fiber glass strand mat, on the bottom surface of the board in use increases board stiffness. The combination of the two is especially effective as the thickness of the board is increased. Still improved performance was noted when mats were applied to both major faces of the board.
The average diameter of the glass fibers in the board of the invention is in the range of 3.5-8.0 microns, the binder content is at least 7% by weight of the board, the density of the board is at least 6.5 pcf and the thickness of the board is in the range of 0.5-2.25 inches. The tear strength of the fibrous mat, whether used on only one face or both faces of the board, should be at least 60 pounds per 3 inches of width of the mat. Although the invention is not limited to the use of any particular type of binder or adhesive, standard urea phenolic binder was found to produce good results.
Obviously, changes to the various parameters of the board and mat may be made within the ranges indicated, so long as the basic steps of drawing the blanket in the manner explained and applying a mat to at least one of the faces of the board are carried out.
It should now be understood that the invention is not necessarily limited to all the specific details of the preferred embodiment but that changes to certain features of the preferred embodiment which do not affect the overall basic function and concept of the invention may be made by those skilled in the art without departing from the spirit and scope of the invention, as defined in the appended claims.
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A fiber glass board useful as a form board for lightweight cement and the like is strengthened by providing for the fibers to be predominantly oriented generally parallel to the major faces of the board in directions both parallel to and transversely of the dimension of the board corresponding to the process direction. A downstream conveyor which moves the blanket of fibers through the curing oven moves faster than the collection conveyor, thereby producing a drawing effect on the blanket and causing the desired fiber alignment. A glass fiber mat is applied to one or both major faces of the blanket prior to movement through the oven to provide additional stiffness to the board.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a laser beam transmitting apparatus for use in construction and civil engineering industries, and particularly to a laser beam transmitting apparatus for use for levelling using a laser beam and marking work along a horizontal plane or a vertical plane.
2. Related Background Art
There is known a laser beam level instrument as disclosed, for example, in U.S. Pat. No. 4,221,483. This laser beam level instrument converts light from a light source such as an He-Ne gas laser or a laser diode into a substantially collimated beam by an optical system having a collimator lens, and causes the beam to emerge in a horizontal direction by way of a rotatable mirror, thereby supplying a beam of light swept on a horizontal plane.
This apparatus according to the prior art will hereinafter be described with reference to FIG. 1 of the accompanying drawings.
A cylindrical inner housing 103 holding a collimator lens 105 is suspended from a beam transmitting unit 101 by means of three wires 102. The inner housing 103 is contained in a cylindrical fixed housing 104 fixed to the beam transmitting unit 101, and the outer peripheral surface of the inner housing 103 is spaced apart by a minute distance d from the inner peripheral surface of the fixed housing 104 and has the function of automatically correcting inclination within this range.
A light source 111 emitting a beam of light L is disposed substantially at the focal position of the collimator lens 105. A cylindrical rotatable member 114 is disposed below the collimator lens 105, and the rotatable member 114 is rotatably mounted on the beam transmitting unit 101 through a bearing 116. A pair of mirrors 115 for reflecting the beam of light L from the collimator lens 105 at a right angle are fixed to the interior of the rotatable member 114. The rotatable member 114 is rotated by a motor 110 through a transmission belt 118. The beam of light L reflected by the pair of mirrors 115 is caused to emerge outwardly through windows 114a and 101a and is swept in the direction of 360° in a horizontal plane.
The beam transmitting unit 101 is placed on a levelling unit 130. The levelling unit 130 comprises an upper plate 131 fixed to the beam transmitting unit 101, and a lower plate 132 mounted on the upper plate 131 through three levelling screws 133. The lower plate 132 is connected to a tripod. A bubble tube 134 is fixed to the upper plate 131.
When installing the apparatus through the tripod, the operator turns the levelling screws 133 while watching the bubble tube 134 and effects rough levelling work. By this work, the operator can correct inclination up to the order of ±10' (minutes). When the manual levelling work by the operator is done, precise level accuracy within ±10" (seconds) is achieved by the above-described automatic inclination correction work of the inner housing 103.
However, the range within which the precise levelling by the automatic inclination correction is possible is as small as several tens of minutes and therefore, the levelling work of turning the levelling screws 133 while watching the positions of bubbles in the bubble tube 134 has required skill and has been practically cumbersome to the operator, and has taken much time until levelling is done up to an angle of several tens of minutes. Accordingly, when the laser beam transmitting apparatus is frequently moved for use, the burden of the operator has become greater, thus resulting in the aggravation of work efficiency.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a laser beam transmitting apparatus which can make the levelling work unnecessary to thereby mitigate the burden of an operator and improve work efficiency.
The laser beam transmitting apparatus of the present invention is provided with a base, a beam transmitter for supplying a beam of light, a housing for holding the beam transmitter, and a levelling mechanism provided between the housing and the base, the housing being oscillatably supported on the base and the center of oscillatory movement thereof being positioned above the centroid of the housing.
The laser beam transmitting apparatus of the present invention is provided with a precise levelling mechanism between the beam transmitter and the housing, whereby it can accomplish double levelling combined with the rough levelling function by the levelling mechanism between the housing and the base.
In a rough levelling mechanism according to an embodiment of the present invention, a concave spherical inner wall surface for receiving the housing is provided on the base, and a bearing device is provided between the housing and the spherical inner wall surface. The centroid of the housing is positioned below the center of curvature of the spherical inner wall surface. A vibration attenuator is provided between the housing and the base. Gimbal structure may be used as the rough levelling mechanism.
Further, according to an embodiment of the present invention, provision is made of an outer case having an upper surface portion, an outer housing oscillatably suspended from the upper surface portion of the outer case, and an inner housing holding the beam transmitter and oscillatably suspended from the outer housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-sectional view of a laser beam transmitting apparatus according to the prior art.
FIG. 2 is a vertical cross-sectional view of a laser beam transmitting apparatus according to a first embodiment of the present invention.
FIG. 3 is a vertical cross-sectional view showing a state in which the apparatus of FIG. 2 is inclined.
FIG. 4 is a vertical cross-sectional view of a laser beam transmitting apparatus according to a second embodiment of the present invention.
FIG. 5 is a vertical cross-sectional view showing a state in which the apparatus of FIG. 4 is inclined.
FIG. 6 is a vertical cross-sectional view of a laser beam transmitting apparatus according to a third embodiment of the present invention.
FIG. 7 is a plan view showing the structure of a magnet.
FIG. 8 is a cross-sectional view taken along the line 8--8 of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the present invention will hereinafter be described with reference to FIGS. 2 and 3. An outer housing 1 is oscillatably suspended in an outer case 6 through a rough levelling mechanism. An arm 7 is integrally provided on the upper end portion of the outer housing 1, and a sphere portion 8 is integrally provided on the tip end portion of the arm 7. A spherical non-magnetic metal plate 9 (e.g. a copper plate) is fixed to the lower end portion of the outer housing 1 by means of a screw 37.
The upper surface portion of the outer case 6 constitutes a base for supporting the outer housing 1 and is formed with a spherical bearing 6a for rotatably supporting the sphere portion 8. Also, the upper surface portion of the outer case 6 has mounted thereon a lid 12 covering the sphere portion 8. The lower portion of the outer case 6 is formed with a window 6b for transmitting a laser beam outwardly therethrough, and protective glass 36 is mounted in the window 6b. An internally threaded portion 13 for mounting the outer case 6 on a tripod, not shown, and three contact portions 30 bearing against the reference surface of the tripod are integrally provided on the lower surface portion of the outer case 6.
A battery box 33 containing therein a battery 32 for supplying electric power to a laser diode 11 and a circuit base plate 40 fixed to the outer housing 1 is provided in the upper portion of the outer case 6. Spherical magnets 34 and 35 are disposed in the lower portion of the outer case 6. The magnet 34 is located above the non-magnetic metal plate 9, and the magnet 35 differing in polarity from the magnet 34 is located below the non-magnetic metal plate 9. The centers of curvature of the spherical non-magnetic plate 9 and the spherical magnets 34, 35 are coincident with the center of oscillatory movement of the outer housing 1 (the center 0 of the sphere portion 8). The non-magnetic metal plate 9 and the magnets 34, 35 together constitute a vibration attenuating mechanism of the magnetic type.
A cylindrical inner housing 3 holding a collimator lens 5 is suspended in the outer housing 1 by means of three wires 2 to thereby constitute a precise levelling mechanism similar to that disclosed in U.S. Pat. No. 4,221,483. The inner housing 3 is contained in a cylindrical fixed housing 4 fixed to the outer housing 1 and the outer peripheral surface of the inner housing 3 is spaced apart by a minute distance d from the inner peripheral surface of the fixed housing 4. The fixed housing 4 and the inner housing 3 contained in the fixed housing 4 together constitute a vibration attenuating mechanism of the air damper type.
The laser diode 11 emitting a beam of light L is disposed substantially at the focal position of the collimator lens 5. A cylindrical rotatable member 14 is disposed below the collimator lens 5 and the rotatable member 14 is rotatably mounted in the outer housing 1 through a bearing 16. A pair of mirrors 15 for reflecting the beam of light L from the collimator lens 5 at a light angle are fixed to the interior of the rotatable member 14. The rotatable member 14 is rotatable by a motor 10 through a transmission belt, not shown.
The operation of the laser beam transmitting apparatus of this embodiment will now be described. An operator first installs the laser beam transmitting apparatus at a predetermined location through the tripod, and sets it roughly (within ±10°) while watching a bubble tube 18. When as shown in FIG. 3, the mounting surface 19 of the laser beam transmitting apparatus is inclined by θ=10° with respect to a horizontal plane H, the outer housing 1 oscillatably moves about the center 0 of the sphere portion 8 in the direction of gravity. By the action of this rough levelling mechanism, the angle of inclination of about 10° is automatically corrected within 8'. The vibration of the outer housing 1 is attenuated by an eddy current generated when the non-magnetic metal plate 9 crosses the magnetic field formed between the magnets 34 and 35.
As a result of the correction by the rough levelling mechanism, the outer housing 1 leaves an inclination within 8' with respect to the direction of gravity, but this inclination is further corrected by the precise levelling mechanism. That is, the three wires suspending the inner housing 3 always try to maintain verticality and therefore, they are parallel-moved in a substantially horizontal direction by the outer housing 1 being inclined. Thus, the collimator lens 5 is always vibrated back to just beneath the laser diode 11 in a vertical direction, and irrespective of the inclination of the outer housing 1, the laser beam L is always directed vertically downwardly. As a result of this precise levelling, correction accuracy within ±10" is obtained.
The slight spacing d between the outer peripheral surface of the inner housing 3 and the inner peripheral surface of the fixed housing 4 is varied by the relative vibration between the outer housing 1 and the inner housing 3. The relative vibration is attenuated by the flow resistance of air produced at that time.
The beam of light L from the laser diode 11 is collimated by the collimator lens 5 and is reflected in a horizontal direction by the pair of mirrors 15. By the rotation of the rotatable member 14 holding the mirrors 15, the beam of light L is caused to emerge outwardly through the windows 4a, 1a and 6b, and is swept in the direction of 360° in a horizontal plane.
A second embodiment of the present invention will now be described with reference to FIGS. 4 and 5. In this embodiment, portions common to those in the aforedescribed first embodiment are given the same reference numerals and need not be described.
In the rough levelling mechanism, in the second embodiment, a hollow arm 57 is integrally provided on the upper end portion of an outer housing 51, a semispherical body 58 is threadably coupled to the tip end portion of the arm 57, and a battery box 53 is integrally provided on the semispherical body 58. Also, a spherical bearing 56a is formed on the upper portion of an outer case 56. The spherical surface 58a of the semispherical body 58 is supported through at least three balls 50 rollably provided in the inner wall of the spherical bearing 56a.
Also, in the vibration attenuating mechanism, in the second embodiment, provision is made of a vibration attenuating mechanism of the magnetic type having an annular non-magnetic metal plate 41 fixed to the lower portion of the inner housing 3, and magnets 42 and 43 disposed above and below it and differing in polarity from each other.
Again by this second embodiment, automatic rough levelling up to correction accuracy 8' and automatic precise levelling within ±10" can be obtained.
In the above-described first and second embodiments, the relation between the collimator lens and the laser diode may be reversed and the light source may be suspended by means of wires. Alternatively, it is also possible to construct the optical element provided between the light source and the collimator lens so as to be suspended. Also, the beam of light emitted from the laser beam transmitting apparatus be not necessarily swept in a horizontal plane. That is, the present invention is also applicable to a laser beam transmitting apparatus simply emitting a beam of light in a predetermined direction.
So, a third embodiment in which the present invention is applied to such a laser beam transmitting apparatus will now be described with reference to FIG. 6. FIG. 6 shows an embodiment of a laser beam transmitting apparatus emitting a beam of light in a vertical direction, and this embodiment is provided with an outer case 61 and a hollow housing 62 suspended in the outer case 61.
The outer case 61 has a barrel-shaped base 63, a barrel-shaped upper case 64 placed on the base 63, and a cap 65 threadably engaged with the upper end of the upper case 64. A magnet 66 for fixing the apparatus to the ceiling is provided on the upper surface of the cap 65, and a spherical-surfaced magnet 67 is provided on the lower surface of the cap 65. As shown in FIGS. 7 and 8, the magnet 67 has magnetic poles of different polarities alternately magnetized in the radial direction thereof. A magnet 82 for fixing the outer case 61 to an iron post 68 is provided on the outer peripheral surface of the base 63. A sliding bearing 69 for oscillatably supporting the housing 62 is provided on the inner peripheral surface of the upper portion of the base 63 to constitute a rough levelling mechanism. This bearing 69 may be replaced by gimbal structure. An electrically conductive resilient ring 70 is provided below the sliding bearing 69.
A lid 71 formed of a non-magnetic metal is mounted on the upper end of the housing 62, and the upper surface of the lid 71 is formed into a spherical surface. The centers of curvature of the spherical surface of the lid 71 and the spherical surface of the magnet 67 coincide with the center of oscillatory movement 0 of the housing 62, and they always keep a constant spacing d. A cylindrical inner housing 73 holding a collimator lens 72 is suspended from the lower portion of the housing 62 by means of three wires 74 to constitute a precise levelling mechanism similar to that in the aforedescribed embodiment. The inner housing 73 is contained in a cylindrical fixed housing 75 fixed to the lower portion of the housing 62, and an air damper is formed between the two housings. A laser diode 76 emitting a beam of visible light L is disposed substantially at the focal position of the collimator lens 72.
The interior of the housing 62 is divided into two containing chambers 62a and 62b, and a control circuit 77 for driving the light source is disposed in the containing chamber 62a, and a battery 83 is contained in the containing chamber 62b. A pair of annular electrical contacts 78 and 79 insulated from each other are disposed on the outer peripheral surface of the housing 62. The resilient ring 70 and the electrical contacts 78, 79 contact with each other when the housing 62 is inclined by a predetermined angle C or greater from a reference position, whereby electrical conduction takes place between the electrical contacts 78 and 79. The control circuit 77 detects this conduction and turns on and off or turns off the laser diode 76, thereby informing that the laser beam transmitting apparatus is installed in an unsuitable posture.
The apparatus of this third embodiment is used to install, for example, the iron post 68 exactly vertically. That is, the apparatus can be fixed to the iron post 68 stood on a floor surface 84 and the beam of light can be transmitted toward the floor surface, and the inclination of the iron post can be adjusted so that the distance from the lower end of the iron post 68 to the position of the light spot on the floor surface may coincide with a reference distance.
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This invention provides a laser beam transmitting apparatus which can make the levelling work unnecessary to thereby mitigate the burden of an operator and improve work efficiency. The apparatus is provided with a base, a beam transmitter for supplying a beam of light, a housing, for holding the beam transmitter, and a levelling mechanism provided between the housing and the base, the housing being oscillatably supported on the base, and the center of oscillatory movement thereof lying above the centroid of the housing. Thus, there is achieved double bearing combined with a precise levelling mechanism, provided between the beam transmitter and the housing.
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BACKGROUND OF THE INVENTION
This invention relates to internal combustion engines. More particularly, this invention relates to engine lubricant level sensors, such as low oil sensors.
Several types of lubricant level sensors are known. In a float-type sensor, a contact is attached to a float which rides on the surface of the lubricant reservoir or crankcase. When the lubricant level sufficiently drops, electrical contact is made between the contact on the float and ground, so that ignition pulses are shorted to ground and the engine is stopped.
There are several problems with such float-type low oil sensors. For example, these sensors may give false readings when a splash-type lubrication system is used in a small internal combustion engine. In a splash-type lubrication system, a slinger gear or paddle splashes lubricant throughout the engine housing while the engine is running. Shortly after the engine has started, much of the lubricating fluid has been splashed throughout the engine housing, so that the actual level in the lubricant reservoir is very low, even though the overall engine lubrication level is satisfactory. As a result, the float switch may be erroneously closed even though the amount of lubricant in the engine is sufficient. To avoid such false readings, it is known to use a timer circuit to delay the indication of a low oil condition for a preset period of time after engine starting. After the time delay period has passed, the lubricant level sensor operates in a normal manner.
Another problem with low lubricant sensors is that the low lubricant level switch tends to oscillate or bounce when the lubricant level in the crankcase is fluctuating. Such fluctuations may occur during normal engine operation, particularly in splash-type lubrication systems, since the amount of lubricant actually in the crankcase is not necessarily a correct indication of the amount of lubricant in the engine. The switch may also oscillate or bounce if the engine is being tilted, which occurs, for example, when the engine is applied to a lawnmower that is moving over an uneven terrain. As a result, the engine may misfire since some of ignition pulses are being grounded and others are not. To overcome this problem, it is known to impose a delay period after the low lubricant level switch closes before an indication is provided of a low lubricant level condition. For example, see U.S. Pat. No. 3,886,517 issued May 27, 1995 to O. H. Taken et al. and U.S. Pat. No. 4,838,082 issued Jun. 13, 1989 to McCoy et al.
A significant disadvantage of these time delay approaches is that they typically require relatively complicated and expensive circuitry, which may not be feasible for a lower cost internal combustion engine.
SUMMARY OF THE INVENTION
A control system is disclosed for use with an engine lubrication level sensor, such as a float-type sensor. The control system is particularly suitable for use with small internal combustion engines having a splash-type lubrication system.
In a preferred embodiment, the control system includes a means for sensing that the engine has a low lubricant level during engine starting, the sensing means including a switch, preferably a float-type switch, of a low lubricant level sensor. The control system also includes means for preventing the engine from starting if the sensing means senses a low lubricant level during engine starting, the preventing means including a circuit having a first semiconductor switch, such as a transistor, a thyristor, silicon controlled rectifier (SCR) or a triac.
A unique feature of the control system is that the control system includes a means for disabling the start preventing means after the engine has started during substantially all of the remaining time that the engine is operated before the engine is shut off. The disable means preferably includes a capacitor that is charged by an ignition winding, and a second semiconductor switch having a control input that is connected in circuit with the capacitor. During normal engine operation, the charged capacitor keeps the second semiconductor switch ON. The second semiconductor switch is connected in circuit to the control input of the first semiconductor switch, so that when the second semiconductor switch is ON, there is insufficient control voltage to switch ON the first semiconductor switch. As a result, the low oil sensor is disabled after the engine has started during the remaining period that the engine is operating.
The control system also includes a means for resetting the disabling means after the engine has been shut off for any reason, so that the engine can be successfully restarted, if, for example, additional lubricant has been added to the engine crankcase after shutoff. A preferred embodiment also includes an indicator that outputs either a visual or an audible signal to tell the operator that the engine cannot be started due to an inadequate level of lubricant during engine starting.
It is a feature and advantage of the present invention to sense the lubricant level in an engine during the first several revolutions of the engine at starting, and thereafter preventing the engine from being shut down during normal engine operation due to a low lubricant level.
It is yet another feature and advantage of the present invention to provide an inexpensive control system that may be used with an off-the-shelf engine lubricant level sensor.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The control system according to the present invention is particularly suitable for low cost, small internal combustion engines having a relatively small fuel tank, where the engine can only be run for a few hours before it is shut down for refueling, or where the engine is stopped periodically for any other reason. In each such case where the control system is used, it is assumed that the engine will run out of fuel before it runs out of lubricating fluid, since the lubricating fluid level was adequate for the engine to start in the first instance. The control system according to the present invention may also be used to prevent damage when the operator attempts to start a brand new engine without first adding lubricating fluid.
The control system according to the present invention is much simpler, less expensive and more reliable than any prior art control system which incorporates starting circuitry as well as a time delay, running-reset and latching features to compensate for the switch bounce and fluctuating lubricant fluid levels that occur in engines, particularly when a heavy engine load is applied.
The control system of the present invention is preferably used with a float-type lubricant level switch, and senses switch position during the first several flywheel rotations during engine starting. If an adequate lubricant level is present, the engine will start and the engine start prevention circuitry will be quickly disabled. If the engine lubricant level is low at the time of engine starting, the engine's ignition coil primary winding voltage will be shunted to ground and the engine will not start.
If the lubricating fluid level is sufficient at engine starting, the engine will start and the start prevention circuit, which shuts down the engine during engine starting if a low lubricant level is sensed, is disabled. If the engine then runs out of fuel, the engine shuts off and the sensing circuitry of the start prevention circuit is reset. The level of the lubricating fluid is rechecked during engine starting, and the engine will not start if the lubricating fluid level is now below a predetermined level.
FIG. 1 is a schematic diagram of a preferred embodiment of the invention. In FIG. 1, switch S1 is preferably a switch in a low lubricant level sensor, preferably of the float-type. One suitable low level sensor is made by Mitsubishi of Nagoya, Japan, Part No. KF09021AA. The Mitsubishi float-type sensor is described in Japanese Patent Application No. 7-317525 published Dec. 5, 1995. As with typical float-type low oil sensors, the Mitsubishi sensor includes a float having a metal contact attached thereto, to which is attached a wire connected in circuit to an engine's ignition primary winding. When the level of a lubricating fluid is below an acceptable level, the float contact becomes electrically connected to ground, thereby shunting the ignition primary winding signals and stopping the engine.
In the present invention and referring again to FIG. 1, when switch S1 is closed during the initial engine starting, SCR S2 is switched ON by a signal from ignition primary winding W1 through closed switch S1, diode D1, resistor R2 and diode D2. Resistor R7 and capacitor C2 act as a filter to prevent transient voltages from switching ON SCR S2.
If the engine begins running, capacitor C1 is charged by the signal from winding W1 through diode D3 and resistor R3. The capacitor voltage turns ON semiconductor switch S3 through a resistor R4. Switch S3 is preferably a darlington transistor, although other types of switches may be used.
When switch S3 is turned ON while the engine is running, the voltage otherwise present at the gate of SCR S2 is shunted to ground through switch S3, thereby preventing the SCR gate from reaching a sufficient voltage to turn ON SCR S2. As a result, the engine is not shut down due to a low lubricant fluid condition, even if switch S1 is closed.
On the other hand, if switch S1 is closed during the initial engine starting, indicating that a low lubricant level condition exists, switch S3 remains OFF since capacitor C1 is not fully charged, and SCR switch S2 is gated ON. As a result, ignition pulses from primary winding W1 are shunted to ground and the engine will not start.
Resistor R8 may be used to select the engine speed, between an engine starting speed and an engine running speed, at which switch S3 is turned ON. As a result, resistor R8 may be used to select the engine speed above which the engine will not be shut down due to a low lubricant level. Reducing the value of resistor R8 increases the engine speed at which the disable means disables the start preventing circuit. Reducing the value of resistor R8 tends to reduce the effects of the bouncing of switch S1.
When the engine fails to start due to a low lubricant level, a light emitting diode (LED) D4 emits a visual indication that the engine is failing to start due to a low lubricant level condition. Resistor R5 protects diode D4 by limiting the current therethrough. Resistor R6 is a low value resistor to generate a voltage across the diode.
Although a LED is disclosed as providing a visual indication that the engine will not start due to a low lubricant level, it is apparent that another type of light could be used, or that an audible alarm or buzzer may be used instead.
Although switch S2 is disclosed as being a silicon controlled rectifier, it is apparent that other types of thyristors, such as a triac, could be used.
After the engine has been shut down for any reason, the control system resets since the voltage from capacitor C1 is no longer present to keep switch S3 gated ON. During a subsequent restart attempt of the engine, engine starting will be prevented if low lubricant level switch S1 is closed.
While a preferred embodiment of the present invention has been shown and described, alternate embodiments will be apparent to those skilled in the art and are within the intended scope of the present invention. Therefore, the invention has to be limited only by the following claims.
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A control system for an engine low oil sensor prevents engine starting if the oil level is below a predetermined level, but thereafter enables the engine to run uninterrupted even if the oil level becomes low during engine operation. After the engine is shut off for any reason, the control system resets so that the low oil switch is operable during the next attempted restart of the engine. The control system also includes a visual or audible indicator that indicates when engine starting is prevented due to a low oil condition.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to a bag that can be unfolded into a resting device, and more generally relates to a bag having a first position and a second position, wherein the first position is in the form of a bag with storage compartments and the second position is in an open position allowing the user to rest upon the device.
BACKGROUND OF THE INVENTION
[0002] Unfortunately, there are many tragedies around the world. The victims of these tragedies have undergone a life changing experience and face many hardships. These victims are typically without the basic needs such as food, potable water, and housing. The victims may have to spend countless days and nights in shelters and without housing. These victims need as quickly as can be provided some semblance of normalcy and comfort, during these trying times. The present invention may be given to these victims so that they can carry what personal belongings they have and to provide a comfortable place to rest by providing a substantial barrier or separation between the user and the ground or surface the present invention is placed.
[0003] Luckily, there are brave and driven individuals that are willing to confront these tragedies and aid the individual victims that have been affected by these tragedies. Very often, these relief workers place their life and health on the line to aid others in a time of need and will find relief in the present invention. This invention may also be utilized by these workers who need a place to rest comfortably during the brief time period they may have to rest. The present invention may also be utilized by relief workers who need a place to rest comfortably. The present invention provides a bag that may carry relief supplies and gear, but also converts into an inflatable and/or expandable device, such as a mattress or the like, for allowing the relief worker a safe and comfortable place to rest.
[0004] The present device may also serve a military function. The device may be utilized by soldiers that need a safe and comfortable place to rest, while also carrying supplies or military wares.
[0005] The present device can also be used by others, such as a traveler, a child or the like that needs to have a readily available and comfortable place to rest. For example, the weary airline traveler that experiences a longer than expected layover at the airport or even a flight cancellation, can utilize the present device to both carry items and provide a readily available and deployable device providing a comfortable place to rest.
BRIEF SUMMARY OF THE INVENTION
[0006] According to an embodiment of the present invention, the present invention is a foldable bag that includes a rear wall part having a front side, a back side, and an interior side; a front wall part having a front side, a back side, and an interior side; a middle part having a front side, a back side, and an interior side. The front wall part is engaged to the middle part along a fold line, and the rear wall part is engaged to the middle part along a fold line. The foldable bag is moveable between a first position in which the front side of the front wall part is adjacent the front side of the middle part, the back side of the middle part is adjacent the front side of the rear wall part; and a second position in which the back side of the front wall part, the back side of the middle part, and the back side of the rear wall part are in a substantially planar relationship with the front side of the front wall part, the front side of the middle part, and the front side of the rear wall part.
[0007] According to another embodiment of the present invention, the foldable bag includes a cavity for receiving an inflatable and/or expandable device.
[0008] According to yet another embodiment of the present invention, the foldable bag includes a portion of the rear wall part that overlaps the front wall part while in the first position.
[0009] According to yet another embodiment of the present invention, the foldable bag wherein the rear wall part includes a side wall, and the middle part includes a side wall, wherein the side wall of the rear wall part and the side wall of the middle part include an engagement means for engaging the side wall of the rear wall part to the side wall of the middle part.
[0010] According to yet another embodiment of the present invention, the foldable bag wherein the front wall part includes a side wall and the middle part includes a side wall, wherein the side wall of the front wall part and the side wall of the middle part includes an engagement means for engaging the side wall of the front wall part to the side wall of the middle part.
[0011] According to yet another embodiment of the present invention, the foldable bag may include other a secondary bag or secondary bags that are engaged to the primary bag, and particularly the rear wall part.
[0012] According to yet another embodiment of the present invention, the foldable bag includes a raised portion on the interior side of the rear wall part.
[0013] According to yet another embodiment of the present invention, the foldable bag includes an interior side of the front wall part, an interior side of the middle part, and an interior side of the rear wall part is substantially bisected by a center fold line.
[0014] According to yet another embodiment of the present invention, the foldable bag includes a rear wall part having a front side, a back side, an interior side, and a side wall part; a front wall part having a front side, a back side, an interior side, and a side wall part; a first middle part having a front side, a back side, an interior side, and a side wall part; a second middle part having a front side, a back side, an interior side, and a side wall part, and a cavity for receiving an inflatable and/or expandable device. The front wall part is engaged to the first middle part along a first fold line, the first middle part is engaged to the second middle part along a second fold line, and the rear wall part is engaged to the second middle part along the third fold line. The foldable bag is moveable between a first position in which the front side of the front wall part is adjacent the front side of the first middle part, the back side of the first middle part is adjacent the back side of the second middle part, and the front side of the second middle part is adjacent the front side of the rear wall part, and the side wall part of the front wall is selectively secured to the side wall part of the first middle part forming a cavity therein, and the side wall part of the second middle part is selectively secured to the side wall part of the rear wall part forming a cavity therein. The foldable bag has a second position in which the back side of the front wall part, the back side of the first middle part, the back side of the second middle part, and the back side of the rear wall part are in a substantially planar relationship with the front side of the front wall part, the front side of the first middle part, the front side of the second middle part, and the front side of the rear wall part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention is illustrated and described herein with reference to the various drawings, in which like reference numbers denote like method steps and/or system components, respectively, and in which:
[0016] FIG. 1 is a perspective view of the foldable bag in the first position;
[0017] FIG. 2 is a perspective view of the foldable bag in an alternative arrangement;
[0018] FIG. 3 is a perspective view of the rear of the foldable bag illustrating straps that may be included on the foldable bag;
[0019] FIG. 4 is a perspective view of the foldable bag illustrating the rear wall part removed from the over top position of the front wall part;
[0020] FIG. 5 is a top perspective view of the foldable bag illustrating the rear wall part removed from the over top position of the front wall part exposing the storage cavities of the foldable bag;
[0021] FIG. 6 is an illustrative view of a user separating an engagement means;
[0022] FIG. 7 is a perspective view of the front wall part separated from the first middle part;
[0023] FIG. 8 is a perspective view of the rear wall part separated from the second middle part;
[0024] FIG. 9 is an illustrative view of a user transitioning the foldable bag from a first position to a second position;
[0025] FIG. 10 is a perspective view of the foldable bag transitioning from a first position to a second position;
[0026] FIG. 11 is a perspective view of the top portions of the foldable bag;
[0027] FIG. 12 is a partial perspective view of the storage pockets folded over the rear wall part;
[0028] FIG. 13 is a partial perspective view of the storage pockets folded outward from the rear wall part;
[0029] FIG. 14 is an illustrative view of a user accessing the inflatable device disposed within the cavity;
[0030] FIG. 15 is a perspective view of the foldable bag in the second position;
[0031] FIG. 16 is a side perspective view of the foldable bag in the second position with the inflatable device inflated;
[0032] FIG. 17 is an illustrative view of a user utilizing the foldable bag;
[0033] FIG. 18 is an illustrative view of a suggested arrangement of the foldable bag.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Referring now specifically to the drawings, a foldable bag device is illustrated in FIGS. 1-18 and is shown generally at reference numeral 10 . The device 10 comprises a rear wall part 12 , a front wall part 14 , and a middle part. The middle part may comprise a first middle part 16 and a second middle part 18 . The rear wall part 12 contains a front side 20 , a back side 22 , a first side wall part 24 , a second side wall part 26 , and an end wall part 28 . The front wall part 14 contains a front side 30 , a back side 32 , a first side wall part 34 , a second side wall part 36 , and a top wall part 38 . The first middle part 16 contains a front side 40 , a back side 42 , a first side wall part 44 , and a second side wall part 46 . The second middle part 18 contains a front side 48 , a back side 50 , a first side wall part 52 , and a second side wall part 54 .
[0035] The rear wall part 12 , front wall part 14 , first middle part 16 , and second middle part 18 collectively form a foldable bag 10 in a first position and a resting device in the second position. The rear wall part 12 , front wall part 14 , first middle part 16 , and second middle part 18 have a cavity 56 formed therein. The cavity 56 is formed within the bag 10 and designed to receive an inflatable device 58 .
[0036] As illustrated in FIG. 11 , the front wall part 14 is engaged to the first middle part 16 along a first fold line 60 , the first middle part 16 is engaged to the second middle part 18 along a second fold line 62 , and the rear wall part 12 is engaged to the second middle part 18 along the third fold line 64 . It should be noted that the fold lines ( 60 , 62 , and 64 ) may be stitched or embedded into the bag 10 , but as illustrated, the fold lines ( 60 , 62 , and 64 ) are the natural fold lines for folding the bag 10 of the present invention. Preferably, the front sides ( 20 , 30 , 40 , and 48 ) of the front wall part 14 , the rear wall part 12 , the first middle part 16 , and the second middle part 18 is formed from a solid piece of fabric. Alternatively, the front sides ( 20 , 30 , 40 , and 48 ) of the front wall part 14 , the rear wall part 12 , the first middle part 16 , and the second middle part 18 is formed from two or more pieces of fabric, but forming a solitary unit. Preferably, the back sides ( 22 , 32 , 42 , and 50 ) of the front wall part 14 , the rear wall part 12 , the first middle part 16 , and the second middle part 18 are formed from a solid piece of fabric. Alternatively, the back sides ( 22 , 32 , 42 , and 50 ) of the front wall part 14 , the rear wall part 12 , the first middle part 16 , and the second middle part 18 are formed from two or more pieces of fabric, but forming a solitary unit.
[0037] The front wall part 14 has a first interior side 66 and a second interior side 68 . The rear wall part 12 has a first interior side 70 and a second interior side 72 . The first middle part 16 has a first interior side 74 and a second interior side 76 . The second middle part 18 has a first interior side 78 and a second interior side 80 . The first interior sides ( 66 , 70 , 74 , and 78 ) are separated from the second interior sides ( 68 , 72 , 76 , and 80 ) by a center fold line 82 . In other words, the interior sides ( 66 , 68 , 70 , 72 , 74 , 76 , 78 , and 80 ) are bisected by the center fold line 82 . It should be noted that the center fold line 82 may be stitched or embedded into the bag 10 , but as illustrated, the center fold line 82 is the natural fold line for folding the bag 10 of the present invention in the longitudinal direction.
[0038] The bag 10 has a first position and a second position. In the first position, the front side 20 of the front wall part 14 is adjacent the front side 40 of the first middle part 16 , the back side 42 of the first middle part 16 is adjacent the back side 50 of the second middle part 18 , and the front side 48 of the second middle part 18 is adjacent the front side 20 of the rear wall part 12 . The first position is illustrated in FIGS. 1-3 . The rear wall part 12 extends overtop the front wall part 14 for forming a selectively secured arrangement. The rear wall part 12 , and preferably the end wall part 28 , contains a retention means 84 . The front wall part 14 , preferably the top wall part 38 , contains a retention means 86 that is intended to engage the retention means 84 of the rear wall part 12 for holding the rear wall part 12 and front wall part 14 in a selectively secured arrangement. The retention means ( 84 , 86 ) can be any device that will selectively secure one retention means to another retention means. As illustrated, the retention means 84 of the rear wall part 12 may have a male portion and the retention means 86 of the front wall part 14 may have a female portion for receiving the male portion of the retention means 84 of the rear wall part 12 for forming a selectively secured arrangement between the rear wall part 12 and front wall part 14 . Alternatively, the retention means 84 of the rear wall part 12 may have a female portion and the retention means 86 of the front wall part 14 may have a male portion, and the female portion of the retention means 84 of the rear wall part 12 receives the male portion of the front wall part 14 for forming a selectively secured arrangement between the rear wall part 14 and front wall part 12 .
[0039] The second side wall part 26 of the rear wall part 12 and the second side wall part 54 of the second middle part 18 contain an engagement means ( 88 , 94 ) that selectively secures the second side wall part 26 of the rear wall part 12 and the second side wall part 54 of the second middle part 18 to each other. The engagement means 94 of the second middle part 18 and the engagement means 88 of the rear wall part 12 are engaged to each other forming a selectively secure arrangement. The second side wall part 36 of the front wall part 14 and the second side wall part 46 of the first middle part 16 contain an engagement means ( 90 , 92 ) that selectively secures the second side wall part 36 of the front wall part 14 and the second side wall part 46 of the first middle part 16 to each other. The engagement means 92 of the first middle part 16 and the engagement means 90 of the front wall part 14 are engaged to each other forming a selectively secure arrangement.
[0040] An additional engagement means may also be disposed on the front side or the rear side of the rear wall part 12 , front wall part 14 , first middle part 16 , and second middle part 18 . This additional engagement means is disposed within close proximity to the center fold line 82 . As illustrated in FIGS. 7 , 8 , 10 , and 11 , the rear wall part 12 includes an engagement means 88 disposed in close proximity to the center fold line 82 . The front wall part 14 includes an engagement means 90 disposed in close proximity to the middle fold line 82 . The first middle part 16 includes an engagement means 92 disposed in close proximity to the middle fold line 82 . The second middle part 18 includes an engagement means 94 disposed in close proximity to the middle fold line 82 . The engagement means 88 of the rear wall part 12 disposed in close proximity to the center fold line 82 is engaged to the engagement means 94 of the second middle part 18 disposed in close proximity to the center fold line 82 for forming a selectively secured arrangement between the rear wall part 12 and second middle part 18 . The engagement means 90 of the front wall part 14 disposed in close proximity to the center fold line 82 is engaged to the engagement means 92 of the first middle part 16 disposed in close proximity to the center fold line 82 for forming a selectively secure arrangement between the front wall part 14 and the first middle part 16 . The engagement means ( 88 , 90 , 92 , and 94 ) as described herein may be a zipper, buttons, snaps, hook and loop fasteners (sold under the trade name Velcro®) or the like. Additionally, the engagement means may have a different color than the opposing engagement means to which it is selectively secured. In other words, the engagement means 88 of the rear wall part 12 may have a different color than the engagement means 94 of the second middle part 18 . Likewise, the engagement means 90 of the front wall part 14 may have a difference color than the engagement means 92 of the first middle part 16 .
[0041] The bag 10 may also contain a handle 96 . The handle 96 may be positioned on the rear wall part 12 and allow a user to carry the bag 10 while in the first position. Alternatively, the handle 96 of the bag 10 may contain a telescoping handle 96 that is raised upwards in the “up” position when transporting the bag 10 and is lowered downward in the “down” position when the bag 10 is not being transported. The bag 10 may also contain wheels that allow the bag 10 to be transported easily. Preferably, the bag 10 contains both wheels and a telescoping handle which allows the user to drag or roll the bag 10 along the ground for easy transport.
[0042] The bag 10 may also contain a bottom retention means 98 . The bottom retention means 98 allows a second bag 100 or other like device or apparatus to be selectively secured to the bag 10 . As illustrated in FIG. 2 , the bottom retention means 98 allows a second bag 100 to be selectively secured to the front wall part 14 of the bag 10 , by way of a retention means 102 of the second bag 100 . The bottom retention means 98 can be any device that will selectively secure one retention means 98 to another retention means 102 . As illustrated, the bottom retention means 98 may have a male portion and the retention means 102 of the second bag 100 may have a female portion for receiving the male portion of the bottom retention means 98 of the bag 10 for forming a selectively secured arrangement between the bag 10 and the second bag 100 . Alternatively, the bottom retention means 98 of the bag 10 may have a female portion and the retention means 102 of the second bag 100 may have a male portion, and the female portion of the bottom retention means 98 of the bag 10 receives the male portion of the retention means 102 of the second bag 100 for forming a selectively secured arrangement between the bag 10 and second bag 100 .
[0043] As illustrated in FIG. 3 , the bag 10 may contain at least one strap 104 disposed on the bag 10 for allowing a user to carry the foldable bag 10 . Preferably, the bag 10 includes two straps 104 disposed on the rear wall part 14 for allowing a user to carry the foldable bag 10 . The straps 104 are adjustable and allow a user to carry the bag 10 on their back. The straps 104 may also contain a padded portion for providing added comfort to the user, while carrying the bag 10 .
[0044] In the process of transitioning the bag 10 from the first position to the second position, the first step is to release the retention means 84 selectively securing the front wall part 14 to the rear wall part 12 . After the retention means 84 has been released, the portion of the rear wall part 12 that is overtop the front wall part 14 is flipped backward along the rear wall part fold line 106 , as illustrated in FIG. 4 . As illustrated in FIG. 5 , the selectively secured engagement of the rear wall part 12 to the second middle part 18 forms a storage cavity 108 therein, and the selectively secured engagement of the front wall part 14 to the first middle part 16 forms a storage cavity 110 therein. Additionally, a side retention means 112 is engaged to the rear wall part 12 and the front wall part 14 . The side retention means 112 can be any device that will selectively secure the rear wall part 12 to the front wall part 14 . As illustrated, the side retention means 112 of the rear wall part 12 may have a male portion and the side retention means 112 of the front wall part 14 may have a female portion for receiving the male portion of the side retention means 112 of the rear wall part 12 for forming a selectively secured arrangement between the rear wall part 12 and front wall part 14 . Alternatively, the side retention means 112 of the rear wall part 12 may have a female portion and the side retention means 112 of the front wall part 14 may have a male portion, and the female portion of the retention means 112 of the rear wall part 12 receives the male portion of the side retention means 112 of the front wall part 14 for forming a selectively secured arrangement between the rear wall part 12 and the front wall part 14 . As illustrated in FIG. 5 , the bag 10 contains two side retention means 112 on each side of the bag 10 , and in other words, the rear wall part 12 has four side retention means 112 and a pair on each side, and the front wall part 14 has four side retention means 112 and a pair on each side.
[0045] As illustrated in FIG. 6 , the engagement means 90 of the front wall part 14 disposed in close proximity to the center fold line 82 is separated from the engagement means 92 of the first middle wall part 16 that is disposed in close proximity to the center fold line 82 . FIG. 7 illustrates the engagement means 90 on the second side wall part 36 of the front wall part 14 is separated from the engagement means 92 of the second side wall part 46 of the first middle part 16 . FIG. 8 illustrates the engagement means 94 of the second middle part 18 that is disposed in close proximity to the center fold line 82 being separated from the engagement means 88 of the rear wall part 12 that is disposed in close proximity to the center fold line 82 . FIGS. 9 and 10 illustrate the engagement means 94 of the second side wall part 54 of the second middle part 18 is separated from the engagement means 88 of the second side wall part 26 of the rear wall part 12 . FIG. 11 illustrates the bag 10 wherein the rear wall part 12 , front wall part 14 , first middle part 16 , and second middle part 18 are in a planar relationship with one another. As illustrated in FIGS. 9 , 11 , and 15 , the interior sides ( 66 , 68 , 70 , 72 , 74 , 76 , 78 , and 80 ) are bisected by the center fold line 82 with the front sides ( 20 , 30 , 40 , and 48 ) facing upwards and the back sides ( 22 , 32 , 42 , and 50 ) facing downwards.
[0046] In one embodiment, the bag 10 contains a pair of pockets 114 that are engaged to the rear wall part 12 . Preferably, the pockets 114 are engaged to the first side wall 24 and second side wall 26 of the rear wall part 12 . It should be noted that the bag 10 may contain one or more pockets 114 , or the two pockets 114 as illustrated in FIG. 12 . The pockets 114 have first position, wherein the pockets 114 rest upon the rear wall part 12 as illustrated in FIG. 12 . The pockets 114 have a second position, where the pockets 114 are folded outward from the rear wall part 12 , as illustrated in FIG. 13 . The pockets 114 have a cavity therein for allowing items or devices to be stored therein. The cavity may be secured by a pocket engagement means 116 , such as a zipper, button, snap, hook and loop fastener (sold under the trade name Velcro®) or the like.
[0047] As illustrated in FIG. 14 , the cavity 56 may receive an inflatable and/or expandable device 58 . The inflatable device 58 is any device that can receive a gas or liquid for increasing in size. As illustrated in FIG. 14 , the inflatable device 58 is an inflatable mattress. The inflatable device 58 may be contain a built in pump, may be inflated with a hand pump, or may be inflated with an electrical pump, may be inflated by a user blowing air into the mattress, or may be inflated by any other means known to one of skill in the art. The expandable device 58 increases in height and may act much like an inflatable device 58 . The purpose of the expandable device 58 is to establish a barrier or separation between the user and the ground or any surface the bag 10 is placed upon.
[0048] FIG. 15 illustrates the bag 10 in the second position wherein the back side 32 of the front wall part 14 , the back side 42 of the first middle part 16 , the back side 50 of the second middle part 18 , and the back side 22 of the rear wall part 12 are in a substantially planar relationship with the front side 30 of the front wall part 14 , the front side 40 of the first middle part 16 , the front side 48 of the second middle part 18 , and the front side 20 of the rear wall part 12 . Additionally, the inner sides ( 66 , 68 , 70 , 72 , 74 , 76 , 78 , and 80 ) are exposed and facing upwards. The first inner side 70 and second inner side 72 of the rear wall part 12 contains a raised portion that may act as a pillow. FIG. 16 illustrates the bag 10 in the second position with the inflatable device 58 fully inflated. FIG. 17 illustrates a user utilizing the bag 10 in the second position. FIG. 18 illustrates the bag 10 in the second position and in a suggested usage.
[0049] Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention and are intended to be covered by the following claims.
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The present invention provides methods and systems for a foldable bag that includes a rear wall part having a front side, a back side, and an interior side; a front wall part having a front side, a back side, and an interior side; a middle part having a front side, a back side, and an interior side. The front wall part is engaged to the middle part along a fold line, and the rear wall part is engaged to the middle part along a fold line. The foldable bag is moveable between a first position and a second position.
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FIELD OF THE INVENTION
This invention relates to a process for producing an organic electrical conductor (hereinafter simply referred to as conductor) which can be used as an organic superconductive material, etc.
BACKGROUND OF THE INVENTION
Known organic conductors exhibiting super conductivity under normal pressure include bis(ethylenedithio)tetrathiafulvalene (hereinafter abbreviated as BEDT-TTF) compounds as disclosed in JP-A-61-277691 (the term "JP-A" as used herein means an "unexamined published Japanese patent application"), dimethyl(ethylenedithio)diselenathiafulvalene (hereinafter abbreviated as DMET) compounds as disclosed in JP-A-63-246383, and methylenedithiotetrafulvalene (hereinafter abbreviated as MDT) compounds as reported by G. C. Papauassiliou, et al. in International Conference on Science and Technology of Synthetic Metals, June 26-July 2, 1988, Santa Fe.
Further, organic conductors known to have a critical temperature (Tc) of 10 K or higher include cation radical salts, e.g., (BEDT-TTF) 2 Cu(NCS) 2 and a deuteration product thereof, (BEDT-TTFd 8 ) 2 Cu(NCS) 2 , as described in H. Urayama, et al., Chem. Lett., 55 (1988).
Synthesis and crystal growth of organic conductors or super conductors are conducted by an electrolytic method in which an electron donating material (donor), e.g., BEDT-TTF, and an electron accepting material (acceptor), e.g., I 3 - and Cu(NCS) 2 - , are dissolved in an organic solvent, and an electrical current of from 0.5 to 2 μA is passed therethrough to effect an electrochemical oxidation-reduction; or a diffusion method utilizing diffusion of the donor and acceptor.
However, the electrolysis method and diffusion method require a considerable time for synthesis and crystal growth of organic conductors. For instance, it takes from 1 week to 2 months to obtain crystals having a size of about 1 to 2 mm.
SUMMARY OF THE INVENTION
An object of this invention is to provide a process for producing an organic conductor in a reduced time.
Another object of this invention is to provide a process for producing a high quality organic conductor having a large crystal size.
Other objects and effects of this invention will be apparent from the following description.
This invention relates to a process for producing an organic electrical conductor comprising the steps of: (1) dissolving or dispersing an electron-donating material and an electron-accepting material in a solvent containing an alcohol; and (2) forming and growing crystals of the organic electrical conductor by subjecting the dissolved or dispersed materials of step (1) to electrochemical oxidation-reduction.
DETAILED DESCRIPTION OF THE INVENTION
According to the process of the present invention, the time required for synthesis and crystal growth of an organic conductor can be reduced and, also, high quality crystals of large size can be obtained. For example, in the production of (BEDT-TTF) 2 Cu(NCS) 2 , conventional processes using a solvent containing no alcohol needed anywhere from 1 week to 2 months to produce crystals of from 1 to 2 mm in size. In comparison, use of a solvent containing an alcohol according to the present invention makes it possible to produce crystals of from about 3 to 4 mm in 1 week, thus achieving crystal growth several times faster than is possible through conventional methods.
The reason for the marked increase in the rate of crystal growth brought about by the use of an alcohol-containing solvent has not yet been elucidated. It is considered that the solubility of inorganic electron-accepting materials, which have a low solubility in commonly employed solvents, is improved by the addition of an alcohol. The alcohol apparently increases the rate of reaction between the electron-donating material and electron-accepting material and thereby increases the rate of crystal growth.
The organic conductor that results from the present invention is a bulk super-conductor exhibiting 80% perfect diamagnetism as determined from magnetic susceptibility and having a critical temperature of 10.4 K (middle point) as determined from electrical resistance.
Examples of suitable electron donating materials which can be used in the present invention are TTF, BEDT-TTF, tetraaminoanthraquinone (TAAQ), dimethyl(ethylenedithio)diselena-dithiafulvalene (DMET), tetramethyltetraselenafulvalene (TMTSF), methylenedithiotetrathiafulvalene (MDT-TTF), tetramethyltetra-thiafulvalene (TMTTF), bis(2,3-butylenedithio)tetrathiafulvalene (BBDS-TTF), bis(1,2-propylenedithio)tetrathiafulvalene, 2,3-butylenedithio(ethylenedithio)tetrathiafulvalene, and 1,2-propylenedithio(ethylenedithio)tetrathiafulvalene; and these compounds with the sulfur atoms thereof replaced by selenium, tellurium or oxygen.
Examples of the electron donors with the sulfur atom thereof replaced by selenium, tellurium or oxygen are tetraselenafulvalene (TSeF), tetramethyltetraselenafulvalene (TMTSF), tetratellurafulvalene (TTeF), bis(ethylenediselena)tetrathiafulvalene (BEDSe-TTF), bis(ethylenediselena)tetraselenafulvalene (BEDSe-TSeF), bis(ethylenedithio)tetraselenafulvalene (BEDT-TSeF), bis(propylenediselena)tetrathiafulvalene (BPDSe-TTF), bis(2,3-butylenediselena)tetrathiafulvalene (BBDSe-TTF), and bis(ethylenedioxy)tetrathiafulvalene (BEDO-TTF).
Among the above electron donors, BEDT-TTF, DMET, TMTSF and MDT-TTF are preferred, and BEDT-TTF is more preferred as the electron donor.
In addition, these electron donors with a part or all of atoms thereof substituted with an isotope, e.g., heavy hydrogen, are also employable.
The electron-accepting materials which can be used in the present invention include I 3 , IBr 2 , AuI 2 , AuCl 2 , AuBr 2 , Au(CN) 2 , (I 3 ) 1-x (wherein x is a positive number less than 1), Hg 3 Br 8 , ClO 4 , ReO 4 , Cu(SCN) 2 , Cd(SCN) 2 , Zn(SCN) 2 , Hg(SCN) 2 , KHg(SCN) 4 , HgCl 2 . HgBr 2 , HgI 2 . Hg(CN) 2 . Ni(dmit) 2 , Pd(dmit) 2 . PF 6 , AsF 6 , SbF 6 , TaF 6 , and FSO 3 . Among these, I 3 and Cu(SCN) 2 are preferred, and Cu(SCN) 2 is more preferred as the electron-accepting material.
Specific examples of the organic conductor obtained in the present invention are (TMTSF) 2 X 1 (wherein X 1 represents ClO 4 , etc.), (BEDT-TTF) 2 X 2 (wherein X 2 represents Cu(SCN) 2 , etc.), (DMET) 2 X 3 (wherein X 3 represents AuBr 2 , etc.), (MDT-TTF) 2 X 4 (wherein X 4 represents AuBr 2 , etc.), TTF[Me(dmit) 2 ] (wherein Me represents Ni, Pd, etc.), and (CH 3 ) 4 N[Ni(dmit) 2 ] 2 . Among these, (BEDT-TTE) 2 Cu(NCS) 2 is preferred in the present invention.
Solvents which can be used in the present invention include 1,1,2-trichloroethane, tetrahydrofuran (THF), 1,2-dichloroethane, dichloromethane, chlorobenzene, fluorobenzene, anisole, acetonitrile, and benzonitrile. Among these, 1,1,2-trichloroethane and THF are preferably used in the present invention.
A raw material forming the anion Cu(NCS) 2 - includes (n-Bu 4 N)SCN (wherein Bu represents a butyl group) and CuSCN.
The alcohol which is added to the solvent is not particularly limited and includes, for example, methanol, ethanol, propanol, isopropanol, n-butanol, sec-butanol, t-butanol, and pentanol. The alcohol is preferably methanol, ethanol or propanol, and more preferably ethanol.
The amount of the alcohol to be added is appropriately selected depending on the kind of the solvent, solubility of the donor molecule, and the like and is usually in the range of from 0.1 to 10% by weight, preferably from 0.5 to 5% by weight, more preferably from 1 to 2% by weight, based on the solvent. If the alcohol content exceeds 10%, solubility of the electron-donating material tends to be reduced which brings a failure of smooth snythesis or crystal growth of organic conductors. If the alcohol content is less than 0.1%, significant increase in crystal growth rate or crystal size tend to be failed.
The amount ratio and the concentrations of the electron donor and the electron-accepting material are not particularly limited, but the electron donor and the electron-accepting material are preferably present in a high concentration as possible. For example, the Synthesis and crystal growth is preferably carried out in which the electron donor and the electron-accepting material are added in an excess amount and their concentrations are maintained at substantially saturated concentrations when they are consumed by the reaction.
The synthesis of the organic conductor and crystal growth by oxidation-reduction reaction can be carried out in accordance with known electrolytic techniques.
The higher the electrical current in the electrolysis, the faster the crystal growth. However, at a current of about 50 μA, extremely small crystals that fail to grow into satisfactory plate crystals tend to form rapidly. Accordingly, a preferred current ranges is from about 0.5 to 20 μA, more preferably from 0.5 to 10 μA. A current range of from 0.5 to 1 μA is most preferred for wire electrodes having an diameter of 1 mm. The electrolysis temperature ranges from about 5° C. to about 50° C., preferably from about 10° C. to about 30° C. At temperatures lower than about 5° C. crystal growth is retarded. At temperatures higher than about 50° C., crystals hardly grow.
Materials of electrodes include, for example, Ni, Pd, Pt, Au, W, p-type and n-type silicon, indium oxide coated glass, indium oxide coated polyester films, and NESA glass. Electrodes that contain Pt give particularly satisfactory results. The electrodes may be of any known configuration such as rod shape, a plate shape, a cylindrical shape, a mesh structure, a porous structure, and so on.
An organic conductor or super-conductor according to the present invention is of lighter weight and easier to synthesize and process at lower temperatures compared to metallic super-conductive materials. As a result, it can be utilized in a wide variety of forms, such as film, tape, fiber, powder, etc.; it can be utilized either alone or in the form of a composite with polymers; and it can also be utilized in the form of a thin membrane. The organic conductor or super-conductor of the invention is thus useful in various applications, such as wires, tapes, strip lines, wiring, and devices.
The present invention is now illustrated in greater detail by way of the following nonlimiting Examples. In these Examples, all the percents are by weight unless otherwise specified.
EXAMPLES 1 TO 10
In a cell for crystal growth whose atmosphere had been displaced with nitrogen were put 30 mg of BED-TTF, 70 mg of CuSCN, 126 mg of KSCN, and 210 mg of 18-crown-6-ether as a catalyst. Subsequently, 1,1,2-trichloroethane and ethanol (of electronics industry grade) or methanol (having a ultra-low water content) were added thereto as a solvent in amounts shown in Table 1 below using an injector. The mixture, shielded from light, was stirred overnight in a nitrogen atmosphere. After any insoluble matter was allowed to precipitate, platinum electrodes 1 mm in diameter were fixed to the cell in a nitrogen stream.
The cell was put in an oven whose temperature was controlled by a thermostat set at 20.0°±0.2° C. After the temperature reached a stable state, a direct current of a value shown in Table 1 below was applied to the electrodes to start the synthesis and crystal growth of an organic conductor.
COMPARATIVE EXAMPLES 1 AND 2
The same procedure of Examples 1 to 4 was repeated, except 100 ml of 1,1,2-trichloroethane alone was used as a solvent. The thermostat temperature was set at 20.0°±0.2° C. for Comparative Example 1 or about 40° C. for Comparative Example 2 during electrolysis.
TABLE 1______________________________________ 1,2-Tri- Alcohol chlor- Metha- content ethane Ethanol nol in solvent CurrentNo. (ml) (ml) (ml) (wt %) (μA)______________________________________Example 1 99 0.9 0 0.5 0.50 ±0.02Example 2 99 1.8 0 1 0.50 ±0.02Example 3 96 3.6 0 2 0.50 ±0.02Example 4 91 8.7 0 5 0.50 ±0.02Example 5 83 16.8 0 10 0.50 ±0.02Example 6 98 0 1.8 1 0.05 ±0.02Example 7 96 0 3.6 2 0.50 ±0.02Example 8 91 0 8.7 5 0.50 ±0.02Example 9 96 3.6 0 2 10 ±0.02Example 10 96 3.6 0 2 47 ±3Comparative 100 0 0 0 0.50Examples 1 ±0.02and 2______________________________________
The BEDT-TTF used above was prepared by purifying a commercially available product by recrystallization (melting point: 242° C.). The KSCN used above was prepared by recrystallization from ethanol, drying under reduced pressure at room temperature, maintaining at 150° C. for 1 hour and then at 200° C. for 15 minutes to remove the solvent, cooling in a desicator, and grinding in a mortar. The CuSCN and 18-crown-6-ether used above were prepared by drying commercially available reagents under reduced pressure. The 1,1,2-trichloroethane used as a solvent was prepared by washing with a 10% sodium hydroxide aqueous solution and a sodium chloride aqueous solution, drying over calcium chloride for at least 1 day, followed by distillation (boiling point: 113°-113.5° C.). The purified 1,1,2-trichloroethane was used immediately after distillation. All the equipment was used after thorough drying. The platinum electrodes were used immediately after heating on a burner.
The mode of crystal growth in a prescribed period of time in Examples 1 to 10 and Comparative Examples 1 and 2 are in Table 2 below. After completion of the crystal growth, the crystals formed were collected on a filter, washed with an alcohol, dried at room temperature under reduced pressure, and weighed. The yield of the crystals is also shown in Table 2 below. All the grown crystals were plate-like, and the size of the crystals shown in Table 2 is the maximum length in terms of mm.
TABLE 2__________________________________________________________________________ Crystal growth time (day) YieldNo. 1 2 5 7 14 (mg)__________________________________________________________________________Example 1 -- -- 1 1.5 1.7 4.5Example 2 nucleus nucleus 2-3 4-5 5 18.8 formation formationExample 3 nucleus nucleus 3-4 4-5 5 19.3 formation formationExample 4 no nucleus 0.1 0.2 0.2-0.5 12.1 change formationExample 5 no nucleus 0.1 0.1 0.1-0.5 17.6 change formationExample 6 nucleus -- 0.8 1.1 1.6 8.0 formationExample 7 nucleus -- 0.4 0.5 1.0 7.0 formationExample 8 no -- 0.2 0.2 0.6 10.0 changeExample 9 nucleus -- 11 -- -- 26.0 formationExample 10 many -- -- -- -- 17.0 crystallites formedComparative no no nucleus nucleus 0.2 13.8Example 1 change change formation growthComparative no no no no no 0Example 2 change change change change change__________________________________________________________________________
In Comparative Example 2 where the solvent contained no alcohol and the electrolysis was conducted at 40° C., virtually no crystal growth was observed. In Comparative Example 1 where the solvent contained no alcohol and the electrolysis was conducted at 20° C.±0.2, formation of ultrafine black crystal nuclei on the platinum anode was observed within 5 days from the start of crystal growth, but this crystal nuclei eventually grew to only about 0.2 mm in 14 days.
It can be seen that addition of ethanol (Examples 1 to 4) or methanol (Examples 6 to 8) to the solvent accelerated crystal nucleus formation by several days. These Examples show that crystals having a size of about 0.1 to 5 mm can be obtained in around 7 days.
In particular, in Examples 2 and 3 started with 1 and 2% ethanol, respectively, the crystals grew to a size of 3 to 4 mm in about 5 days and to a size of 5 mm in about 7 days. Thus, the crystals in these Examples grew faster axid the crystals were of larger size compared to those in Examples 1, 4, and 5 started with 0.5, 5, or 10% ethanol or Examples 6 to 8 started with methanol.
With respect to the electrolysis current, in Example 9 a current of 10 μA, which was higher than that of Examples 1 to 8, was applied. The crystals grew to 11 mm in 5 days. Thus, compared with Example 3 in which 0.5 μA was used with the other conditions being the same, Example 9 showed faster crystal growth, produced crystals of larger size, and at an increased yield. In Example 10, 47 μA was applied and although crystal precipitation took place immediately after the start of electrolysis no growth of plate crystals was observed except for precipitation of crystallites.
In addition, the results of Table 2 reveal that the addition of ethanol also increases yield.
The critical temperature (Tc) of the resulting crystals was determined by measuring magnetic susceptibility. All of the crystals obtained in Examples 1 to 10 and Comparative Examples 1 were found to exhibit diamagnetism at 9.8° K. The electrical resistance of the crystals obtained in Examples 2 and 3 was determined using a four-terminal network and in both a sharp reduction in resistance was noted at around 11° K. These results reveal that the crystals were super conductors.
According to the present invention, synthesis and crystal growth of an organic conductor and an organic super-conductor can be achieved in a reduced time. The process of the present invention is, therefore, suitable for mass-production of organic conductors and organic super-conductors. Additionally, the process produces crystals of large size and high quality.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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A process for producing an organic electrical conductor comprising the steps of: (1) dissolving or dispersing an electron-donating material and an electron-accepting material in a solvent containing an alcohol; and (2) forming and growing crystals of the organic electrical conductor by subjecting the dissolved or dispersed materials of step (1) to electrochemical oxidation-reduction.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The application is a continuation of International Application No. PCT/CN2008/071617, filed on Jul. 11, 2008, which claims priority to Chinese Patent Application No. 200710129583.8, filed on Jul. 11, 2007, both of which are hereby incorporated by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to the telecommunications field, and in particular, to method and system for authentication based on NASS.
BACKGROUND OF THE INVENTION
[0003] Customer Network Gateways (CNGs) are characterized by large quantities and wide distribution. To meet the requirement for CNG Configuration Function (CNGCF) authentication, a unique credential needs to be generated for each CNG. However, the generation, reliable distribution (to the CNG and CNGCF), and update of the huge quantity of credentials (shared keys and digital certificates) are difficulties imposed to the operators.
[0004] In the prior art, the unidirectional or bidirectional authentication solution between the CNG and the CNGCF is: A shared credential (such as username or shared key) is deployed statically on the CNG and the CNGCF. Specifically, in the service deployment stage, the operation and maintenance engineers of the telecom operators generate an credential (such as username and shared key) for each CNG; and the credential is configured onto the CNG and the CNGCF, and the CNGCF is correlated with the CNG identifier; the CNG and the CNGCF perform bidirectional or unidirectional authentication according to the credential during the interoperation; the shared authentication mode configured statically in the prior art generates a unique shared key for each of the numerous CNGs, and such unique shared keys need to be configured to the CNG and the CNGCF manually, thus involving complicated work and high costs.
SUMMARY OF THE INVENTION
[0005] Embodiments of the present invention provide a method and system for authentication based on NASS to implement simple and cost-efficient authentication of the CNG and CNGCF, to reduce the operation cost and to improve the operation efficiency.
[0006] A method for t authentication based on Network Attachment Sub-System (NASS) includes:
[0007] performing, by a user access authorization module, access authentication for a CNG;
[0008] generating, by the user access authorization module, an management credential between the CNG and a CNGCF;
[0009] sending, by the user access authorization module, the generated management credential to the CNGCF so that the CNG obtains the management credential;
[0010] authenticating, by the CNG, the CNGCF according to the obtained management credential; and, authenticating, by the CNGCF, the CNG according to the management credential.
[0011] A system for authentication based on NASS includes:
[0012] a user access authorization module, configured to perform access authentication for a CNG, generate an management credential between the CNG and a CNGCF, and send the management credential;
[0013] the CNG, configured to obtain the management credential, and authenticate the corresponding CNGCF according to the credential; and
[0014] the CNGCF, configured to receive the management credential, and authenticate the corresponding CNG according to the management credential.
[0015] The method and system for authentication based on NASS provided herein generate, distribute and modify credentials automatically, thus reducing the operation and maintenance costs of distributing numerous CNGs, and improving the operation efficiency massively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a first schematic diagram of an architecture of a method for authentication based on NASS according to an embodiment of the present invention;
[0017] FIG. 2 shows a first flowchart of a method for authentication based on NASS according to an embodiment of the present invention;
[0018] FIG. 3 shows a second schematic diagram of an architecture of a method for authentication based on NASS according to an embodiment of the present invention;
[0019] FIG. 4 shows a second flowchart of a method for authentication based on NASS according to an embodiment of the present invention;
[0020] FIG. 5 shows a first schematic diagram of a structure of a system for authentication based on NASS according to an embodiment of the present invention;
[0021] FIG. 6 shows a second schematic diagram of a structure of system for authentication based on NASS according to an embodiment of the present invention;
[0022] FIG. 7 shows a third schematic diagram of a structure of a system for authentication based on NASS according to an embodiment of the present invention;
[0023] FIG. 8 shows a first flowchart of another method for management authentication based on NASS according to an embodiment of the present invention;
[0024] FIG. 9 shows a first schematic diagram of a structure of another system for management authentication based on NASS according to an embodiment of the present invention; and
[0025] FIG. 10 shows a second schematic diagram of a structure of a method and system for management authentication based on NASS according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention is hereinafter described in detail with reference to accompanying drawings and exemplary embodiments.
[0027] A NASS-based method for authenticating a CNG and a CNGCF in one of the embodiment of the present invention includes the following steps:
[0028] Step 1: A user access authorization module performs access authentication for the CNG.
[0029] Step 2: The user access authorization module generates a management credential between the CNG and the CNGCF.
[0030] Step 3: The user access authorization module sends the generated management credential to the CNGCF and the CNG, and sets up a correlation between the CNG and the management credential.
[0031] The user access authorization module may also send only the key algorithm, initial vector and lifecycle information in the management credential to the CNG, and the CNG generates the key according to the key algorithm, initial vector and lifecycle information.
[0032] Step 4: The CNG and the CNGCF in the bidirectional interaction use the stored management credential to authenticate each other and judge whether the operation is authorized. That is, the CNG authenticates the CNGCF according to the management credential; and the CNGCF authenticates the CNG according to the management credential.
[0033] FIG. 1 is the first schematic diagram of an architecture of a method for authentication based on NASS in an embodiment of the present invention. The NASS includes these functional entities: a Network Access Configuration Function (NACF) capable of network access configuration; a Connectivity Session Location and Repository Function (CLF) capable of connectivity session location; a User Access Authorization Function (UAAF) capable of user access authorization; a CNGCF capable of configuring a User Equipment (UE).
[0034] The NASS is adapted to: authenticate a user who attempts to log in based on the subscription profile of the user, authorize the user to use network resources, configure the network according to the authorization information, and allocate IP addresses.
[0035] The NASS-based architecture includes: a CNG 1 , an Access Management Function (AMF) 2 , a UAAF 3 , a CLF 4 , a NACF 5 , and a CNGCF 6 . The interface between the NACF 5 and the AMF 2 is a 1 ; the interface between the NACF 5 and the CLF 4 is a 2 ; the interface between the AMF 2 and the UAAF 3 is a 3 ; the interface between the UAAF 3 and the CLF 4 is a 4 ; the interface between the CLF 4 and the CNGCF 6 is a 5 ; the interface between the UE 1 and the AMF 2 is e 1 ; the interface of the CLF 4 itself is e 2 ; the interface between the CNGCF 6 and the UE 1 is e 3 ; and the interface of the UAAF 3 itself is e 5 .
[0036] FIG. 2 is the first flowchart of a CNG management authentication method in an embodiment of the present invention. The method includes the following steps:
[0037] Step 501 : The UAAF performs access authentication for the CNG. Specifically, the CNG sends an access authentication request to the UAAF to trigger the security association negotiation between the CNG and the UAAF, with a view to obtaining the security association subsequently. The security association is also known as an management credential.
[0038] Step 502 : According to the local policy, the UAAF decide whether it is necessary to generate an management credential between the CNG and the CNGCF. If necessary, the UAAF generates an management credential between the CNG and the CNGCF.
[0039] The UAAF may use the user access authentication key information or the root key configured by the operator to generate an management credential between the CNG and the CNGCF.
[0040] The management credential may include a security protocol, a key algorithm, the key used in the key algorithm, an initial vector, and a lifecycle of the management credential. The management credential is also known as a security association.
[0041] Step 503 : Through the extended a 4 interface and the a 5 interface between the CLF and the CNGCF, the UAAF configures the generated management credential to the CNGCF by means of the CLF. The UAAF adds the management credential to an authentication response message and sends the response message to the CNG through the e 3 interface connected to the AMF.
[0042] The UAAF may also send only the key algorithm, initial vector and lifecycle information in the management credential to the CNG, and the CNG generates the key according to the key algorithm, initial vector and lifecycle information.
[0043] Subsequently, when the user attaches to the network, the UAAF uses the key in the management credential generated in the previous login authentication as a root key to generate a new management credential; or still uses the user access authentication key information or other information configured by the operator as a root key, and configures the key to the CNGCF and the CNG in the same way.
[0044] Besides, when the user attaches to the network subsequently, according to the policy configured by the operator, the UAAF decides whether a new management credential needs to be generated for every other system access. If it is not necessary the last generated management credential may still be used between the CNG and the CNGCF.
[0045] In the actual network deployment, one CLF may correspond to multiple CNGCFs. The CLF may locate the CNGCF in two modes. The first mode is: The CLF sets up a correlation between the CNG and the corresponding CNGCF according to the CNG location information (physical location information or logical location information) pushed by the UAAF for access authentication at the time of user login. Therefore, the CLF needs to configure the mapping between each CNGCF and the physical location or logical location. The other mode is: The CLF sets up the correlation between the CNG and the CNGCF according to the access network identifier allocated by the NACF to the CNG for access authentication at the time of user login, but the prerequisite is that the CLF has configured the mapping relation between each CNGCF and the access network identifier.
[0046] Step 504 : The CNG and the CNGCF in the bidirectional interaction use the stored management credential to authenticate each other and decide whether the operation is authorized. That is, the CNG authenticates the CNGCF according to the management credential; and the CNGCF authenticates the CNG according to the management credential. If the CNG registers with the CNGCF upon power-on, with a credential being carried in the registration request, the CNGCF compares the received CNG credential with the stored CNG credential. If the CNG credentials are the same, the CNGCF authenticates the CNG successfully and returns an authentication success message. The CNG authenticates the CNGCF in the same way.
[0047] The method provided in this embodiment generates, distributes and modifies management credentials automatically, thus enabling authentication between the CNG and the CNGCF fundamentally, reducing the operation and maintenance costs of distributing numerous CNGs, and improving the operation efficiency massively.
[0048] FIG. 3 is the second schematic diagram of an architecture of a CNG management authentication method in an embodiment of the present invention. The authentication method is also based on the NASS architecture, which includes a CNG 1 , an AMF 2 , a UAAF 3 , a CLF 4 , a NACF 5 , and a CNGCF 6 . The interface between the NACF 5 and the AMF 2 is a 1 ; the interface between the NACF 5 and the CLF 4 is a 2 ; the interface between the AMF 2 and the UAAF 3 is a 3 ; the interface between the UAAF 3 and the CLF 4 is a 4 ; the interface between the UAAF 3 and the CNGCF 6 is a 6 ; the interface between the UAAF 3 and the NACF 54 is a 7 ; the interface between the CNG 1 and the AMF 2 is e 1 ; the interface of the CLF 4 itself is e 2 ; the interface between the CNGCF 6 and the CNG 1 is e 3 ; and the interface of the UAAF 3 itself is e 5 .
[0049] FIG. 4 is the second flowchart of a CNG authentication method in an embodiment of the present invention. The method includes the following steps:
[0050] Step 701 : The UAAF performs access authentication for the CNG.
[0051] Step 702 : According to the local policy, the UAAF decide whether it is necessary to generate a management credential between the CNG and the CNGCF. If necessary, the UAAF generates a management credential between the CNG and the CNGCF.
[0052] The UAAF may use the user access authentication key information or the root key configured by the operator to generate a management credential between the CNG and the CNGCF.
[0053] The management credential may include a security protocol, a key algorithm, the key used in the key algorithm, an initial vector, and a lifecycle of the management credential. The management credential is also known as a security association.
[0054] Step 703 : Through the a 6 interface between the UAAF and the CNGCF, the UAAF configures the generated management credential to the CNGCF. The UAAF adds the management credential to an authentication response message and sends the response message to the CNG through the e 3 interface connected to the AMF.
[0055] The UAAF may also send only the key algorithm, initial vector and lifecycle information in the management credential to the CNG, and the CNG generates the key according to the key algorithm, initial vector and lifecycle information.
[0056] Subsequently, when the user attaches to the network, the UAAF uses the key in the management credential generated in the previous attachment process as a root key to generate a new management credential; or still uses the user access authentication key information or other information configured by the operator as a root key, and configures the key to the CNGCF and the CNG in the same way.
[0057] Besides, when the user attaches to the network subsequently, according to the policy configured by the operator, the UAAF decides whether a new management credential needs to be generated for every other system access. If it is not necessary the last generated management credential may still be used between the CNG and the CNGCF. In the actual network deployment, one UAAF may correspond to multiple CNGCFs. The UAAF may locate the CNGCF in two modes. The first mode is: The UAAF searches for the home CNGCF corresponding to the CNG according to the CNG location information (physical location information or logical location information) that exists when the user logs in and undergoes access authentication. Therefore, the prerequisite is that the UAAF configures the mapping between each CNGCF and the physical location or logical location. The other mode is that the UAAF searches for the CNGCF corresponding to the CNG according to the access network identifier allocated by the NACF to the CNG (through the a 7 interface) when the user logs in, or by using the access network identifier allocated by the NACF to the CNG (through the a 4 interface) and forwarded by the CLF, but the prerequisite is that the UAAF configures a mapping relation between each CNGCF and the access network identifier.
[0058] Step 704 : The CNG and the CNGCF in the bidirectional interaction use the stored management credential to authenticate each other and decide whether the operation is authorized. That is, the CNG authenticates the CNGCF according to the management credential; and the CNGCF authenticates the CNG according to the management credential.
[0059] The method provided in this embodiment generates, distributes and modifies management credentials automatically, thus enabling authentication between the CNG and the CNGCF fundamentally, reducing the operation and maintenance costs of distributing numerous CNGs, and improving the operation efficiency massively.
[0060] FIG. 5 is the first schematic diagram of a structure of a CNG management authentication system in an embodiment of the present invention. The system includes:
[0061] a UAAF 13 , adapted to: perform access authentication for a CNG 11 , generate an management credential between the CNG 11 and a CNGCF 16 , and send the management credential; the CNG 11 , adapted to: receive the management credential, and set up a correlation with the management credential;
[0062] the CNGCF 16 , adapted to: receive the management credential, whereupon the CNG 11 authenticates the CNGCF 16 according to the management credential and the CNGCF 16 authenticates the CNG 11 according to the management credential;
[0063] an AMF 12 , adapted to forward the CNG location information to the UAAF 13 ; and
[0064] a NACF 15 , adapted to: allocate an access network identifier to the CNG and send the access network identifier to the UAAF 13 .
[0065] FIG. 6 is the second schematic diagram of a structure of a CNG management authentication system in an embodiment of the present invention. The system includes:
[0066] a UAAF 23 , adapted to generate an management credential between a CNG 21 and a CNGCF 36 ;
[0067] the CNG 21 , adapted to: receive the management credential, and perform management authentication according to the management credential;
[0068] the CNGCF 26 , adapted to: receive the management credential, and perform management authentication according to the management credential;
[0069] an AMF 22 , adapted to forward the CNG location information to the UAAF 23 ; and a CLF 24 , adapted to forward an access network identifier to the UAAF 23 , where the access network identifier is allocated by a NACF 25 to the CNG.
[0070] FIG. 7 is the third schematic diagram of a structure of a CNG management authentication system in an embodiment of the present invention. The system includes:
[0071] a UAAF 33 , adapted to generate an management credential between a CNG 31 and a CNGCF 36 ;
[0072] the CNG 31 , adapted to: receive the management credential, and perform management authentication according to the management credential;
[0073] the CNGCF 36 , adapted to: receive the management credential, and perform authentication according to the credential;
[0074] an AMF 32 , adapted to forward the CNG location information to the UAAF 33 ;
[0075] a CLF 34 , adapted to forward the management credential generated by the UAAF 33 to the CNGCF 36 ; and
[0076] a CLF 34 , adapted to forward the management credential generated by the UAAF 33 to the CNGCF 36 .
[0077] The CNG management authentication system provided in this embodiment generates, distributes and modifies management credentials automatically without manual configuration, thus enabling authentication between the CNG and the CNGCF fundamentally. The system implements automatic control for key distribution, thus providing high security. The system updates the key conveniently, thus reducing the operation and maintenance costs of distributing numerous CNGs, and improving the operation efficiency massively.
[0078] Another method for authenticating a CNG and a CNGCF in an embodiment of the present invention includes the following steps:
[0079] Step 1: The UAAF performs access authentication for the CNG. The CNG generates a first Pre-Shared Key (PSK), and the access authorization module generates a second PSK.
[0080] Step 2: The CNG authenticates the message received from the CNGCF according to the first PSK and the second PSK.
[0081] Step 3: The CNGCF authenticates the message received from the CNG according to the first PSK and the second PSK.
[0082] FIG. 8 is the first flowchart of another CNG management authentication method in an embodiment of the present invention. The method includes the following steps:
[0083] Step 801 : The CNG sends an access authentication request to the UAAF.
[0084] Step 802 : In the security association stage of the access authentication, many negotiation processes may occur: Challenge (Session ID, random string S, . . . ).
[0085] Step 803 : The CNG calculates out the first PSK according to the stored user ID, the original access authentication key, the random string S obtained in the negotiation process, and the authentication session ID, and sends the first PSK to the UAAF.
[0086] The calculation method may be the Hash algorithm, namely, the first PSK=HASH (Session ID, random string S, user ID, key).
[0087] Step 804 : The UAAF calculates out the second PSK according to the stored user ID, the original access authentication key, the random string S obtained in the negotiation process, and the authentication session ID.
[0088] The calculation method is the Hash algorithm, namely, the second PSK=HASH (Session ID, random string S, user ID, key).
[0089] Step 805 : The UAAF performs access authentication according to the second PSK and the first PSK. If the two PSKs are the same, the authentication succeeds; otherwise, the authentication fails.
[0090] Step 806 : The UAAF sends the second PSK and the correlation between the second PSK and the CNG to the CNGCF.
[0091] Step 807 : The CNGCF performs authentication according to the first PSK in the message received from the CNG and the second PSK stored in the CNGCF; and the CNG performs authentication according to the second PSK in the message received from the CNGCF and the first PSK stored in the CNG.
[0092] The CNG management authentication method in this embodiment shares the same user ID or key with the CNG access authentication, and uses the first PSK and the second PSK generated in the access authentication process, thus simplifying the security association negotiation process of the CNG management authentication, and improving the efficiency while ensuring the security. Therefore, this method reduces the operation and maintenance costs of distributing numerous CNGs and improves the operation efficiency.
[0093] FIG. 9 is the first schematic diagram of a structure of another CNG authentication system in an embodiment of the present invention. The system includes:
[0094] a CNG 41 , adapted to: send access authentication information, send and receive management authentication information, and generate a first PSK;
[0095] a CNGCF 46 , adapted to receive and send the management authentication information;
[0096] a UAAF 43 , adapted to: receive the access authentication information, generate a second PSK, and send the second PSK to the CNGCF 46 , whereupon the CNGCF 46 authenticates the message received from the CNG 41 according to the first PSK and the second PSK and the CNG 41 authenticates the message received from the CNGCF 46 according to the first PSK and the second PSK;
[0097] an AMF 42 , adapted to forward access authentication information between the CNG 41 and the UAAF 43 ; and
[0098] a NACF 45 , adapted to: allocate an access network identifier to the CNG 41 and send it to the UAAF 43 , whereupon the UAAF 43 searches for the CNGCF corresponding to the CNG according to the CNG and access network identifier information sent by the NACF and forwards the second PSK to the found CNGCF 46 .
[0099] The authentication process involves no AMF.
[0100] FIG. 10 is the second schematic diagram of a structure of another CNG management authentication system in an embodiment of the present invention. The system includes:
[0101] a CNG 51 , adapted to: send access authentication information, send and receive management authentication information, and generate a first PSK;
[0102] a CNGCF 56 , adapted to receive and send the management authentication information;
[0103] a UAAF 53 , adapted to: receive the access authentication information, generate a second PSK, and send the second PSK to a CLF 54 ;
[0104] the CLF 54 , adapted to forward the second PSK to the CNGCF 56 ;
[0105] the CNGCF 56 , adapted to: authenticate the message received from the CNG 51 according to the first PSK and the second PSK, and authenticate the message received from the CNGCF 56 according to the first PSK and the second PSK; and
[0106] an AMF 52 , adapted to forward access authentication information between the CNG 51 and the UAAF 53 .
[0107] The CNG authentication system provided in this embodiment generates, distributes and modifies management credentials automatically, thus enabling authentication between the CNG and the CNGCF fundamentally, reducing the operation and maintenance costs of distributing numerous CNGs, and improving the operation efficiency massively.
[0108] Although the invention is described through several exemplary embodiments, the invention is not limited to such embodiments. It is apparent that those skilled in the art can make modifications and variations to the invention without departing from the spirit and scope of the invention. The invention is intended to cover such modifications and variations provided that they fall in the scope of protection defined by the following claims or their equivalents.
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A method for authentication based on NASS is disclosed. UAAF authenticates the accessing of CNG. UAAF produces the management authentication credential between CNG and CNGCF, and sends the management authentication credential to CNGCF. CNG obtains the management authentication credential. CNG authenticates CNGCF by the obtained management authentication credential and CNGCF authenticates CNG by the management authentication credential. A system for authentication based on NASS is also disclosed. The authentication credential can be automatically produced, distributed and modified. And the operation cost is reduced and the operation efficiency is enhanced.
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CROSS REFERENCE TO RELATED APPLICATIONS
U.S. Patent Documents
[0001] U.S. Pat. No. 5,885,829 March 1999 Mooney et all
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] This invention lies in the field of medical or biological science. The range of the application will include cosmetic and medical functions. The application will include a treatment the restoration of proteins such as collagen and elastin. The procedure is similar to both mammalian cloning and to gene replacement therapy.
[0005] In mammalian cloning, an egg with the original genetic material removed is injected with genetic material from another mammal. This was performed by Dr. Ian Wilmut's team and resulted in the first cloned mammal, “Dolly” the sheep. The techniques here include the removal of a full genome and placing it in an egg. In gene replacement therapy, a damaged or harmful gene is replaced with a copy created in the laboratory. If the gene is accepted into the cell, then the phenotypic result should become evident as the patient's cells express themselves and/or reproduce. This technique includes the identification of the gene of interest, the creation of the replacement gene, it's incorporation into a vector, and the use of the vector to introduce the new material. In the scope of this patent, we will be using the extraction of the genome, the incorporation of the genome into a vector, and it's insertion into a diploid cell.
[0006] Currently, there are a number of different skin care treatments that are designed to reduce wrinkles and restore collagen and elastin levels. These must be reapplied, as the effects are designed to cover the phenotypic effect caused by the aging genotype. There is a concentration on fixing proteins and polypeptides that are eroded by the effects of aging, such as the introduction of collagen, but there is no mainstream concentration on the regeneration of the genes that are creating the effect. The cosmetic industry is a billion dollar business, which is designed to enhance a person's looks with artificial colors, smooth out a persons natural features, or reduce the look of aging.
[0007] The market for anti-aging products currently carries many approaches to the problem. One commonly used technique is to inject dead Botulism Type A into the muscles around the face to reduce wrinkles (4). Another uses skin firming agents, elasticizers, and skin hydrators to make the skin look smoother and firmer (5). This requires repeated applications, several times a day, to be effective. More extreme measures, such as surgical manipulation, have been used for some time to reduce the effects of larger wrinkles and sagging skin. These procedures can require a hospital stay, and pain medication. For the face, these usually involve cutting the skin in an inconspicuous place, pulling on the skin to remove the most prominent wrinkles, and surgically reattaching the skin. One of the undesired effects is that the natural openings in the skin, such as the mouth and eyes, can also become stretched and can thus appear malformed, especially when compared to the rest of the face. The procedure will usually require recovery time for the patient, and there is no guarantee that the surgery will not need to be performed again. The process is also non-reversible.
[0008] As any living thing ages, the DNA becomes less like it was at birth. This is due to carcinogens, oxidative reduction reactions, and to random mutations that are not repaired, or are done so incorrectly, by our cells. (11) In humans, this can lead to skin collagen and elastin loss. All of these phenotypic responses are caused from the genes controlling them being affected by simple aging.
[0009] In the permanent teeth of a human, the DNA stops replicating once the tooth is fully developed. The process of developing these teeth begins at around age six. The tooth of a human grows by allowing new material to develop from the center, and push the old material towards the sides. This will mean that the youngest genetic material will be seen at the edge just below the enamel, in an area called the mantle dentin. Whatever genetic alterations happen to the body will usually occur to reproducing cells. (13) As the fully developed permanent teeth have none, the DNA is unaffected. A person whom is eighty years old will still have six-year-old genetics within them, if the teeth are still present. We are suggesting that the genome found here can be used to fix the damage caused later in life in other cells.
BRIEF SUMMARY OF THE INVENTION
[0010] The aforementioned problems have genetic links. The idea behind this invention is that the genome of affected cells can simply be replaced with DNA that a person already has within them. Once the genome is replaced, some genetic problems will no longer exist.
[0011] Inside the permanent tooth of a person, excluding the wisdom teeth that can develop later, there is a layer of mantle dentin. This layer of cells contains DNA that was created when the person was about 6 years old. Since the cells here do not reproduce, there will be no genetic difference in these cells from the moment they were created until their demise. Despite the rest of the body's constant cycling of cells, the teeth remain the same. This DNA can be extracted, introduced into a vector, and used to replace the genome of other cells in the body that have had genetic damage. If the genotype of one cell in the body is virtually the same as any other genome-bearing cell in the body, then the DNA is interchangeable. The cells simply express what is needed from the DNA, according to what the cell is and what the cell is supposed to do. If the DNA from the tooth is unchanged from it's creation at around six-years-old, then the cell it is introduced to will read from six-year-old DNA, despite the age of the person.
[0012] If age is viewed as a genetic problem, then genome replacement will have a key effect on skin properties and hair growth. Since hair loss, as well as hair pigment loss, is a genetic factor for most, the application can be used to regrow and recolor hair. As soon as the cell has the genetic blueprint for hair growth, the rest of the cell can perform to the task. Skin that has been exposed to tanning beds and/or natural light over several years can be exfoliated and introduced to the new genetic material. This should allow the skin to regrow collagen, elastin, and any other protein or polypeptide that it could at the age of six, and at the same levels. This can be performed anywhere on the skin, not just the face. This can be a great advantage from agents such as skin creams that are currently used primarily on the face and neck, as this more permanent solution can be used anywhere on the same person. The result can be more effective than current skin rejuvenation creams as well, as the entire genetic make-up will be reset to the point of a child, despite the person's age.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0013] Not applicable.
DETAILED DESCRIPTION OF THE INVENTION
[0014] All working surfaces will be decontaminated with a wash sequence of sodium hypochlorite (10%), hydrochloric acid (0.1%), and ethanol (70%). All equipment will be sterilized by autoclaving and decontaminated by exposure to ultraviolet light and bleaching. Novocain will be used to numb the tooth at the gums. A cordless, variable-speed, hand-held electric drill with a 1.0-1.5 mm drill bit, will be used to obtain 0.01-0.02 g of mantle dentin powder from a tooth. A drilling speed of less than 100 revolutions per minute (r.p.m.) was used to minimize heat production, which could result in DNA degradation. The hole or holes drilled will be approximately 1.5-2.0 mm wide and 2.0-3.0 mm deep. Holes will be drilled preferably at the base of the gum line, or on the inside of the tooth to minimize visible damage. Prior to drilling, the drill site will be cleaned with 70-100% ethanol to remove dust and particulate matter. Cotton will be used to keep the area dry. A new, autoclaved drill bit and autoclaved collection tray made from aluminum foil will be used for each patient. The head will be held at an incline during drilling to ensure the tooth powder produced falls into the collection tray. The tooth will be filled as if it were any other dental hole. Tooth powder will be transferred from the tray to a sterile 2 mL tube by careful decanting. This will be packed in ice and stores in a thermal container to be sent to a lab, if the lab work will not be performed on site. After the drilling of each tooth, drill bits and all disposable equipment, including gloves, will be discarded, and working surfaces decontaminated, as described above. (14),(15)
[0015] The tooth powder sample is added to a lysis buffer containing alpha-casein. Next, guanidine thiocyanate (GuSCN) and silica are introduced for 10 minutes. After centrifuging, the supernatant will be removed, and the pellet will be washed with 1 ml of acetone, the process is repeated at least three times, until the sample remaining is pure DNA from the mantle dentin. (16)
[0016] PCR can be used to replicate the genome, as long as a specific primer is not used to isolate a single gene. This will require the DNA, a solution of primers to start the reaction, and a healthy supply of base pairs (Adenine, Guanine, Cytosine, and Thymine). PCR uses a strand of DNA, in this case one for each chromosome, and heats it to 96 degrees C. to separate the DNA strands from their hydrogen bonds. These are then lowered to 68 degrees C. to allow the primers to attach to the template strands of DNA. Once it is lowered to 72 degrees C., the new strands are allowed to recombine. This temperature will need to be maintained for about four hours, to allow for the entire genome to replicate. This will allow one strand to become two. The next cycle of these temperature changes will allow two strands to become four. After twenty cycles, over a million strands are present. This can be accomplished in three days. An alternative to PCR is to grow the mantle dentin from a small sample. This process will allow for more cells to be grown, thus more DNA. Once a sufficient supply of DNA is present, the solution can be introduced to a detergent to create a vector. This will create a Detergent-DNA complexes. One of the most common methods is to use a non-ionic detergent (e.g., lipofectin) that forms a complex with the DNA and by mechanisms still not well understood allow for introduction of DNA into the cell. (17) Some of the solution will be stored in a cold climate for preservation, to ensure that future application will not require more extraction from the patient. What is required for the current application will be placed in the necessary form and distributed.
[0017] If introduced as a cosmetic, the patient must first use an abrasive exfoliate, such as a pumice scrub, to relieve any dead skin from the area. Next, the solution will be placed into a hand/body cream that also contains propylene or butylene glycol, glycerine or glyceryl stearate, stearic acid or linoleic acid, sorbitan stearote, and urea, as do most body lotions. After it is applied and the cells accept the DNA, the skin and hair should revert back to the phenotypic properties seen at approximately six years of age.
REFERENCES
[0018] (1), (2) http://www.bosley.com
[0019] (3) http://www.hairsite.com/color/color-technical.htm
[0020] (4) http://www.botox.com
[0021] (5) http://www.strivectin-kleinbecker.comnFAQ.php?question=FAQ1. Txt
[0022] (6) D L Tait, P S Obenmiller, S Redlin-Frazier, R A Jensen, P Welcsh, J Dana, M C King, D H Johnson, and J T Holt, A phase I trial of retroviral BRCA1sv gene therapy in ovarian cancer Clin. Cancer Res. 1997
[0023] (7) X Jin, D Nguyen, W W Zhang, A P Kyritsis, and J A Roth Cell cycle arrest and inhibition of tumor cell proliferation by the p16INK4 gene mediated by an adenovirus vector Cancer Res. 1995 55: 3250-3253.
[0024] (8) Qiao J, Diaz R M, Vile R G Genome Biology 2004, 5(8):237 (29 Jul. 2004)
[0025] (9) Profiling of pathway-specific changes in gene expression following growth of human cancer cell lines transplanted into mice Creighton C, Kuick R, Misek D E, Rickman D S, Brichory F M, Rouillard J M, Omenn G S, Hanash S Genome Biology 2003, 4(7):R46 23 Jun. 2003
[0026] (10) Holt, Rinehart and Winston's Biology, Principles and Exploration, p 128
[0027] (11) Smeal T, Claus J, Kennedy B, Cole F, Guarente L: Loss of transcriptional silencing causes sterility in old mother cells of S. cerevisiae. Cell 1996, 84:633-642.
[0028] (12) Thomas H, Ougham H J, Wagstaff C, Stead A D: Defining senescence and death. J Exp Bot 2003, 54:1127-1132.
[0029] (13) Smeal T, Claus J, Kennedy B, Cole F, Guarente L: Loss of transcriptional silencing causes sterility in old mother cells of S. cerevisiae. Cell 1996, 84:633-642
[0030] (14) Boom R, Sol C J A, Jansen C L, Wertheim-van Dillen P M E & van der Noorda J (1990) Rapid and simple method for purification of nucleic acids. Journal of Clinical Microbiology, 28, 495-503.
[0031] (15) Matisoo-Smith E, Allen J S, Lagefoged T N, Roberts R M & Lambert D M (1997) Ancient DNA from Polynesian rats: extraction, amplification and sequence from single small bones. Electrophoresis, 18, 1534-1537.
[0032] (16) Onnnm R., Sol C., Beld M., Weel J., Goudsmit J., and Wertheim-van Dillen P. 1999. Improved Silica-Guanidiniumthiocyanate DNA Isolation Procedure Based on Selective Binding of Bovine Alpha-Casein to Silica Particles. Journal of Clinical Microbiology, March, Vol. 37, No. 3: 615-619
[0033] (17) (http://www-users.med.cornell.edu˜/jawagne/genes,_promoters,_DNA_&_ge.htmi
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Genomic Replacement Therapy uses the human genome found in mantle dentin of a patient's tooth to affect other cells of the body. Mantle Dentin cells in the developed tooth do not reproduce, therefore the DNA is “younger”. Replacing the genome with a “younger” one will hopefully return youthful appearances to clients.
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[0001] This application claims priority from copending U.S. Provisional Application Ser. No. 60/214,963 filed on Jun. 29, 2000 which is hereby incorporated by reference herein.
[0002] This application is part of a government project. The research leading to this invention was supported by a Grant Number 9876251 from the National Science Foundation. The United States Government retains certain rights in this invention.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0003] The invention relates to the field of providing a synthesis technique to grow bulk quantities of semiconductor nanowires at temperatures less than 500° C.
DESCRIPTION OF THE PRIOR ART
[0004] One-dimensional semiconductor fibers are useful for many applications ranging from probe microscopy tips to interconnections in nanoelectronics. By “one-dimensional” it is meant that the fibers have extremely small diameters, approaching 40 Angstroms. The fibers may be termed “nanowires” or “whiskers.” Several methods are known for synthesis of these fibers. Included are VLS (vapor-liquid-solid) growth, laser ablation of silicon and silicon oxide species and combinations of these techniques.
[0005] In VLS growth, a liquid metal cluster or catalyst acts as the energetically favored site of absorption of gas-phase reactants. The cluster supersaturates and grows a one-dimensional structure of the material. A VLS method has been used to grow silicon nanowires by absorption of silane vapor on a gold metal surface. Variations of this methods have been used to produce other semiconductor fibers.
[0006] One variation is laser ablation. In this technique, the silicone species, such as SiO 2 , is ablated to the vapor phase by laser excitation.
SUMMARY OF THE INVENTION
[0007] The present invention provides a method of synthesizing semiconductor fibers by placement of gallium or indium metal on a desired substrate, placing the combination in a low pressure chamber at a vacuum from 100 mTorr to one atmosphere pressure in an atmosphere containing desired gaseous reactants, raising the temperature of the metal to a few degrees above its melting point by microwave excitation, whereby the reactants form fibers of the desired length. When the metal is gallium, a temperature of about at least 50° C. is sufficient, preferably near 300° C. for best solubility and mobility within the melt. When the metal is indium, a temperature of about 200° C. is preferred. Preferably the substrate is silicon, most preferably silicon comprising an electronically useful pattern; the metal is gallium, the gaseous reactant is hydrogen, and the fibers formed comprise SiH x . The gallium metal may be applied either in solid or droplet form or in the form of patterned droplets for patterning silicon microwires. Other forms of gallium droplet patterns may also include droplets in two dimensional and three dimensional channels for directed growth.
[0008] Another preferable substrate is germanium with hydrogen as gaseous reactant. The reactant hydrogen will form germane, GeH x in the gas phase which upon decomposition on a gallium substrate results in the deposition of germanium into gallium droplets. The dissolved germanium grows out as germanium nanowires.
[0009] Other semiconductors materials may be synthesized according to the methods of this invention. In each case, gallium or indium metal is used as the absorption sit-catalyst. Where the substrate is not readily vaporized to provide a gaseous reactant, a vapor substrate will be added to the reactive atmosphere. For example, GaAs substrates may be used, with a gallium drop and nitrogen in the gas phase, to grow GaN nanofibers.
[0010] These and other objects of the present invention will be more fully understood from the following description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the several views and wherein:
[0012] [0012]FIG. 1 shows fibers in the process of growth, each having a droplet of molten gallium on its tip.
[0013] [0013]FIG. 2 is a scanning electron micrograph showing fibers in growth, with droplets of molten gallium
[0014] [0014]FIGS. 3 and 4 are scanning electron micrographs showing the range of fiber diameters obtained by practicing the methods of this invention.
[0015] [0015]FIG. 5 is a transmission electron micrograph shows silicon nanowires with diameters <10 nanometers.
[0016] [0016]FIG. 6 is a schematic of the reaction chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] This invention provides a novel synthesis route for growing one-dimensional structures of semiconductor materials in wire, whisker and rod shapes at temperatures well under 550° C., preferably less than 300° C. This low-temperature synthesis is made possible by the use of gallium as a catalytic absorption site. Gallium has a low melting temperature (˜30° C.) and broad temperature range for the melt phase (30-2400° C. at 1 atm). Indium, which has a melting temperature of 156.6° C., and a melt range of 156.6 to 2000° C., is also useful as a catalyst. In one embodiment of the invention of the invention, growth of silicon fibers was observed when silicon substrates covered with a thin film of gallium were exposed to mixture of nitrogen and hydrogen in a microwave-generated plasma. The resulting silicon wires ranged from several microns to less than ten (10) nanometers in diameter. The observed growth rates were on the order of 100 microns/hour. Results indicate that this technique is capable of producing oriented rods and whiskers with reasonable size distributions. The growth mechanism in this method is hypothesized to be similar to that in other VLS process, i.e., rapid dissolution of silicon hydrides in gallium melt, which catalyzed subsequent precipitation of silicon in one dimension in the form of fibers.
[0018] This techniques offers several advantages over conventional VLS techniques using silicon-gold eutectic for catalyzed growth. When the fibers desired comprise silicon or germanium, there is no need to supply silicon or germanium in gaseous form. Secondly, the very low temperatures required when using gallium as the catalyst allows easier integration with other processing techniques and materials involved in electronics and opt-electronic device fabrication. Such nanometer scale one-dimensional semiconductor structure such as nanowires and nonwhiskers are expected to be critically important in advanced mesoscopic electronic and optical device applications.
[0019] The advantage of low-temperature fabrication are also useful for those semiconductors in which the substrate and the fibers differ in composition. In such case, both or all fibers components may be provided in the vapor phase.
[0020] To more explicitly teach the methods of this invention, the following detailed embodiments are provided for purposes of illustration only. Those skilled in the art may readily make substitutions and variations in substrates and reactants to synthesize other semiconductors on a gallium catalyst. Such substitutions and variations are considered to be within the spirit and scope of this invention.
EXAMPLE 1
Synthesis of SiH x Fibers
[0021] A silicon substrate (2 cm×2 cm) was prepared by cleaning with a 45% HF solution, thorough rinsing in acetone and ultra-sonication. Droplets of gallium metal at 70° C. were applied to form a film with a thickness of approximately 100 microns. A thermocouple was placed on the underside of the substrate to measure the temperature and the nitrogen flow rate was set to 100 sccm. The pressure in the reactor was set to 30 Torr. Microwaves at 2.45 Ghz were used to ionize the nitrogen gas. The input microwave power was 1000 W. The nitridation experiments were done in an ASTeX model 5010 bell jar reactor chamber equipped with an ASTeX model 2115 1500 W microwave power generator. Five sccm of hydrogen were introduced into the nitrogen plasma. The reaction was continued for six hours. Graphite blocks were used as substrate stage. The quartz bell jar volume was approximately 2000 cc. FIG. 6 shows a schematic of the reactor. The silicon substrate covered with an ashy structure was observed under a scanning electron microscope (SEM). FIGS. 1 through 5 show micrographs of varying thickness and length. FIG. 1 shows a group of nanowires, each with a tiny drop at the end. These fibers were grown with H 2 /N 2 ratio of 0.05, pressure of 30 Torr and microwave power of 1000 W. FIG. 2 shows initial highly oriented growth of silicon nanofibers for short time scale growth (initial one hour). FIG. 3 shows a web of fibers grown for a longer time, five hours. Due to the long growth (initial one hour). FIGS. 3 shows a web of fibers grown for a longer time, five hours. Due to the long growth duration, the grown wires were very long and intermingled. The limitation on size is time-dependant, but not process-dependant. FIG. 4 shows nanowires with different thicknesses. FIG. 5 shows a transmission electron micrograph of silicon nanowires with diameters in single digit nanometer scale. These fibers were grown with H 2 /N 2 ratio of 0.0075, pressure of 50 Torr and 1000 W of microwave power. The elemental composition of the fibrous structures was determined using Energy Dispersive Spectroscopy (EDS).
EXAMPLE 2
Synthesize of Germanium Fibers
[0022] Germanium fibers can be grown using the above technique by using either germanium substrate or using germane in the vapor phase. The gas phase will preferably consist of hydrogen with or without nitrogen to result in the formation of germane, a gaseous source of germanium. German will be catalytically decomposed on the gallium substrate resulting in accelerated dissolution of germanium into the gallium melt.
EXAMPLE 3
Synthesis of Gallium Nitride Fibers
[0023] Nitrogen can also be dissolved into gallium melt, but at relatively higher temperatures than above, i.e., above ˜600° C. At these temperatures, suing gallium droplets exposed to an atomic nitrogen source, such as plasma, one can achieve nitrogen saturated gallium melts. These nitrogen saturated gallium melts will form gallium nitride either in the whisker or nanowire format.
EXAMPLE 4
Synthesis of Silicon Nitride Fibers and Whiskers
[0024] Using a similar setup as that used for example 1, one can expose the gallium droplet to nitrogen and hydrogen plasma at relatively higher temperature, i.e., ˜600° C., to achieve the dissolution of both nitrogen and silicon into the gallium droplet. The resulting silicon nitride whiskers or nanowires can be adjusted in diameter by varying the size of the gallium droplet.
[0025] The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made upon departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplifications presented hereinabove. Rather, what is intended to be covered is within the spirit and scope of the appended claims.
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A method of synthesizing semiconductor fibers by placement of gallium or indium metal on a desired substrate, placing the combination in a low pressure chamber at a vacuum from 100 mTorr to one atmosphere pressure in an atmosphere containing desired gaseous reactants, raising the temperature of the metal to a few degrees above its melting point by microwave excitation, whereby the reactants form fibers of the desired length.
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FIELD OF THE INVENTION
[0001] The invention relates to methods and systems for providing a dispensing device such as a beverage vending machine and similar, by using a communication device capable of communicating data to the dispensing machine. More specifically, the invention relates to methods and systems for managing a dispensing device by using radio frequency (“RF”) communication tags attached to or embedded on the package containing the food material to be dispensed.
BACKGROUND OF THE INVENTION
[0002] Radio frequency identification tags (hereinafter referred to as “RFIDs”) are well-known electronic devices which have uses in many areas. An RFID works by first recording or “burning in” identification or other data on the RFID device. Thereafter, the RFID sends the recorded identification or other information to the RFID reading device. A particular advantage of RFIDs over bar code, optical characters and magnetic storage (such as the magnetic strip on many credit cards) is that the RFID does not require physical contact, or as is the case with optical character and bar code readers, line of sight, between the tag and the reading device to be read.
[0003] RFIDs come in two varieties: active and passive. An active RFID includes a battery or other power source, and is activated by a signal from a reading device. The activated RFID then broadcasts its identification or other data, which is picked up by the reading device. An advantage of active RFID's over passive RFIDs is that the inclusion of a power source allows the active RFID to transmit to a receiver without entering into an electromagnetic field to power the tag circuit. They are also generally able to transmit over a longer distance. This has led to its use in automatic toll-paying systems, such as EZ-Pass™. An active RFID has several disadvantages compared to a passive RFID. Since it requires a battery or other power source, it is more expensive and heavier then a passive RFID. More importantly, the active RFID becomes useless when the battery or other power source is depleted.
[0004] Passive RFIDs have no power supply per se, but power is provided to the RFID circuitry by using an electromagnetic power receiver. The RFID reading device sends power to the RFID's electromagnetic power receiver, thus powering up or turning on the RFID's circuits. Next, the passive RFID broadcasts a response signal containing identification or other information, which is then read by the reading device. Since the passive RFID has no battery, it is less expensive and lighter. Passive RFIDs have been in use for some time, notably in security access cards where the user holds the card near the card reader to unlock a door, and in clothing stores as security tags attached to expensive clothing items. Until recently, this technology has been prohibitively expensive for use in food product dispensing.
[0005] Food product dispensing machines come in a numerous variety, depending upon the food product being dispensed and the preparation steps required. Food products so dispensed may be solid or liquid, and may be dispensed at room temperature, hot, cold, or any other temperature. Additional preparation steps may be involved, such as adding a diluent, mixing, whipping, heating, etc. Although the following discussion focuses on prepared beverage dispensing machines and their associated processing, as one of ordinary skill in the art of vended or machine-dispensed foods will realize, the background and invention herein described applies equally to dispensing of other food products.
[0006] Conventional beverage dispensing machines employ food material, such as powder products, concentrates or ready-to-drink products (“RTD”), which are refilled in the machine on a regular basis by a food service operator or route person. The dispensing machine may perform a number of operations to deliver a cold or warm beverage to the user. Typically, powder products or concentrates are maintained in storage areas, dosed on demand according to a desired dilution rate, mixed with a cold or hot diluent, usually water, in a mixing area and delivered in a dispensing container. RTD products may be maintained under specialized storage conditions, such as under refrigeration or other temperature control for sanitary and organoleptic reasons. These products will typically have a more limited shelf life. It is also common for the shelf life of RTD products to be altered or shortened when opened or punctured and placed into the unit for dispensing. As an example, an RTD product may have an unopened shelf life of 6 months to 1 year under proper storage conditions. However, when the product is open and placed in the dispenser the product will now have an opened shelf life which is much shorter (possibly 7-14 days), which is usually dependent from the day of opening of the package.
[0007] Beverage dispensing machines which use powder or concentrates may store these ingredients in bins which are then refilled by the food service operator, with each bin holding powder or concentrates for multiple servings of the beverage. Powder products may be stored in disposable packages such as flow wrap packs, that are used for refilling the reservoirs or hoppers of the dispensing machines. The package itself may alternatively be adapted to remain in the machine and to serve as a reservoir or bin. Alternatively, the powder or concentrate may be held in a single-serving packet, which are also refilled by the food service operator. When multiple packets are used, each packet is opened by the beverage dispensing machine at the time it is being dispensed.
[0008] There may exist a variety of instructions and variables pertaining to beverage reconstitution in the machine. For example, the machine may need to be instructed of the proper amount of a powder or concentrate to use. Other variables include the amount of diluent needed, which may depend upon which powder or concentrate is used and the nature of the beverage to be prepared, the temperature at which the beverage should be served, and the degree of whipping, if any, required to provide a foamy texture, etc.
[0009] Usually, dispensing machines are preprogrammed in the factory to receive specific types of foodstuff in order to make a limited number of specific types of beverages. When the instructions to the machine need to be modified for any reason such as because of modifications of the composition of the refill food product or because new types of food product are demanded, the dispensing machine should be reprogrammed. Reprogramming currently is accomplished by having a technically trained food service operator visit the dispensing machine on-site, or by returning the dispensing machine to the factory. On-site programming is generally preferred for reasons of cost and flexibility. This, however, requires the food service operator to be equipped with portable programming to utilize a local controller interface and to be sufficiently qualified to use the equipment. Also, the food service operator should insure that the data and instructions are correctly loaded into the dispensing machine. This, in turn, requires that the food service operator should run tests of beverage preparation at each machine that is reprogrammed. Portable equipment usually needs to be frequently updated with data, instructions, and other software specialized for the types of foodstuff with which the dispensing machine is to be filled. The number of variables used in programming should be limited and the instructions simplified to avoid incorrect operations, errors and confusion, malfunction of the machine, and consequently inconvenience to the consumer.
[0010] Therefore, it would be desirable to provide instructions and variables to the machine which specifically refer to the product to be refilled while eliminating the need for an operator's manual or semi-automatic programming with portable programming equipment, or for returning the machine to the factory. It would also be desirable to provide a flexible and operational system for immediately programming a dispensing machine to accommodate each and every type of refill food product that may be dispensed, without limiting the number of variables, data, instruction schemes, code or other information used in the programming. Therefore, it would be desirable to program the dispensing machine more frequently, and without the assistance of a food service operator, or at least with minimal operator assistance. It would also be desirable to customize this more frequent programming for each product dispensed from the machine, and remove the need for an operator to do a test run of each programmed product on every programmed dispensing machine.
[0011] Another shortcoming of current beverage dispensing systems is that it is almost impossible to control the vending of food products that the dispensing machine is not intended for. These food products may be undesirable for various reasons. For example, the food products may not meet quality and/or safety standards. For instance, the dispensing machine may accept low quality coffee, milk powder or concentrates the same way it may accept premium or top quality food products. There is also a risk of the consumer being deceived by products that may not meet the consumer's legitimate expectation, especially when the machines are branded with famous food product brands.
[0012] Similarly, dispensing machines are unable to refuse or reject powders or concentrates for which the deadline or expiration date for vending has expired. This is particularly dangerous when low acid food products, such as dairy products, are used. There could also be a potential risk of causing serious food poisoning. It would be desirable to ensure that the food product dispensed from the machine is always of sufficient quality to guarantee safety, and that, if it does not, to ensure the product cannot be vended to the consumer. If the food product in the machine is not desirable or is no longer desirable, there is a need for easy detection and tracking of the food product. This would allow for sufficient and immediate steps to be taken to replace the food product and ensure service to the consumer without significant disruption.
[0013] Therefore, it would also be advantageous to not only have the machine be able to detect such undesirable food products, but to then send a notification to either the consumer and/or the food service operator. Of course, the notification to the consumer might be simplified to merely indicate that the chosen food product is not available.
[0014] Another shortcoming of existing food product dispensing systems is the limited ability to collect and retrieve historical information or usage data. For example, usage information might be gathered to gain a better understanding of consumer habits, or conversely, for providing information to the customer such as nutritional facts, promotional information, etc. Therefore, it would be desirable for a food product dispensing system to retrieve information or usage data and/or to provide information to the customer using the food product dispensing system as an information retrieval and/or disseminating system.
[0015] U.S. Pat. No. 5,285,041 to Wright (“'041 patent”) relates to a food vending system which is integrated with a specially-shaped oven for providing hot food service. The device is capable of being automatically instructed to vend food using different temperatures, cooking cycles or time periods by using a standardized package that matches the specially-shaped oven cavity and a bar code on the package. The bar code is read by a bar code reader when a selected package is taken from the dispenser outlet and inserted in the specially-shaped oven. The device includes a bar code reader to read codes printed on the food package, and allows that a magnetic or optical character reader may be alternatively used. Further, in order to ensure a proper reading of the code, the food packaging is standardized and the microwave oven has a specialized shape which matches the food product packaging. The package is held in a predetermined position by the specialized shape of the oven cavity, and the bar code reader is located in a predetermined position in the oven cavity. Thus, the code printed on the food package is automatically read by the bar code reader when the package is inserted in the oven. The device is adapted to accommodate three-dimensional products such as pizza packs of predetermined shape that properly match the reading zone. In particular, to read information, the device of the prior art needs to ensure the product properly matches the shape of the reading zone so that the bar code reader can properly read the bar, magnetic or optical code imprinted on the exterior of the product package.
[0016] Raw beverage-making materials are often packed in bulk in flow wrap packs that are not often left in the device, but only used for refilling the raw beverage-making material in hoppers arranged in the device. The device of the '041 patent would not be adaptable to receive information, decode and instruct from a variety of different raw beverage-making materials in such hoppers, such as coffee, cocoa, milk or soup powders, concentrates or RTD, which do not necessarily have a well defined three-dimensional package.
[0017] Also, it would be desirable to propose a method that allows the communication of vending instructions and/or other data to a food product dispensing device from a package that does not necessarily need to match the shape of a preformed reading zone of the dispensing device, and does not require either physical contact or a line-of-sight between the reading device and the package.
[0018] Current inventory control and tracking systems for food products require operator input at several points in the packaging, shipping, and food product dispensing process. For example, the factory would gather the raw food product and place it into containers, such as flow packs (for some powdered beverages). At this stage, an operator might record, possibly in a computer database, a batch or identification number.
[0019] Later, another operator would note where the batch of product was shipped for distribution in a log of information. It is possible that the food service operator might make a further notation on another log when the product is finally loaded into the dispensing machine.
[0020] Thus, it would be desirable to have a system which allows for the tracking of a product from the factory to the final dispensing to a consumer without the need for an operator to manually input the product information. Also, a desirable characteristic of such a system would be the ability to track a large amount of information, not merely a product and/or batch identification number, but also information such as expiration date, preparation instructions, and more.
[0021] It would also be desirable to have a system that provides for tracking of certain variables and/or other data from a product in order to guarantee safety, quality and to retrieve other useful information.
SUMMARY OF THE INVENTION
[0022] The invention relates to an article comprising a receptacle having at least one wall member that defines an enclosure, a food- or beverage-forming product present within the enclosure, and a tag associated with the receptacle, wherein the tag includes machine-readable information regarding the product. Advantageously, the tag is programmable. Preferably, the tag is an RFID device which includes identification information in electronic form for the product, includes instructions in electronic form for preparation of the product, includes a date of expiration in electronic form for the product, or includes a set of information in electronic form regarding features, characteristics or properties of the product.
[0023] When the tag includes expiration date information, it may be determined relative to two different scenarios. The first is when the receptacle and the associated product are within the predetermined acceptable life-span and placed into the container. The second is when the receptacle and associated product are not within the acceptable life-span, opened and placed with the dispenser. In the present application, reference to “date information” refers to any possible time related information data that provides directly or indirectly an indication or reference to time including but not necessarily limited to a calendar date or a time related code. Typically, the food- or beverage-forming product provides a single serving portion of the food or beverage, but multiple serving portions can be provided if desired. When multiple portions are dispensed, the calculation of the expiration date may even be of more importance to obtain the appropriate organoleptic properties of the food or beverage.
[0024] Another embodiment relates to a method of dispensing a food or beverage, which method comprises encoding instructions for preparation of the food or beverage on a machine-readable tag associated with a receptacle that contains a food-forming or beverage-forming product; placing the receptacle in or sufficiently close to a dispenser; reading of the machine-readable tag by the dispenser prior to preparation of the food or beverage to be dispensed; and executing the instructions encoded on the machine-readable tag by the dispenser to dispense the food or beverage.
[0025] The invention also relates to a method of controlling the dispensing of a food or beverage product from a food-forming or beverage-forming product, which method comprises encoding a verification code on a machine-readable tag associated with a receptacle that contains a food-forming or beverage-forming product; placing the receptacle in a dispenser; reading of the machine-readable tag by the dispenser prior to preparation or dispensing of the food or beverage; and comparing of the verification code read from the machine-readable tag with a list of valid verification codes. The food or beverage is prepared and dispensed when the verification code read from the machine-readable tag matches a valid verification code from the list but an error code is generated when it does not. In this method, the error code can disable the dispenser from preparing or dispensing the food or beverage. Alternatively, the error code can notify a consumer that the product selected for dispensing is not available, or can notify an operator of the dispenser that an invalid product verification code has been read.
[0026] The invention also relates to a method of determining consumption of foods or beverages from a dispenser, which method comprises recording information on a machine-readable tag associated with a receptacle that contains a food-forming or beverage-forming product; updating a computer database with the recorded information; reading of the machine-readable tag by the dispenser when the food or beverage is dispensed; updating the computer database with information about the foods or beverages that are dispensed; and sorting the information to determine consumption patterns for the foods or beverages that are dispensed. This method includes the steps of reading the machine-readable tag before the receptacle is delivered to the dispenser to obtain supply information; updating the computer database with the supply information; and sorting the information to determine supply sources of the receptacles for the dispenser. Also, the consumption pattern information can be used to schedule times for re-supplying the dispenser with receptacles.
[0027] Another embodiment of the invention relates to a system for dispensing a product, comprising a dispenser for holding one or more receptacles as described herein, and for preparing and dispensing a food or beverage from the food-forming or beverage-forming product(s) of the receptacle(s). The receptacle is generally composed of a non-conductive material and the tag is located within the enclosure. When the receptacle is composed of a conductive material, the tag may be attached to the at least one wall member on a side opposite that of the enclosure.
[0028] In another embodiment of the invention, the system for dispensing a product is adapted to receive instructions from a dispensable receptacle for the purpose of refilling the dispenser with the raw material.
[0029] The tag is preferably an RFID device that includes information in electronic form regarding the features, properties or processing of the product, and the dispenser includes a tag reader for reading the tag, and a processor having memory operatively associated with the dispenser, and the tag reader, and a connection to an external communications network. The processor is preferably configured to signal the tag reader to read the tag; receive information read from the tag by the tag reader; store the information in the memory; and place the information on the external communications network.
[0030] The tag may includes product preparation instructions in electronic form and the processor is also configured to carry out the instructions to prepare and dispense the product, and the processor sets one of an operating temperature, a dilution ratio, a mixing time, or a dispensing time for the dispenser in accordance with the set of instructions in electronic form. If desired, the processor can be further configured to read a current time and date from an electronic clock, and then the processor compares the current time and date with a time and date of expiration contained in the set of information. When the current time and date is earlier than or equal to the time and date of expiration, processor disables the dispenser from dispensing the product. Also, when the current time and date is earlier than or equal to the time and date of expiration, the processor places a data set on the external communications network, the data set to include a name of the product, the time and date of expiration, and an indicia of identification for the dispenser.
[0031] Yet another embodiment of the invention relates to a system for authenticating and dispensing a prepared product, comprising a plurality of receptacles, each having at least one wall member that defines an enclosed area containing a food- or beverage-forming product and a machine-readable tag associated with each receptacle, a mechanism for extracting the food- or beverage-forming product from each receptacle, and preparing a food or beverage from food- or beverage-forming product(s), a device for reading the machine-readable tag, and a processor operatively coupled to the device and the mechanism, the processor configured to collect information from the machine-readable tag from the device for reading the machine-readable tag; compare the collected information with a pre-determined quality indicia; control the mechanism to extract and prepare the food or beverage when the collected information matches the pre-determined quality indicia; and preventing the mechanism from extracting or preparing the food of beverage when the collected information does not match the pre-determined quality indicia. As above, the machine-readable tag is an RFID and the device for reading the machine-readable tag is an RFID reader. The pre-determined quality indicia typically is a brand name, an indication of origin, a generic product grading or an expiration date.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] In the accompanying drawings:
[0033] FIG. 1 is a block diagram depiction of a system of a food product vending machine in according to a preferred embodiment of the present invention.
[0034] FIG. 2 is a block diagram of the controlling unit of a food product dispensing machine according to a preferred embodiment of the present invention.
[0035] FIG. 3 is a flowchart of the action sequence of dispensing a food product according to a preferred embodiment of the present invention.
[0036] FIG. 4 is a flowchart of the action sequence of dispensing a food product including an expiration date check according to a preferred embodiment of the present invention.
[0037] FIG. 5 is a diagram of the mechanical flow of a food dispenser system according to a preferred embodiment of the present invention.
[0038] FIG. 6 is a schematic representation of the components and interactions of an RFID according to a preferred embodiment of the present invention.
[0039] FIG. 7 is a block diagram of a broad system including inventory control in accordance with a preferred embodiment of the present invention.
[0040] FIG. 8 is a block diagram of a manufacturing and distribution information gathering and report generation system according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] The following description is presented to enable any person of ordinary skill in the art to make and use the present invention. Various modifications to the preferred embodiment will be readily apparent to those of ordinary skill in the art, and the disclosure set forth herein may be applicable to other embodiments and applications without departing from the spirit and scope of the present invention and the claims hereto appended. Thus, the present invention is not intended to be limited to the embodiments described, but is to be accorded the broadest scope consistent with the disclosure set forth herein.
[0042] The present method includes various features, including: providing instructions and variables to a food product dispensing machine which specifically refers to the product to be refilled without the need for operator intervention or a factory trip; providing a method and system for programming identification, preparation, and other information onto a tag to be associated with a food product to be dispensed by a machine; providing a flexible and operational system for immediately programming a food product dispensing machine; providing for frequent programming of a food product dispensing machine; providing for a food product vending machine to be programmed in a customized way; providing for the control of vending of products other than that which the food product dispensing machine was designed for; providing a method to ensure that food product dispensed from a machine is of sufficient quality to guarantee safety for the consumer; providing the ability to gather and retrieve information, including usage data from a food product dispensing machine; providing the ability to communicate information and/or data to a consumer using a food product dispensing machine; providing a method that allows communication of vending instructions and/or other data from a food product package not necessarily matching the shape of a preformed reading zone of a food product dispensing machine; and providing a system that allows for suitable tracking of certain variables or other data from a dispensed food product in order to guarantee product safety, quality and/or retrieval of useful information.
[0043] The ability to provide instructions and variables to a food product dispensing machine which specifically refers to the product to be refilled without the need for operator intervention or a factory trip is advantageous for optimum dispensing of the food product, compared to a device that operates on standard processing conditions for all food products.
[0044] The flexibility of the operational system for immediately programming a food product dispensing machine contributes to the versatility of the device. For example, the device is capable of frequent programming and reprogramming depending upon the specific food product to be dispensed, which product is ascertained by the device prior to dispensing. Thus, the food product dispensing machine of a preferred embodiment of the invention can be programmed in a customized way depending upon the type of product to be dispensed.
[0045] Another advantage of the present invention is that it prevents the vending of products other than that which the food product dispensing machine was initially designed for, thus avoiding undesired product substitutions. As one can appreciate, when a certain brand of drink is desired, the substitution of an inferior product would not be seen by the end user, and the device becomes inoperable in this situation to protect the goodwill and reputation of the branded product. Also, the present invention provides a method to ensure that food product dispensed from a machine is of sufficient quality to guarantee safety for the consumer.
[0046] Another advantage of the present invention is that provides the ability to gather and retrieve information, including usage data from a food product dispensing machine. Thus enables the food product manufacturer to plan service times for re-filling the machine, as well as obtain demographic data for strategic market planning. Thus, the dispensing devices can be filled only with desirable products, thus increasing product turnover and profitability.
[0047] The present invention also provides the ability to communicate information and/or data to a consumer using a food product dispensing machine, such as product attributes or nutritional information, as well as an economic benefit, such as an electronic coupon or other future discount or rebate due to purchase of the product.
[0048] In addition, the present invention provides a method that allows communication of vending instructions and/or other data from a food product package not necessarily matching the shape of a preformed reading zone of a food product dispensing machine. The tag enables quick and accurate reading of the product vending instructions regardless of the exact positioning of the package.
[0049] Finally, the present invention also provides the advantage that the system allows for suitable tracking of certain variables or other data from a dispensed food product in order to guarantee product safety, quality and/or retrieval of useful information. This tracking can occur from the time the product is prepared at the manufacturer's location, through packaging and shipping, delivery to the location where the machine is located to final vending of the product.
[0050] Turning now to the drawings, FIG. 1 is a block diagram depiction of a system of a food product vending machine according to a preferred embodiment of the present invention 1 . The food product container 2 includes the actual food packaging 3 and an RFID 4 . The food packaging 3 may contain an individual serving of the food product, or may be a package containing a larger quantity, sufficient for multiple servings. As an example, a powdered drink mix may be packaged in a disposable vacuum pack containing enough dry powder mix for several reconstituted servings of a beverage. In this case, the food package 3 is emptied into a powder hopper 12 by a food service operator. Alternatively, the food packaging may be a multi-serving flexible bag or pouch with a fitment, as known in the art, containing a liquid concentrate that is arranged in fluid communication with tubings of the dispensing machine 7 . Alternatively, the food packaging 3 may consist of a single-serving packet, which may be opened by a dispensing machine 7 without the need for storage in an intermediate powder hopper 12 .
[0051] The RFID 4 is associated with the food packaging 3 in a manner which allows for the RFID 4 to be programmed by an RFID tag programming device 5 , which may be located in the manufacturing plant, and read by an electronic tag reader 8 associated with the dispensing machine 7 . For example, in the case of food packaging 3 with a quantity of a dry powder food product or concentrate, if the food packaging 3 is of a material that blocks or partially blocks radio signals, such as metallicized plastic, the RFID 4 should be affixed to an exterior surface of the food packaging 3 . Alternatively, if the food packaging 3 is transparent to radio signals, such as a thin layer of wax paper, the RFID 4 may be affixed to either an interior or exterior surface of the food packaging 3 . Another example is a flow-wrap pack containing multiple servings of a dry powder food product. If such a pack were made of a material which allows radio signals to pass through it without changing the radio signals, then the RFID 4 may be affixed to an interior surface of the flow-wrap pack, or even left loose in the pack, or inserted into a pocket or compartment, either internal or external.
[0052] The RFID 4 on or in the food package 3 is first read by first programmed with information (“tag data”) in the manufacturing plant by a RFID programming device 5 . Many different types of information may be programmed into the RFID at the manufacturing plant. Such information may include the type and quality of the food product, the brand or manufacturer of the food product, the expiration date of the food product, the “born on” data of the food product, identification of the manufacturing and packaging center, warehouse(s) at which the food product was stored, and even the personnel who have come into contact with the food product. Importantly, it may also include information relevant to the preparation of the food product, such as preparation and service temperature(s), preparation steps, duration and speed of blending, mixing, and/or whipping to create the final food product for dispensing to the consumer.
[0053] This tag data, along with other information, may also be sent to a host data storage system 6 , which may be an enterprise-based network and/or Internet accessible. The RFID may have information programmed into or read from it at various stages of the manufacturing, warehousing, shipping, distribution, and/or dispensing processes. This information may also be stored into a host data system 6 , which, in turn may be accessed via a network or the Internet.
[0054] While the preferred embodiment makes extensive use of host data storage and the Internet, as well known to those of knowledge in the arts of computer science and communications, “host data storage” may actually include a large variety of hardware and software combinations. Likewise, any communications network may substitute for the Internet without changing the scope or meaning of the present invention.
[0055] When the food product container 3 is loaded into a dispensing machine 7 by a food service operator, the RFID 4 is read by an RFID reading device 8 . The dispensing machine depicted in FIG. 1 includes an RFID reading device 8 operated by a control unit 9 , both powered by a power supply 11 . Depending on the configuration of the food packaging 3 and the placement of the RFID 4 , there are actually several options as to when the RFID 4 is read by the RFID reading device 8 . For example, when a multiple-serving flow-wrap package is used, the food service operator generally opens the flow-wrap package when the dispensing machine 7 is loaded. In this procedure, the operator would open the dispensing machine 7 to expose at least one powder hopper 12 , open the package, load the food product into the hopper 12 , and close the dispensing machine 7 . Due to the proximity of the RFID with the reading device 8 , the RFID associated with the food package 3 is automatically scanned using the dispensing machine's RFID reading device 8 . The empty flow-wrap package and its associated RFID 4 may then be discarded or returned to the manufacturing center. Alternatively, the RFID 4 may be left in or attached to the powder hopper 12 , thereby allowing the RFID 4 to be read at a later time, such as when the consumer orders the food product to be dispensed. Of course, in this instance the food service operator would preferably remove the tag from an empty powder hopper 12 prior to filling the hopper 12 . The removed RFID would likewise be discarded or, preferably, returned to the manufacturing plant for reuse. In order to ensure a proper reading of the RFID, the electronic reading device 8 may preferably comprise a plurality of multiplexed read points located close to the hoppers. Each read point may be activated to read one or several RFID. In order to ensure a proper reading of the RFID several different methods of implementation could be used. The electronic reading device 8 may preferably be comprised of a plurality of multiplexed read points each located within very close proximity to the hopper and limited read distances of anywhere from zero, requiring physical contact with the tag 4 , to several inches, thus eliminating the opportunity of false or incorrect reads. Further more a method of assurance could be employed within the machine control sequence that would require the operator to confirm the identity of the product 3 placed within each hopper 12 . A second possible scenario would include only one electronic reading device 8 coupled with a machine control sequence that would prompt the operator to scan the RFID 4 and indicate which of the hoppers 12 the product 3 is being placed.
[0056] Another example would be the filling of a dispensing machine 7 with a food package containing a single serving of a food product. Again, the RFID 4 may be read at the time the operator loads the food packaging 3 into the dispensing machine 7 , or it may be read at a later time, such as when the consumer selects the food product to be dispensed. Also, the RFID 4 may be read at both times. After the food product is dispensed, the empty food packaging 3 with its RFID 4 may be discarded, or preferably, recovered by the food service operator for return to the manufacturing center, where it may be reused.
[0057] When or after the RFID 4 is read, the dispensing machine's control unit 9 may communicate the tag data and other information via a remote communication module 10 to a host data storage system 6 , which may be linked to an enterprise-based network, possibly via the Internet. In addition to the tag data from the RFID, the information read can include additional information, such as the type, serial number and location of the dispensing machine. It may also include sales data, such as the amount and type of food products dispense and even may send a notification that a machine has been tampered with, or that unapproved and/or potentially dangerous (to the consumer) food products have been loaded into the machine.
[0058] Moreover, the control unit 9 may use the tag data to orchestrate the preparation of the food product into a product ready for the consumer. This is accomplished in the case of powdered and/or concentrated beverages by first controlling the amount of a diluent, in this example water, from a supply source 15 into an internal tank 16 . Storage of the diluent in an internal tank 16 may be advantageous because it allows for the diluent to be measured, filtered, and heated efficiently.
[0059] Assuming water as the diluent, the water in the water tank 16 is heated by a heater 17 to a temperature, which may be set by the control unit 9 based on tag data read from the food product container 2 . Of course, when a powder hopper 12 is in use and the food packaging 3 and RFID 4 has been read and discarded or returned to the manufacturing center, the control unit 9 would preferably rely on the initial reading of the RFID 4 at the time the food service operator loaded the food product into the dispensing machine. The heater may be any sort of heating device well known in the art, including a thermoblock, a thermoelectric heater or a simple resistance coil in a water tank, as well as others.
[0060] When the water has attained the proper temperature, it is pumped by a pump 18 under the control of the control unit 9 into a mixing bowl 19 .
[0061] Concurrently, a dosing device 14 operated by a actuating device 13 , both under the control of the control unit 9 , extracts the proper amount of the food product from the powder hopper 12 , into which the contents of the food product container 2 had previously been placed.
[0062] As an alternative, the powder hopper 12 may actually be the food product container 2 itself. In this case, the dispensing machine would also be equipped with apparatus to open, empty and discard the food product container 2 . The pre-measured food product inside the food product container 2 would preferably be transferred into a mixing bowl 19 . The discarded food product container 2 could be stored for recovery by the food service technician and return to the manufacturing center.
[0063] When a hopper 12 with multiple servings of the food product is employed, however, a quantity of food product is measured by a dosing device 14 powered by an actuating device 13 such as a DC electrical motor. The amount of food product for the dosing device 14 to extract may also be tag data. The dosing device 14 deposits the resultant measured food product into the mixing bowl 19 .
[0064] The mixing bowl 19 mixes the food product with the measured proper temperature water for a duration which may also be determined from tag data. Next, a whipping apparatus 20 may whip the mixed food product to provide froth at a speed and duration which may also be determined using tag data. Finally the finished food product is delivered to the consumer 21 .
[0065] Another schematic view of the controlling unit 9 , its interactions and associated components in a preferred embodiment of the present invention is shown in FIG. 2 . Herein the control unit 9 is associated with various sensors 23 , which provide input to the control unit 9 . The various sensors 23 may include but are not limited to sensors to determine if the proper money has been paid (in the case of a vending machine) and sensors to determine the food product desired by the consumer. Other sensors 23 may notify the controlling unit 9 if the dispensing device has been tampered with. Still other sensors 23 may notify a water temperature, a level of powder in a hopper, etc.
[0066] The controlling unit 9 also controls an RFID reader 8 (“tag reader”), which, in turn, is associated with one or more RFID input units 4 . For example, each product channel on the dispensing machine may have a device to pick up the RFID information from an RFID 4 being loaded and/or dispensed from that channel. This information is then routed to the tag reader 8 , which converts the radio frequency signals into actual digital data before sending it on to the controlling unit 9 . The controlling unit 9 may then formulate a package of data and other information to send to the communications module 10 , and then to a host data storage system 6 .
[0067] Other devices and apparatus of the dispensing machine are then controlled by the controlling unit 9 to prepare the food product, possibly in accordance with food product preparation instructions stored on the RFID 4 . These instructions may be read at the time the consumer requests the dispensing of the food product, or may be read at the time the food service operator loads the food product into the dispensing machine, in which case the controlling unit would need to store the instructions in a memory (not depicted) until needed. Alternatively, the food product preparation instructions may be stored in a host data storage system, which may be but does not need to be the same host data storage system 6 previously mentioned. In the case of offsite storage of food preparation instructions, the controlling unit 9 should then download the food preparation instructions from the host data storage system 6 using the communication module 10 .
[0068] The other devices controlled by the controlling unit 9 may include but are not limited to a water heater 17 , a water pump 18 (when water diluent is used), a mixing bowl 19 , a whipping device 20 , and dosing device(s) 14 , among others. Examples of parameters controlled by the controlling unit 9 are: temperature for a water heater 17 , volume for a water pump 18 , speed and duration of mixing for a mixing bowl 19 , speed and duration for a whipping device 20 , and food product quantity for dosing device(s) 14 .
[0069] FIG. 3 depicts a flowchart of the action sequence 23 of dispensing a food product according to a preferred embodiment of the present invention. First the vending operator scans the tag and starts the process 24 . Next, the consumer selects and pays for a food product. For example, the consumer might select a particular beverage product to be prepared by viewing a description of the product, possibly including a picture, then inserting coins into the dispenser and selecting a button or combination of buttons to push to indicate their preference. Payment and selection of food products from dispensing machines may take several forms. The particular means of selecting a food product and paying for it to be dispensed in not relevant to the invention herein described.
[0070] Next, the data and information for the particular food product is read from the RFID 25 . Alternatively, when the RFID has been read previously as described above, the RFID data may then be retrieved from a local or remote data storage. Regardless of which method is used to obtain this data, it may include a product code which can then be compared with a reference code, either from a local data bank 26 , or from a remote data bank accessed online 27 , or some hybrid combination thereof. For example, a local data bank may be employed, but it may be refreshed from time to time from a remote online data bank. The comparison process 28 results in either a verification of a valid product code or non-verification. If the code is not verified, it may be the result of an incorrect or tampered-with product being placed in the dispensing machine, so the vending system will be blocked 34 , and an error signal generated 35 . If this occurs, the error signal may cause the control unit of the dispensing machine to activate a display visible to the consumer indicating that the desired food product is not available. Additionally, the control unit of the dispensing machine can then send a message to either the food service operator, the owner/operator of the dispensing machine, or even the manufacturer of the branded product which should be in the dispensing machine stating the error and identifying the dispensing machine. This will allow for fast corrective action to be taken.
[0071] Otherwise, if the code is verified, preparation instructions will then be read from the RFID 29 . Note that the preparation instructions may have already been read at the time the code was read. If this is the case, the preparation instructions do not need to be re-read from the RFID, but may be referenced from local memory and used to prepare the product for the consumer. Alternatively, preparation instructions may be read from a data bank 30 , which, of course, may be either locally or remotely stored. Regardless, the preparation instructions are stored in the memory of the processor of the control unit 31 , where a final check of parameters and set points is performed 32 . This final check includes but is not limited to verifying that the preparation instructions were not inadvertently corrupted (by looking at a checksum, for example) and determining that the preparation instructions make some sense (such as not requiring mixing for 45 hours, or a water temperature that will melt steel, etc.) If the check of parameters and set points 32 indicates reasonable parameters, the food product is then able to be vended to the consumer 33 . Otherwise, the vending is blocked 34 and an error signal is generated 35 . Again, the error signal may cause the control unit of the dispensing machine to activate a display visible to the consumer indicating that the desired food product is not available. Additionally, the control unit of the dispensing machine can then send a message to either the food service operator, the owner/operator of the dispensing machine, or even the manufacturer of the desired product stating the parameter/set point error and identifying the dispensing machine, again allowing for expedient corrective action to be taken.
[0072] Similarly, FIG. 4 depicts a flowchart of the action sequence of dispensing a food product including an expiration date check according to a preferred embodiment of the present invention. First, the vending operator scans the tag and starts the process 37 . Next, the consumer selects and pays for a food product, as previously described. Then, the data and information is read from the RFID 38 , or the RFID information previously read is retrieved from a local or remote data store. This data may include a product code which can then be compared with a reference code, either from a local data bank 40 , or from a remote data bank accessed online 39 , or some hybrid combination thereof. As in FIG. 3 , the comparison process 41 results in either a verification of a valid product code or non-verification if the product code is not valid. If the product code is not verified, it may be the result of an incorrect or tampered-with product being placed in the dispensing machine, so the vending system will be blocked 44 , and an error signal generated 45 . This error signal may then cause the control unit to take the actions detailed above to notify the food service operator and/or others so corrective action can be taken.
[0073] Otherwise, if the code is verified, the food product expiration date is gathered from the data and other information on the RFID, as well as any product recall information 42 . Product recall information preferably consists of identification indicia, such as lot numbers. When a product recall is to be made, a list of recalled product lot numbers may be made available, either from a local data bank 40 , or from a remote data bank accessed online 39 . If the lot number read off the RFID matches a product lot number on such a list of recalled product lot numbers, vending is blocked 44 and an error signal is generated 45 . Likewise, if the expiration date is prior to the current date (as determined by either an online clock or an internal clock in association with the control unit), then the vending system is blocked 44 and an error signal is generated 45 . In both cases, the error signal may cause the control unit to send a message as indicated above, in order to notify the consumer that their desired product is not available and contact the food service operator that the dispensing machine is in need of a refill of either non-recalled or newer food product.
[0074] Continuing with FIG. 4 , if the food product is not beyond its expiration date, and if it has not been recalled, preparation instructions will then be read from the RFID 46 . As previously mentioned, the preparation instructions might have already been read into the control unit, or may be in a local or remote data store. Ultimately, the preparation instructions are placed in the memory of the processor of the control unit 47 , where a final check of parameters and set points is performed 48 . If the check of parameters and set points 48 indicates reasonable parameters, the food product is then vended to the consumer 49 . Otherwise, the vending is blocked 44 and an error signal is generated 45 , as already described for FIG. 3 .
[0075] FIG. 5 diagrams the mechanical flow of a food dispenser system according to a preferred embodiment of the present invention 48 . This example describes a dispensing mechanism for mixing and dispensing a beverage reconstituted from a dry powder with a water diluent. After the consumer has selected the food product to be dispensed, a motor 50 operates a screw device 51 which transfers a predetermined quantity of the dry powdered food product from a powder hopper 49 into a mixing bowl 52 . In an alternative embodiment, the screw device 51 —powder hopper 49 combination is preferably replaced by a single-serving food product container itself in combination with an extraction mechanism for removing the food product from the food container and placing it into the mixing bowl 52 . It would also be possible to allow for additional whipping of product to produce additional body of the beverage as identified in the system FIG. 1 . This would require the addition of a whipping stage 20 after the mixing bowl. In another alternative, the food product is a liquid or extract stored in a flexible pouch or bag adapted in fluid communication with a dosing device such as a peristaltic pump or similar.
[0076] Concurrently, a water tank 54 is filled with a predetermined amount of water from a water source 53 . Alternatively, the water in the water tank may be heated to prepare a hot beverage or cooled to prepare a cold beverage. The water is then pumped from the water tank 54 into the mixing bowl 52 by a pump 55 . The water and powder is then mixed in the mixing bowl 52 for a predetermined time and at a predetermined speed and the final product is then delivered to the customer 56 . The predetermined time and speed are preferably information carried by the RFID device and read either at the time the dispensing machine is loaded by the food service operator or at the time the consumer selects the food product.
[0077] FIG. 6 is a schematic representation of the components and interactions of a RFID according to a preferred embodiment of the present invention. A typical RFID is composed of circuitry the various components as depicted here. Additionally, the RFID includes an electromagnetic power receiver 64 to provide power to the various circuitry. A receiver 58 is connected to and controlled by a processor 59 with a programmable persistent memory 61 . The programmable persistent memory 61 is preferably programmed via instructions received through the receiver 58 and executed upon by the processor 59 . Alternatively, an RFID could be powered by a battery, in which case the battery would take the place of the electromagnetic power receiver 64 . A preferred embodiment of the invention might use an RFID powered by an electromagnetic power receiver 64 due to its lower cost and lighter weight compared with an RFID with a battery.
[0078] FIG. 7 is a block diagram of a large-scale system including inventory control in accordance with a preferred embodiment of the present invention. A computer network 67 is employed to interconnect the various system components. The computer network is preferably enterprise-wide, and may be implemented using the Internet. Of course, the network may also connect different co-packers and vendors involved at various manufacturing stages to a centralized manufacturing authority.
[0079] A manufacturing database 66 acts as the central repository for all of the necessary data associated with material usage within the factory, processing steps, date of manufacture, product SKU information and the necessary preparation instructions associated with a particular product. The manufacturing database 66 may be implemented on a dedicated server, possibly with communication links to the Internet. Any large capacity scaleable commercial database may be used. An example of a manufacturing database 66 implementation would be on a Microsoft Windows NT™ server running the Oracle™ database package.
[0080] The computer network would connect terminals on the factory floor 71 , logistics and warehousing data systems 69 , and RFID reading and writing devices 78 , 80 that would encode the appropriate electronic information onto the RFIDs as the food packages with the RFIDs move through the manufacturing process.
[0081] In the manufacturing process, food product, packaging supplies and RFIDs enter the receiving area 74 , where the food product proceeds to processing 75 while the RFIDs proceed already associated or to be associated with the packaging material 76 . This is the step at which the RFID will be attached or otherwise affixed to or placed within the food product packaging material, if not done so already. Thereupon the primary packaging operation 77 preferably takes place, and the RFID read/write device 78 programs initial information into the RFID, communicating the programmed information also to the manufacturing database 66 over the network 67 .
[0082] Next, a secondary packaging operation 79 is preferably performed, in which, for example, accumulations of food product packages might be co-packaged. A second RFID read/write device 80 then continues by preferably updating the RFID and/or the manufacturing database 66 . The completed package containing the food product packaged with the RFIDs is then stored in warehouse storage 81 until it is distributed 82 . Upon placing the product in the warehouse the RFID may be read and the manufacturing database updated to indicate the current location of the food product. Likewise, the RFID can be read when the food product package is removed from the warehouse for distribution. There are numerous inventory-related accounting and tracking advantages to using RFIDs and a manufacturing database for keeping a record of the movement history of each food product package.
[0083] For example, it is possible to optimize the process of reordering food product to use industry-standard concepts such as the economic order quantity if better information is available about the amounts of food product in the supply pipeline. Also, knowing the expiration dates of all the food product in the various dispensing machines, warehouses, and distribution centers allows for better planning and less waste. Only the amount of a particular food product that is used needs to be replaced. So, if the manufacturing database shows that a certain dispensing machine only sells a limited quantity of a food product, the distribution center and food service operator can refill the particular dispensing machine with only a limited quantity of the food product.
[0084] Moreover, if the manufacturing database shows that a particular product's sales in a given dispensing machine differ significantly from the sale of other food products in the same machine, then the packaging process can be altered to allow the serving-volume of the packaging for the slower-selling food product to be packaged in smaller quantities. For example, if food product A sells only half as much as food product B, then the packages of A could be sized to provide half the number of servings of A as the packages of B, thus allowing the food service operator to refill both products in the dispensing machines at the same time, with less chance of waste of either food product. The scenario of altering the pack size to accomodate slow selling products is possible, though unlikely.
[0085] An example of a manufacturing and distribution information gathering and report generation system according to a preferred embodiment of the current invention is depicted in FIG. 8 . When the product container 2 has been tagged and filled with food product at the manufacturing center, information which preferably includes product identification, product preparation instruction, manufacturing center, product expiration date (or, in the case of some food products, the number of until expiration days once the product container has been opened), product lot number, product validation code, and other information, are gathered at the manufacturing center 83 and deposited in a manufacturing database 66 . The transfer of the information may be facilitated using the Internet 87 (and appropriate encryption or other safeguards to insure the integrity of the information stored to the manufacturing database 66 ). Alternatively, the a non-Internet network may be employed.
[0086] Regardless of the actual information transfer network employed, information is likewise collected and stored in a manufacturing database 66 at important phases of the product container's 2 life cycle. For example, when the product container 2 is transferred to a product warehouse for storage, the warehouse's information system 84 may update the manufacturing database 66 to indicate that the product container 2 is now at the product warehouse. Likewise, when the product container 2 leaves the product warehouse for distribution, the distribution center's information system 85 may update the manufacturing database 66 with information regarding the distribution of the product container 2 , as well as other information, such as the food service operator who will be transporting the product container 2 .
[0087] Later, when the product container 2 is loaded into a product dispenser 7 (or when a product container is emptied into the product dispenser 7 , such as is the case with flow-wrap packages of dry powdered food products), the product dispenser 7 may update the manufacturing database 66 . The product dispenser 7 may also update the manufacturing database 66 on other occasions, such as when an invalid product verification code is detected, or when a product has reached its expiration date, or for other reasons. Also, the product dispenser 7 may generate database inquiries to get information from the manufacturing database 66 , such as updated product preparation instructions, a current product lot recall lists, information to present to a consumer of a given product (perhaps promotional), or other information. These information requests may be made before, during, or immediately after the product is dispensed 86 .
[0088] The information stored in the manufacturing database 66 may be used to generate many types of reports 90 . For example, one report 88 might indicate the current location of every product container. Another report 89 might indicate all dispensers with product containers whose expiration date has been reached. Reports may be compiled using any data element as a primary sort key, secondary sort key, tertiary sort key, etc. Also, hot reports may be generated of where invalid or improper (i.e., incorrectly branded) product has been improperly placed in a dispenser.
[0089] It is also preferable to generate reports of the flow of product containers through the manufacturing, warehousing, distribution, and dispensing system to determine bottlenecks, excess inventory, etc.
[0090] It is also preferable to generate reports of sales by product, by distributor, by warehouse, and to identify sales trends of individual dispensing machines in order to optimize sales and to optimize refill visits by the food service operator.
[0091] Thus, in accordance with the foregoing, the objects of the present invention are achieved. Of course, as is well known in the art, there are many methods which may be used to implement the present invention. Thus, while the preferred embodiments of the present invention are described, further changes and modifications can be made by those skilled in the art without departing from the true spirit of the invention, which includes all such changes and modifications that come within the scope of the claims set forth below.
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A method of and system for providing machine-readable tags, preferably programmable RFID tags are provided. In one embodiment of the present invention, a receptacle having at least one wall member that defines an enclosure and a tag associated with the receptacle, which includes machine-readable information regarding a product occupying the enclosure is provided. In accordance with another embodiment of the invention, the tag includes identification information in electronic form for the product.
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This is a Division of application Ser. No. 07/390,581 filed August 4, 1989 which is a Continuation of application Ser. No. 07/080,290 filed July 31, 1987.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a printed substrate wiring device for connection to electrode-including optical elements such as photodiodes and semi-conductor lasers provided in chip form, and an optical head device using the same printed substrate.
2. Description of the Prior Art
In video disk and digital audio disk media, an information signal is recorded by forming a spiral track of pits corresponding to the information signal through the irradiation of the record surface of the disk with a fine spot of light. Further, in the case where the information signal thus recorded is to be reproduced, the original information signal is reproduced in accordance with the changes in the light reflected by or transmitted through the media upon irradiation of the track with a light source.
Various types of optical head devices for performing the aforementioned recording and reproducing functions have been developed. For example, these optical head devices include light-emitting elements, such as semiconductor lasers and the like; objective lenses for converging light emitted from the light-emitting elements onto the recording surface of the disk in the form of a spot; and light receiving elements, such as photodiodes or the like, for receiving light reflected from the recorded surface of the disk for generating a signal corresponding to the conditions of their light reception.
Referring to FIG. 6, there is shown a member used in a conventional optical head device, in which a semiconductor laser 51 in raw chip form is housed in an airtight package 55 constituted by a cylindrical portion 52, a glass plate 53 and a cover 54 and is connected to terminals 56 by wiring (not shown). The member together with other optical members, is attached to a body 57 as shown in FIG. 7. Referring to FIG. 8, there is shown another member used in the conventional optical head device, in which photodiodes 59 and 60 provided in chip form are sealed within a package 61 formed by a molded resin and are connected to terminals 62 by wiring (not shown). This member is also attached to the body 57 as shown in FIG. 7. The relative positions of the semiconductor laser and photodiodes are adjusted with high accuracy so that the laser light reflected from the recorded surface of the disk 64 is precisely incident upon the photodiodes 59 and 60.
In order to assemble the semiconductor laser 51 and photodiodes 59 and 60 while maintaining this predetermined relation in the relative positions thereof, conventionally, these elements are housed in their respective exclusive packages 55 and 61 and then the packages are attached to the body 57.
The semiconductor laser 51 and photodiodes 59 and 60 in themselves are very small parts, but the packages 55 and 61 surrounding them are relatively large. Accordingly, the body 57 supporting the packages also becomes a large member. This is a problem to be solved in the miniaturization of the optical head device.
Recently it has been considered that the semiconductor laser and photodiodes may be formed in the raw chip state and assembled without use of the aforementioned packages. However, it is difficult to assemble the semiconductor laser and photodiodes while positioning them with high accuracy, because they are very small in size as described above.
Where the relative positions of the semiconductor laser and diode are to be adjusted, this is done by observing the light reception condition of the photodiode due to the light emitted from the semiconductor laser. Toward this end, electrical power is supplied to the wiring attached to the two parts, with the wiring arranged in a manner such that the relative positions of the two parts can be changed on the basis of the results of the measurement. However, it is particularly difficult to form the complex wiring so that the positions of the small-scale semiconductor laser and diodes can be suitably changed. Accordingly, the development of wiring to make this task easy has been desired.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to solve the aforementioned problem.
It is another object of the present invention to provide a wiring member which may be connected to the electrodes of small electrode-including optical elements provided in chip form, which member is simple in its construction and enables easy adjustment of the position of the optical elements relative to their support members.
It is a further object of the present invention to provide an optical head device of smaller scale than the prior arrangements.
In order to attain the above objects, according to an aspect of the present invention, a printed substrate acting as a wiring member is connected to the electrodes of the optical elements, the printed substrate having carrier positions for carrying the optical elements, the carrier portions being formed so as to be flexible independently of each other.
According to another aspect of the present invention, the optical head device is arranged such that a light-emitting element and a light-receiving element in chip form are disposed within the interior space of a common package constituted of a package body and a cover, so that, for example, the elements are airtightly housed in the common package together with a protection gas.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will appear more fully from the following description in conjunction with the accompanying drawings, in which:
FIG. 1 is a longitudinal sectional view of the important parts of an optical head device according to the present invention;
FIG. 2 is a side view taken along the line II --II of FIG. 1;
FIG. 3 is an exploded perspective view of the major elements;
FIGS. 4 and 5(a) to 5(c) are views showing a printed substrate according to the present invention; and
FIGS. 6, 7 and 8 are views for explaining the conventional optical head device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An optical head device including an optical element-carrying printed substrate will be described in detail with reference to the accompanying drawings, as an embodiment of the present invention.
As shown in FIGS. 1 to 3, the optical head device has a package body 2 provided with an interior volume or space 1, and a cover 3 for closing the opening of the interior space 1. A cylindrical portion 4 is formed at the upper end of the package body 2, and an objective lens 5 is provided at the upper end of the cylindrical portion 4. As shown in FIG. 2, the objective lens 5 converges light emitted from a semiconductor laser (which will be described later) onto the recording surface of a disk 7.
Two holders 8 and 9 are disposed within the interior space 1 of the package body 2. A semiconductor laser 10 and a monitor photodiode 11 are attached to the holder 8. More specifically, the semiconductor laser 10 is attached to an oblique portion 12 formed on the holder 8 so that it is inclined at 45 degrees relative to the light path. A quartering photodiode 13 is attached to the other holder 9. The semiconductor laser 10, the monitor photodiode 11 and the quartering photodiode 13 are formed as raw chip elements and are protected by nitrogen gas injected into the space 1. The quartering photodiode 13 receives light reflected from the recorded surface of the disk 7 to generate a signal corresponding to the transmissivity or reflectivity of the disk. The monitor photodiode 11 detects a change in the output of the semiconductor laser 10, especially a change in output due to temperature, to perform feedback control of the output.
A parallel-plane plate 14 is disposed in the vicinity of the quartering photodiode 13 and is fixed to the inner wall of the package body 2.
The light path in the optical head device and the functions of the respective optical elements will now be briefly described.
Light emitted from the semiconductor laser 10 is reflected by a semitransparent mirror plane 15 of the parallel-plane plate 14 and is then converged by the objective lens 5 to form a beam incident on the recorded surface of the disk 7. Light reflected from the surface of the disk 7 owing to the incident light is converged by the objective lens 5, passed through the semitransparent mirror plane 15 of the parallel-plane plate 14 and reflected by a reflection plane 16. The parallel-plane plate 14 is arranged so that the incident plane (semitransparent mirror plane 15) is inclined relative to the axis of the light reflected from the disk 7. Accordingly, the parallel-plane plate 14 imparts an astigmatism to the light passed through the semitransparent mirror plane. The reflected light to which astigmatism is given by the parallel-plane plate 14 enters the quartering photodiode 13. By the astigmatism imparted to the reflected light, the form of the reflected light imaged on the light-receiving surface of the quartering photodiode 13 is changed corresponding to the positional relation between the recorded surface of the disk 7 and the convergent bundle of light incident on the disk 7. In order to detect a change in the shape of the reflected light, the quartering photodiode 13 is arranged so as to be divided into four elements by two lines perpendicularly intersecting each other. The light-receiving surface of the quartering photodiode 13 is formed by the four independent elements so formed and is arranged so as to be located at a place where the reflected light is circularly shaped when focused (i.e., when the focus error is zero). The difference between two measured values calculated by adding the measured value at each element to that of an opposite element with respect to the center of the light-receiving surface of the quartering photodiode 13 is taken as a focus error signal. In accordance with the focus error signal, the whole of the arrangement shown in FIG. 1 is servo-driven in two directions, that is, in the direction of the optical axis of the objective lens 5 and in the direction perpendicular thereto.
In the following, the arrangement for adjusting the relative positions of the semiconductor laser 10 and the quartering photodiode 13 is described.
As shown in FIGS. 1 to 3, the holder 8 holding both the monitor photodiode 11 and the semiconductor laser 10 is directly tightly fixed to the package body 2 by two screws 18. On the other hand, the holder 9 holding the quartering photodiode 13 is attached to the package body 2 through an intermediate member 20 by a screw 21. The screw 21 is loosely received with a predetermined clearance into a round hole 22 formed in the lower end of the package body 2, and the top end of the screw 21 is screwed into the intermediate member 20. It is apparent from FIG. 3 that the intermediate member 20 is provided with a linearly extending rectangular-pillar-like projection 23. After the projection 23 is fit with a predetermined clearance into a rectangular hole 24 formed in the holder 9, the holder 9 and the intermediate member 20 are fused to each other by laser irradiation at a portion designated by the reference numeral 26 in FIG. 1. Thus, the holder 9 is fixed to the intermediate member 20. A pair of throughholes 27 are formed in the holder 9 so as to be engaged by an adjustment jig which will be described later.
As shown in FIGS. 1, 4 and 5(a) to 5(c), a printed substrate 32 has carrier portions 29, 30 and 31 for carrying the semiconductor laser 10, the monitor photodiode 11 and the quartering photodiode 13, and the respective electrodes of the semiconductor laser 10, the monitor photodiode 11 and the quartering photodiode 13 are connected to the carrier portions 29, 30 and 31 respectively, so that the semiconductor laser 10, the monitor photodiode 11 and the quartering photodiode 13 are attached to the holders 8 and 9 through the printed substrate 32. It is apparent from FIG. 4 that the carrier portions 29, 30 and 31 carrying the semiconductor laser 10, the monitor photodiode 11 and the quartering photodiode 13 are partially separated from each other by the openings 33 and are formed so as to be flexible independent of each other.
As shown in FIG. 1, an end of the substrate 32 is drawn out through a slit 34 formed in the cover 3. The aforementioned nitrogen gas acting as a protection gas is injected into the space 1 through a fine hole 35 formed under the slit 35. Upon completion of the injection of the nitrogen gas; the fine port 35 is closed.
In the following, the adjustment of the relative positions of the semiconductor laser 10 and the quartering photodiode 13 is described. In this case, the semiconductor laser 10 is fixed and the adjustment of the relative position is made by moving the quartering photodiode 13. The semiconductor laser 10, the monitor photodiode 11 and the quartering photodiode 13 are preliminarily heat-pressure welded onto the carrier portions 29, 30 and 31 of the printed substrate 31 and are fixed to the holders 8 and 9 with an adhesive while suitably bending the respective carrier portions.
First, as shown in FIG. 2, an adjustment jig constituted by a pair of pointed-head pins 36 and a frame 37 is prepared and the pins 36 are engaged with the throughholes 27 of the holder 9. The adjustment jig is driven in the X, Y and Z directions by precision movement means such as a robot hand.
In this condition the semiconductor 10 is energized to emit light. The light reception condition of the quartering photodiode 13 is measured by a predetermined measurement instrument, and the relative positions of the elements are adjusted by moving the holder 9, and hence the quartering photodiode 13, until the measured values reach that desired. The movement in the Z-direction is carried out by means of the clearance between the screw 21 and the round hole 22 of the package body 2. The movement in the X- and Y-directions is carried out by means of the movement through the clearance between the rectangular hole 24 of the holder 9 and the rectangular-pillar-like projection 23 of the intermediate member 20. After the relative positions of the semiconductor laser 10 and the quartering photodiode 13 are determined as described above, the holder 9 and the intermediate member 20 are welded to each other by laser irradiation on a portion designated by the reference numeral 26 in FIG. 1. Then, the screw 21 is strongly tightened. After the adjustment of the relative positions is thus perfected, the adjustment jig is taken off.
As described in detail above, the wiring member according to the present invention comprises a printed substrate (32) which is connected to the electrodes of fine optical elements (semiconductor laser 10, monitor photodiode 11 and quartering photodiode 13) and which has carrier positions (29, 30 and 31) for carrying the optical elements, the carrier portions being formed as separated fingers or the like of the substrate, so as to be flexible independently of each other.
The complex wiring to the fine optical elements can be made very simple when such a printed substrate is used as the wiring member, and the positional adjustment of the optical elements relative to the support member for supporting the optical elements can be made easily because of the independent flexibility of the carrier portions.
In the optical head device according to the present invention, both parts, that is, the light-emitting element (semiconductor laser 10) and the light-receiving element (quartering photodiode 13) are provided as raw chips and are disposed within the interior space of a common package constituted of a package body (2) and a cover (3), so that for example, the parts are airtightly housed in the common package, which is filled with a protection gas. The package need not be incorporated into a body (57) which is far larger than the package and which has been used in the conventional optical head device. In short the package also functions as the body. Accordingly, the optical head device can be remarkably reduced in size as a whole.
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A component package for the semiconductor laser and photodiodes of an audio or video disk recording and/or playback system includes a wiring substrate which provides electrical wiring to these components and in addition provides support for the same. The substrate is configured to include independently flexible fingers or the like, with the laser and the photodiodes being supported by different fingers. The substrate is itself supported within a package body which is filled with a protective gas. This arrangement allows the electro-optical elements to be provided in chip form without independent protective cases.
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FIELD OF THE INVENTION
This application claims the benefit of U.S. Provisional Application No. 60/732,053 filed Nov. 2, 2005, incorporated by reference.
The invention relates to an appliance for the destruction of residential and building waste to form hydrogen-rich syngas to power a fuel cell for the generation of electric power, steam and heat or cooling for use in residences and buildings as well as hydrogen fuel for vehicles.
BACKGROUND OF THE INVENTION
Across the nation, and indeed the world, the energy content of this household waste is enormous; for example, for each person in the U.S. this municipal solid waste can be converted to produce roughly 6 kWh of electricity per person per day. This is really very significant, when one considers that the average person in the U.S. consumes about 7 kWh per person per day.
There have not been any new appliances for single family or small multiple family residents to convert their household waste into useful recyclables and/or energy. The closest appliance has been the garbage compactor. Typical suppliers of such appliances include G.E., DeLonghi, Kenmore, Sears, Honeywell, Beoan, KitchenAid, Whirlpool, and others. Compactors have not been successful since garbage pickup costs are not reduced significantly by reducing the volume of the garbage. The cost of pickup of one can is the same regardless of the volume of the residential garbage in the can. Also, there are many operational problems: special and hard-to-locate compactor bags, consumable carbon filters that have to be replaced in order to avoid serious odor problems, frequent jammed rams from bottles, cans, and bulky waste not placed in the center of the load that can jam the drawer, leaking bags from punctures from sharps within the garbage spilling out disgustingly odiferous bio-hazardous liquids, and the necessity to use the compactor regularly and to remove the bags to avoid rotting garbage left in the unit, and the like. Further, the compactor does not produce energy or heat; instead it consumes energy.
There is a need for a household appliance that can eliminate a major portion of household waste and convert the waste into useful recyclables and/or energy.
SUMMARY OF THE INVENTION
The present invention offers a new approach in which a substantial amount of residential waste can be eliminated in a small, compact appliance that has appearance of a washer/dryer stack found in households.
The appliance of the present invention comprises a waste receptor module having a rotary drum having an opening for receiving household wastes, and steam reforming means for converting at least a substantial amount of the household waste into synthesis gas and an energy generation module having an inlet that is connected to said waste receptor module for receiving the synthesis gas and a fuel cell for converting the synthesis gas into at least electrical energy. The appliance of the present invention has vent, electrical, gas, sewer, and water connections. The appliance cures the problems of garbage compactors by greatly reducing the mass of the garbage, producing sterilized recyclable glass and metals, eliminating garbage requiring landfills, and using the organic chemical fraction of the waste to produce electricity, steam and heat.
The waste receptor module carries out endothermic reactions of steam reforming and is heated with waste heat and electrical power. Alternatively, this module can be heated by a natural gas burner. The module includes a rotary drum, into which are placed bags of waste that can consist of normal garbage as well as toilet solid waste. Glass and metal are not melted in this drum and are recovered as completely sterilized at the end of the process cycle.
Household waste contained in common paper or plastic bags is thrown into the waste receptor module through a sealed door like a dryer. The door is closed and the “on” button is pushed, beginning the processing of the waste. The automatic cycle is about 90 minutes. All of the organic waste is converted to synthesis gas (hereafter called “syngas”). The sterilized glass and metal remaining in the drum are cooled and retrieved for curbside recycling pickup.
The waste inside the drum is tumbled slowly while it is heated from the hot cartridge heater/steam reformer (SR) in the center of the drum. This SR central cylinder is heated internally by induction heat or with natural gas by means of a matrix heater. The vapors from this heated waste are pulled through the outer perforated portions of the SR cartridge to a hotter interior, in which the vapor temperature is raised to about 900-1050° C. (1650-1900° F.) and reacted with the steam from the waste and the re-circulated syngas. The hot syngas leaving the SR cartridge is cooled by two tandem heat exchangers to 50-90° C. (120-190° F.) and is pulled through a gas cleaning bed and condenser from which the liquid water is dropped out and sent to drain or to non-potable landscape watering.
The energy generation module receives the syngas produced by the waste receptor module and a fuel cell within the energy generation module converts the syngas into electricity, steam and heat. Specifically, cleaned gas from waste conversion module is pulled into the suction side of a blower out of which is discharged the syngas under pressure to feed the anode side of the fuel cell. The anode side of the fuel cell converts the syngas to hot CO 2 and steam at about 650° C. (1200° F.), while producing electricity from the H 2 and CO in the syngas. A fraction of this hot CO 2 and steam passes into the SR cartridge for recycling through the drum of the waste conversion module and the balance of this fraction passes through a heat exchanger to recover heat at high temperature useful for producing domestic hot water. The cathode side of the fuel cell is fed a high volume of hot air that is heated in the heat exchanger from the hot syngas and passes into the fuel cell cathode where the oxygen is electrochemically reduced on the catalytically active fuel cell elements. Leaving the hot cathode is as high volume of hot nitrogen at around 400° C. (750° F.) which is available for raising steam, space heating or cooling, or other applications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are conceptual drawings of two possible arrangements of the two modules of the residential household waste-to-energy appliance;
FIGS. 2A and 2B shows the details of the rotary drum and its sealing and locking drum door on a swing arm;
FIG. 3 shows a preferred embodiment of a rotary drum that is heated by induction coils, typically supplied by InductoHeat of New Jersey and others; and the process configuration downstream of the rotary drum where the syngas is used for production of electricity, steam and heat;
FIG. 4 shows a preferred embodiment of a rotary drum that is heated by natural gas matrix heater cartridge and the process configuration downstream of the rotary drum where the syngas is used for production of electricity, steam and heat; and
FIG. 5 shows the details of this natural gas matrix heater cartridge, typically supplied by the Hauck Burner Corp., Baekert, Gmbh, and others.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows an isometric view of the residential appliance in a stacked arrangement Waste Receptor Module a module on the top of module 4 , which includes a waste processing system that steam reforms the waste into valuable syngas. Energy generation module uses the syngas to feed a fuel cell located therein for the production of electricity, steam and heat and optionally hydrogen and method also contains heat exchangers, blowers, valves, piping and controls that are described in reference to FIGS. 3 and 4 .
FIG. 1B shows an isometric view of another embodiment of the residential appliance of the present invention in a side-by-side, arrangement with the waste receptor module on the right.
Referring to FIGS. 1A and 1B , waste receptor module 4 consists of an assembly that includes a rotary drum for processing of the waste fitted with a sealing drum door 6 with a locking mechanism, pivot and swing arm 8 to permit the opening and closing of this drum door. There is also an outer door 9 that is closed to cover up the locking drum door handle that turns when the drum rotates as the processing of the waste is underway. The energy generation module 2 uses this syngas that feeds a fuel cell 60 located therein for the production of electricity, steam and heat and optionally hydrogen. Module 2 also contains heat exchangers, blowers, valves, piping and controls. The two modules are connected together by a pipe 47 that feeds the syngas produced from the waste receptor module 4 to the energy generation module 2 . Pipe 50 returns unreacted syngas, steam, and carbon dioxide from the energy generation module 2 to the waste receptor module 4 .
Referring to FIG. 2A , the locking and sealing drum door 6 mounted on swing arm 8 fits the main receptacle receiving the waste that consists of a rotary drum 14 that is well insulated on the inside. Referring to FIG. 2B there is shown a cross-section through drum 14 that is pivoted by rotary shaft 16 . The inner wall of the drum 14 consists of a heavy wall alloy 18 as well as a central cylinder of even thicker alloy wall 20 to contain the highest temperature heat. This drum 14 rotates around a rotary shaft and seal 16 that excludes air and allows gases to pass through and is described in more detail in FIGS. 3 and 4 . The drum door 6 has to rotate and seal at the same time, so that it is designed with a door handle 22 to operate the door locking mechanism 24 that consists of an array of bars which pivot and slide away from the drum top edge lip. When the handle 22 is rotated, these bars pivot off of a ramp releasing pressure on the drum and its seal so that it can be opened. There are pressure sensors that insure that drum 14 is closed, locked and pressure sealed before it is rotated and any heat is applied. Since handle 22 rotates through swing arm 8 , it needs to be protected by an outer closing door 9 for safety reasons. The outer layer of rotating drum 14 is very well insulated by layers of insulation, 13 and 15 , to insure good energy efficiency. The inner enclosure of module, 2 , is also well insulated with conversion layer 26 to avoid burns from users of the appliance and to further achieve high energy efficiency. The outer wall also contains induction coils 30 for heating conductive susceptors 18 and 20 .
FIG. 3 shows one of the preferred embodiments of the present invention that uses a steam reforming means that includes an internal heater, which in this embodiment is in the form of induction coils 30 for heating the rotary drum 14 in which is placed the waste 44 and tube 32 . This rotary drum heats the waste 44 to about 450-600° C. (840-1100° F.) and starts the steam reforming reactions. The waste volatiles and initially formed syngas are produced in a volume 42 inside rotary drum 14 . When the steam reforming reactions within this drum volume 42 form syngas, these gases pass through the heated perforated central cylindrical tube 32 that is heated by the fixed induction heaters 30 around the outside of the enclosure. Within this central cylindrical tube 32 the syngas is heated to about 900-1050° C. (1650-1900° F.) and reacted with the steam and CO 2 to form very hot syngas exiting this central cylindrical tube 32 is syngas stream 47 at 800-950° C. (1470-1750° F.). Within perforated cylindrical tube 32 is a removable filter cartridge 34 which captures any entrained particulate matter to avoid carrying this fine material downstream in the process lines 47 , through which the syngas so produced exits the rotary drum system that is rotated by motor system 45 . A rotary process piping seal 36 is used to inject steam and carbon dioxide through pipe 46 and the synthesis gas so produced exits through pipe 47 .
This very hot syngas 47 enters heat recuperator exchanger 52 that cools this syngas to 600-800° C. (1100-1450° F.) in pipe 58 with the cooler stream 56 at 550-750° C. (1020-1380° F.) containing CO 2 and steam. Air 84 is blown via blower 72 through heat exchanger 70 to supply heated air 71 to serve the cathode of the fuel cell. The cathode exhaust gas 74 comes from fuel cell 60 . The fuel cell anode exhaust stream 56 can contain a small fraction of unconverted syngas, which can be recirculated back to the steam reformer drum volume 42 shown in cross-section for utilization. Part of this 800-950° C. (1470-1750° F.) exchanger exit stream 54 also is recirculated as stream 50 back into the cartridge steam reformer 32 to make more syngas. The gas 54 leaving heat exchanger 52 will be about 800-950° C. (1470-1750° F.) and can be used to drive a Brayton cycle turbine to make more electricity and use its exhaust to raise steam for sale, or stream 54 can be used for other useful purposes. One such purpose is to feed a commercial pressure swing absorber such as those manufactured and sold by Air Products, Quest Air, and others, for producing pressurized fuel-quality hydrogen for local storage and used to fuel vehicles.
The very warm syngas 58 leaves heat exchanger 52 at about 650-750° C. (1200-1380° F.) and enters heat exchanger 70 , which can also be a second set of coils in exchanger 52 . Cool outside air 84 is fed into this exchanger 70 by blower 72 to be heated to 570-670° C. (1050-1150° F.) as exit stream 71 , which in-turn is the hot air feeding the fuel cell 60 . The air stream is electrochemically reduced in the cathode to exit as nitrogen gas 74 at about 600-700° C. (1100-1300° F.) and is fed to exchanger 76 and exiting as 77 at about 130° C. (270° F.) to be used for other purposes, such as generating domestic hot water.
The cooled syngas 67 at about 150-200° C. (300-400° F.) passes into packed bed absorber 66 to clean the syngas of impurities containing chlorine and sulfur and other potential poisons to the fuel cell. A condensate stream 68 leaves this absorber 66 to go to sewer drain. The clean, cool syngas 64 is pulled from the absorber 66 at about 130° C. (270° F.) by blower 62 and feeds the exchanger 76 which raises the syngas temperature to 600-700° C. (1100-1300° F.) for feeding the anode side 78 of the fuel cell 60 . Natural gas, propane, or other fuel source can be used in line 79 to start up fuel cell 60 and the system via mixing valve 80 .
Another preferred embodiment of the present invention is shown in FIG. 4 , which involves heating volume 42 of the rotary drum 14 through combustion of natural gas. This embodiment has two disadvantages because it uses expensive natural gas and it involves the evolution of carbon dioxide. As shown in FIG. 4 , drum 14 shown in isometric has internal volume 42 . It has a manually operated means of handle 22 to lock the autoclave-type sealing door 6 that rotates with the drum. The waste 44 enters the rotary drum that is rotated by means of a motor drive system 45 . Inside and co-centric to the rotary drum there is a stationary heated cartridge cylinder 100 through which the waste volatiles pass that is heated by an internal heater, which in this embodiment, is in the form of a matrix heater, 112 shown in FIG. 5 fed by a outside combustible gas fuel stream 46 venting to the outside through pipe 49 . This rotary drum volume 42 heats the waste to about 700-900° C. (1300-1650° F.) and starts the steam reforming reactions. The waste volatiles and initially formed syngas produced inside this rotary drum are pulled into the inside of this cartridge wherein the organics are heated to about 900-1050° C. (1650-1900° F.) and reacted with the steam and CO 2 to form very hot syngas exiting this central cartridge as syngas stream 47 at 800-950° C. (1470-1750° F.)
This very hot syngas 47 enters heat recuperator exchanger 52 that cools this syngas to 650-750° C. (1200-1380° F.) in pipe 58 with the cooler stream 56 at 570-670° C. (1050-1150° F.) containing CO 2 and steam. The cathode exhaust gas 74 comes from fuel cell 60 . The fuel cell anode exhaust stream 56 can contain a small fraction of unconverted syngas, which can be recirculated back to the steam reformer drum volume 42 for utilization. Part of this 700-900° C. (1300-1650°) exchanger exit stream 54 also is recirculated as stream 50 back into the cartridge steam reformer 100 to make more syngas. The gas 54 leaving heat exchanger 52 will be about 700-900° C. (1300-1650°) and can be used to drive a Brayton cycle turbine to make more electricity and use its exhaust to raise steam for sale, or stream 54 can be used for other useful purposes. One such purpose is to feed a commercial pressure swing absorber, such as those manufactured and sold by Air Products, Quest Air, and others for producing pressurized fuel-quality hydrogen for local storage and used to fuel vehicles.
The very warm syngas 58 leaves heat exchanger 52 at about 650-750° C. (1200-1380° F.) and enters heat exchanger 70 , which can also be a second set of coils in exchanger 52 . Cool outside air 84 is fed into this exchanger 70 by blower 72 to be heated to 570-670° C. (1050-1150° F.) as exit stream 71 , which in turn is the hot air 71 feeding the fuel cell 60 . The air stream is electrochemically reduced in the cathode to exit as nitrogen gas 74 at about 570-700° C. (1050-1300° F.) and is fed to exchanger 76 and exiting as 77 at about 130° C. (270° F.) to be used for other purposes, such as generating domestic hot water.
The cool syngas 67 at 80° C. passes into packed bed absorber 66 to clean the syngas of impurities containing chlorine and sulfur and other potential poisons to fuel cell 60 . A condensate stream 68 leaves absorber 66 to go to sewer drain. The clean, cool syngas 64 is pulled from the absorber 66 at about 130° C. (270° F.) by blower 62 and feeds via 82 the exchanger 76 which raises the syngas temperature to 600-700° C. (1100-1300° F.) for feeding the anode side 78 of fuel cell 60 . Natural gas, propane, or other fuel source can be used in line 79 to start up fuel cell 60 and the system via mixing valve 80 .
The details of the steam reforming cartridge 100 are shown in FIG. 5 . The cartridge is inside the end of the rotary drum wall 102 and remains fixed while the drum rotates and remains sealed by rotary seal 120 . The hot waste volatiles and partially formed syngas are pulled in through ports 104 . This gas is heated while it travels along the outer annulus 105 of the cartridge and turns around at the end of the annulus 106 to travel along the hotter inner annulus 107 and exiting at port 118 . The annulus tube assembly is kept centered by a plug insulator 108 at the right end of the annulus tube. The center of the cartridge inside tube 110 is heated by burning a combustible gas 114 in the matrix heater 112 that radiates heat out to the surrounding annuli 105 and 107 . The combustion products of this matrix gas burning leave at port 116 . Alternately this central heater could also be supplying heat by electrical resistance heaters, induction heaters, or other means of generating heat.
EXAMPLE
The first step in the reduction to practice of the appliance of the subject invention was to conduct experimental, small-scale pilot tests to reveal the identity and nature of the syngas produced. Accordingly, just completed was a gas test using the Bear Creek Pilot plant where solid waste was steam/CO 2 reformed to make syngas. The syngas composition is shown in Table 1 below.
TABLE 1
H 2
Hydrogen
62.71
Vol %
CO
Carbon Monoxide
18.57
CO 2
Carbon Dioxide
10.67
CH 4
Methane
7.58
C 2 H 6
Ethane
0.48
C 3 TO C 6
Propane through hexane
<0.01
C 6 H 6
Benzene
<17
ppm
COS
Carbonyl Sulfide
4
ppm
CS 2
Carbon Disulfide
0.05
ppm
H 2 S
Hydrogen Sulfide
<5
ppm
C 10 H 8
Naphthalene
2.6
ppb
C 10 H 7 CH 3
2-Methylnaphthalene
~0.6
ppb
C 12 H 8
Acenaphthalene
~0.4
ppb
C 12 H 8 O
Dibenzofuran
0.36
ppb
PCDF + PCDD
Polychlorinated-dibenzo-
0.0041
ppt TEQ
furans + Dioxins
What has been found was that the syngas was very rich in hydrogen and carbon monoxide—most suitable for a variety of high temperature fuel cells (such as molten carbonate, solid oxide, and similar fuel cells.). And the minor contaminants, such as carbonyl sulfide, hydrogen sulfide, carbon disulfide, hydrogen chloride, and polychlorinated organics were identified and a removal system specified.
The pilot process configuration used to conduct these tests was published, see reference (1) below, and was used as the basis for improvements shown in FIG. 3 . The standard, common-knowledge process train was configured for cleaning the syngas: Standard chilled caustic scrubber, demister mat, carbon bed and HEPA filter, after which the product syngas was subjected to a very exhaustive chemical analyses. Three parallel gas-sampling trains were used: Gas-Chromatography, GC-MS for volatile hydrocarbons, semi-volatile hydrocarbons, chlorine-containing and sulfur-containing compounds.
The standard scrubber widely used in industry for gas clean-up removed hydrogen sulfide and hydrogen chloride, but not carbonyl sulfide, carbon disulfide, or polychlorinated organics. It was found that these compounds penetrated right through this syngas standard clean-up process train and that these compounds would be poisons to a molten carbonate or solid oxide high temperature fuel cell by the mechanism of chlorine or sulfur poisoning. So this important information was used to design the syngas clean-up system that would handle all these contaminants.
Volatile heavy metals can also poison the fuel cell and the collected solids in the scrubber were analyzed for such heavy metals and they were mostly removed. Highly volatile heavy metals, such as mercury or heavy metal chlorides or fluorides would be removed in the future clean-up system.
The scrubbed syngas was next fed to a room temperature demister mat, onto which a steadily increasing deposit of fine soot-like particles occurred. The pressure drop across this demister during the run was determined and found it to show a steady, linear increase in pressure drop as the deposit layer built up on the upstream face. These deposits were not analyzed. The downstream side of this demister filter remained clean and white throughout the entire run. Deposits appear to be soot with a slight odor of naphthalene.
The syngas leaving the demister was next fed into a granular activated carbon bed, which was designed to capture the volatile organics and volatile heavy metals that reached this point. The carbon bed was found to remove a great amount of these minor constituents and quickly became saturated throughout its entire length and broke through about 2 hours into the 3 hour solid waste feed period. The carbon load is believed to be mostly benzene and low molecular weight volatile chloro-organics.
The final step in the syngas cleanup was the HEPA filter, which worked very well during the whole run, not showing any build up in pressure from entrained fines or humidity; however, there was a substantial amount of volatile heavier hydrocarbons and sulfur- and chlorine-containing hydrocarbons that got through: benzene<16 ppm, naphthalene=2.6 ppb, methylnaphthalene=0.6 ppb, acenaphthalene=0.4 ppb, and non-chlorinated dibenzofuran=0.36 ppb, polychlorinated dibenzodioxin and dibenzofuran TEQ=0.0041 ppt, COS=4 ppm, and CS 2 =0.05 ppm. H 2 S was below level of detection so the chilled scrubber did well on H 2 S, as well as HCl.
The very small, but still detectible polychlorinated dibenzodioxin and dibenzofurans were probably formed at the cooler end of the process train, since they are not formed during the steam reforming process. Their formation was probably before the quenching portions of the scrubber. Thus, the industry-standard scrubber approach alone is not sufficient for making syngas of high enough quality for fuel cells but the new syngas clean-up system does this.
The pilot tests showed that very high hydrogen content syngas can be produced using the steam/CO 2 reforming chemistry with a typical feed-stream of household waste.
Reference: (1) T. R. Galloway, F. H. Schwartz and J. Waidl, “Hydrogen from Steam/CO 2 Reforming of Waste,” Nat'l Hydrogen Assoc., Annual Hydrogen Conference 2006, Long Beach, Calif. Mar. 12-16, 2006.
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An appliance is provided having a waste receptor module and an energy generation module for converting household waste into energy. The receptor module has a rotary drum with an opening for receiving the household waste and a steam reforming means for converting the waste into synthesis gas. A swing arm is attached adjacent to the opening in the rotary drum and a sealing door is mounted on the swing arm for sealing the opening when the waste receptor module is in operation. An outer door is used to cover the sealing door. The steam reforming means includes a tube mounted within the rotary drum for receiving the volatilized organic waste and an internal heater for heating the organic waste to temperatures to convert the waste into the synthesis gas. The energy generation module has an inlet in fluid communication with the waste receptor module for receiving the synthesis gas and a fuel cell for converting the synthesis gas into electrical energy.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation and claims the benefit of U.S. patent application Ser. No. 14/696,266, filed Apr. 24, 2015, which is a continuation claiming the benefit of U.S. patent application Ser. No. 13/336,881, filed Dec. 23, 2011, now U.S. Pat. No. 9,039,359, which claims the benefit of U.S. Provisional Pat. App. Ser. No. 61/430,164, filed Jan. 5, 2011, all of which applications are incorporated herein in their entirety by reference.
FIELD OF INVENTION
[0002] This invention relates to nanometer-scale electromechanical systems. This invention relates particularly to systems using a nanometer-scale engine to convert the kinetic energy of molecules in a gas or fluid into useful work.
BACKGROUND
[0003] Brownian motion is the random motion of molecules in a gas or fluid due to the kinetic energy of the molecules. The kinetic energy, and thus the motion, of a molecule is directly related to its temperature, with a warmer molecule having more kinetic energy. The kinetic energy E of a molecule, measured in joules, is given by the formula:
[0000] E= 3/2 k*T
[0000] where T is the absolute temperature, in degrees Kelvin, of the molecule and k is the Boltzmann constant of 1.38*10 −23 J/K. In a gas or fluid at room temperature of about 23 degrees Celsius, or 296K, a single molecule has kinetic energy of about 6.13*10 −21 J.
[0004] Since the discovery of Brownian motion, many attempts have been made to design an apparatus that “taps into” the kinetic energy of molecules, using it as fuel to generate electricity, to propel a structure, or to perform other tasks. Such an apparatus must itself be subject to Brownian motion and therefore must be, or have components that are, microscopic or smaller in size. A Brownian-level apparatus was only theorized until the recent advent of technologies, such as microelectromechanical systems (“MEMS”) technology, that allow the construction of discrete articles at a suitably small scale. In one recent potential solution, U.S. Pat. No. 7,495,350 describes an array of beams measuring only a few nanometers across, wherein a particle that collides with a beam imparts some of its kinetic energy onto the beam, causing the beam to bend and then oscillate as it returns to its original position. The motion of the beam generates a small but measurable current in attached circuitry.
[0005] It would be advantageous to provide a device that converts the Brownian motion of molecules into rotational or revolving movement, in order to efficiently produce electricity as well as to directly operate pumps, wheels, axles, and other devices requiring rotational motion. One well-known example is the generically-termed “Brownian motor,” which includes a paddle wheel connected to a ratchet and pawl. The ratchet and pawl theoretically restrict the rotation of the paddle wheel to one direction, so that impacts of molecules on the paddle wheel's paddles cause one-way rotation of the wheel in discrete steps. This design has two primary drawbacks. Most importantly, it has been shown that the ratchet and pawl must also be at the nanoscale and are therefore also subject to Brownian motion. As a result, when the paddle wheel, ratchet, and pawl are at the same temperature, there is no net motion of the paddle wheel, and in fact the pawl is subject to failure that causes the paddle wheel to rotate in the opposite direction. The pawl and ratchet must be maintained at a lower temperature than the paddle wheel, which requires external application of energy to the system. The other main drawback is that, assuming a functioning device, the paddle wheel moves in discrete increments rather than moving continuously. A nano-scale engine that rotates or revolves substantially continuously without a temperature gradient is needed.
[0006] Therefore, it is an object of this invention to provide an apparatus for converting the kinetic energy of a molecule into useful work. It is a further object that the apparatus generate useful work from the Brownian motion of molecules in a gas or fluid. It is a further object that the apparatus generates the work through rotational or revolving motion. It is another object of the invention to provide an apparatus that converts the kinetic energy of molecules into electricity. It is another object of the invention to provide an apparatus that converts the kinetic energy of molecules into rotational motion for powering a rotary device. It is a further object that the apparatus power a nano-scale rotary device. It is still another object of the invention to provide an apparatus that moves, in a substantially controlled manner, due collisions with surrounding molecules. It is a further object of the invention to use the movement to transport a material along a path.
SUMMARY OF THE INVENTION
[0007] An apparatus for converting molecular kinetic energy into useful work includes a housing that encloses a gas or fluid and an actuator immersed in the gas or fluid. The gas or fluid may be contained in the housing under pressure. The actuator is small enough to be directly affected by the Brownian motion of the molecules in the fluid or gas, specifically between a few nanometers and 100 micrometers in total length. The actuator is configured to move in response to molecular collisions. The actuator has at least one leading face and at least one trailing face, the leading and trailing faces being offset from each other by an angle of more than 180 degrees. In the preferred embodiment, each leading face is parallel to and facing away from a trailing face. The leading face is substantially composed of a first material and the trailing face is substantially composed of a second material having a coefficient of restitution, with respect to the molecules of the gas or fluid, which is substantially lower than the coefficient of restitution of the first material. Preferably, the coefficient of restitution of the first material is approximately 1.0, and the coefficient of restitution of the second material is substantially close to zero.
[0008] The Brownian motion of the molecules in the gas or fluid causes them to collide with each other, with the walls of the housing, and with the leading and trailing faces of the actuator. Due to the arrangement of the first and second materials, the molecular collisions with the trailing face impart a greater momentum on the actuator than the molecular collisions with the leading face, causing the actuator to move. The kinetic energy of the actuator may then be used to perform other work. Suitable uses include: constraining the actuator to circular movement to operate a wheel, turbine, pulley, pump, or another device that may directly employ the movement; converting movement along a closed loop to linear motion to operate a pushrod or gate; attaching a magnetic material to the actuator and placing an inductor in proximity to create a magnetic flux; using movement of the actuator along a path to transport a material; or simply dissipating heat within the gas or fluid. The housing may be made of a material having good properties of heat transfer, so that a gas or fluid outside the housing may be used to heat the gas or fluid inside the housing. The invention contemplates arrangements of the housing-actuator assembly in arrays of several thousand to several billion or more assemblies, according to design requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a plan view of a first embodiment of the invention, showing an actuator with one blade.
[0010] FIG. 2 is a cross-sectional view of the first embodiment of the invention, taken along line 2 - 2 of FIG. 1 .
[0011] FIG. 3 is a plan view of a second embodiment of the invention, showing an actuator with two blades.
[0012] FIG. 4 is a plan view of a third embodiment of the invention, showing an actuator with four blades.
[0013] FIG. 5 is a plan view of a fourth embodiment of the invention, showing an actuator configured to travel along a linear chamber.
[0014] FIG. 6 is a plan view of a fifth embodiment of the invention, showing the actuator of FIG. 5 configured to travel inside a circular chamber.
[0015] FIG. 7 is a plan view of a sixth embodiment of the invention, showing the actuator of FIG. 5 configured to travel along a circular track.
[0016] FIG. 8 is a plan view of a seventh embodiment of the invention, showing the actuator of FIG. 5 configured to travel along a circular track having a channel.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring to FIGS. 1 and 2 , there is illustrated a first embodiment of the present invention designated generally as 10 which is used to convert the kinetic energy of molecules in a gas or fluid into extractable, usable kinetic energy. The device 10 comprises an actuator 13 substantially contained within a housing 11 . The housing 11 is a substantially gas- and water-tight enclosure having walls that define a chamber 12 in which the actuator 13 is positioned. The housing 11 and chamber 12 may be any shape suitable for containing the actuator 13 and the gas or fluid that powers it as described below, according to the implementation of the invention. Preferably, the housing 11 is a regular or irregular hexahedron or another shape with planar sides that allow the device 10 to be stacked or placed side-by-side with other devices 10 . The size of the housing 11 may be determined by the size of the actuator and the type of gas or fluid contained in the chamber 12 . The housing 11 may be made of a non-permeable material that may be manipulated at the microscopic, and preferably nanoscopic, level, such as aluminum, silicon, doped silicon, or carbon crystal. Preferably the material used has good heat transfer properties, such as aluminum or doped silicon. The wall thickness of the housing 11 is chosen to constrain the enclosed gas or fluid at a desired pressure while allowing heat to be easily transferred through the wall and also accommodating the interoperation of the actuator 13 with other components of the device 10 in certain embodiments as described below. The wall thickness may also depend on the material chosen for it. For example, a carbon crystal lattice, such as diamond, may be 1 nm or less in thickness while still retaining certain gases at pressure, while a wall made from a silicon substrate, as is known in MEMS construction, may be about 60 nm in width. One or more sealable ports (not shown) may be disposed through the walls of the housing 11 to provide access to the chamber 12 or to allow the actuator 13 to escape the housing.
[0018] The gas or fluid contained within the chamber 12 contains a known composition of molecules. Preferably, the gas or fluid is substantially pure, meaning it contains a substantially homogenous composition of a single type of molecule, because it is easier to predict an expected amount of movement and energy extraction when the molecules are the same size. However, a composition such as air, having oxygen, nitrogen, argon, and other gases therein, may be used. Further, the chosen gas or fluid must not react chemically with the material used for the housing 11 and actuator 13 , in order to prevent degradation of the materials or pollution of the gas or fluid. The molecules have kinetic energy based on the average temperature of the gas or fluid. The kinetic energy of the molecules is transferred in varying amounts to the components of the device 10 as the molecules collide with the components during Brownian motion. The amount of energy transferred by a molecule to a component during a collision is directly related to the coefficient of restitution (“COR”) between the material of the component and the molecule. The COR between two masses A and B may be found using the formula:
[0000] COR=( v b −v a )/( u a −u b )
[0000] where u a and u b are the initial velocities of masses A and B, respectively, and v b and v a are the final velocities of masses A and B, respectively. A COR of 1.0 represents a completely elastic collision, and a COR of 0.0 represents a completely inelastic collision. As used herein, the COR of a material used on the actuator 13 described below is defined with respect to the molecules of the enclosed gas or fluid, which collide with the actuator 13 . The COR of a material is determined by the particles that comprise it and the structure in which they are arranged, said structures ranging from highly crystalline to amorphous. Commonly known material properties that affect the COR include its Young's modulus, its Poisson's ratio, and its dissipative constant, the last value being a function of the material's viscosity.
[0019] The mass of the actuator 13 must be small enough to be affected by the Brownian motion of the molecules. However, the less massive the actuator 13 , the greater the velocity imparted upon the actuator 13 by the molecular impacts. A low-mass actuator 13 may be subject to significant velocity changes as the molecules randomly hit it from all directions. Preferably, therefore, the actuator 13 is large enough to minimize the magnitude of velocity changes. An appropriate mass will depend on the implementation, in particular molecular composition and density of the gas or fluid contained in the chamber 12 . For example, in air the actuator 13 may weigh up to about 1 microgram, while in water the actuator 13 may weigh up to 600 micrograms. The actuator comprises at least one pair of faces, a leading face 14 a and a trailing face 15 a, that are substantially planar surfaces facing away from each other; that is, the angle a between the leading and trailing faces is greater than 180 degrees. Preferably, the leading face 14 a is substantially parallel to and facing away from the trailing face 15 a, meaning the angle between the faces is about 360 degrees. See FIG. 1 .
[0020] The leading face 14 a is substantially composed of a first material having a first COR and the trailing face 15 a is substantially composed of a second material having a second COR that is lower than the first COR. The difference between the first and second CORs is preferably maximized, where the first COR is approximately 1.0 and the second COR is near zero. However, while the difference in CORs maximizes the efficiency of energy extraction as described below, other materials having a lower COR difference may be selected for the first and second materials for other reasons such as manufacturing costs or availability of materials. Non-exhaustive examples of possible pairings of first and second materials include a conventional solid, or crystalline, metal and an amorphous metal, a rigid crystalline material and a flexible structure, or any other combination of materials that results in a difference of CORs between the first and second materials. For comparison purposes, the materials may be chosen from diamond, silicon, and nylon, which have Young's moduli of about 1300 GPa, about 130-190 GPa, and about 2 GPa, respectively. The difference in CORs between diamond and nylon is higher than any other combination of these materials and will render the most efficient actuator 13 . However, selecting silicon instead of diamond may be significantly more cost-effective even though the actuator 13 would not be as efficient. It will be understood that in any combination of materials, the first material, which comprises the leading face 14 a, has a higher COR than the second material, which comprises the trailing face 15 a. In alternate embodiments, the leading face 14 a and trailing face 15 a may be composed of a plurality of materials that, taken together, have a total COR that satisfies the requirement for a difference between the CORs of the leading face 14 a and trailing face 15 a. In still other embodiments, the leading face 14 a and trailing face 15 a may be composed of the same material having different arrangements that result in the COR of the material on the leading face 14 a being higher than the COR of the material on the trailing face 15 a.
[0021] Immersed in the gas or fluid contained in the chamber 12 , the actuator 13 is subject to substantially constant collisions with the surrounding molecules, which have velocities dictated by temperature and the principles of Brownian motion. Conventionally, it is understood that the effect of Brownian motion of all of the molecules in a constrained gas or fluid, referred to as “thermal noise,” is symmetric, meaning the net velocity of the particles is zero. However, due to the differences in CORs of the materials comprising the leading face 14 a and trailing face 15 a, the average kinetic energy imparted upon the actuator 13 over time causes a net velocity of the actuator 13 in one direction. Specifically, in a model where the actuator moves substantially linearly and the leading face 14 a is on the right side of the actuator 13 , the actuator 13 will move toward the right. See FIG. 5 . The present device 10 comprises components that constrain the motion of the actuator 13 onto an open or closed path as described below with respect to particular embodiments. Thus, in the device 10 , the molecular collisions with the leading and trailing faces result in the actuator 13 experiencing a net torque from the unequal transfer of kinetic energy.
[0022] Referring again to FIGS. 1 and 2 , and further to FIGS. 3 and 4 , the actuator 13 may be configured to move in a circle, the circle preferably having a center near the center of the chamber 12 so as not to impact the walls of the housing 11 during movement. The actuator 13 may comprise one or more blades, each having a proximal end, a distal end, and a pair of leading and trailing faces. The blades have dimensions that are sufficiently small to be subject to Brownian motion, specifically in the range of a few nanometers to about 100 micrometers in any dimension. The blades preferably are shaped to maximize the available surface area for molecular impacts upon at least the trailing face. The blades may be attached to or integral with a base 16 at the proximal end of the blade. The base 16 may be configured to rotate around an axle 17 attached to or disposed through one or more of the walls of the housing 11 . In one embodiment, the base 16 and axle 17 are separated and arranged to minimize the friction between them, and a lubricant or additional friction-reducing material may be used. In another embodiment, the base 16 is permanently attached to or integral with the axle 17 , which passes out of the housing and mechanically or electrically attaches to a means for extracting the energy produced by the actuator 13 , such as a sprocket or another wheel, a pulley, a turbine, a propulsion system, a pushrod assembly for converting the rotational motion of the axle 17 into reciprocal motion, or another structural component designed to use the actuator's 13 rotational energy.
[0023] The specific size, shape, and number of blades may be varied to optimize performance in a given implementation. FIGS. 1 and 2 illustrate a first embodiment wherein the actuator 13 has one blade 18 with a leading face 14 a and a trailing face 15 a. In the illustrated embodiment, the blade 18 is substantially hexahedral, with the leading face 14 a being substantially parallel to the trailing face 15 a. The blade 18 may be divided in the plane that is parallel to the leading face 14 a, preferably divided in half, with the portion containing the leading face 14 a being substantially comprised of the first material, and the portion containing the trailing face 15 a being substantially comprised of the second material. The width of the portions may affect the COR at each of the leading face 14 a and trailing face 15 a, such that both portions may be made of the same flexible material and yet have different CORs in order to satisfy the requirements for the actuator 13 . The portions are permanently attached to each other or are formed integrally with each other, and further are attached to or integral with the base 16 . In the illustrated embodiment, the actuator 13 will spin clockwise around the axle 17 , but the leading face 14 a and trailing face 15 a may be reversed to cause the actuator to spin counter-clockwise.
[0024] FIGS. 3 and 4 illustrate a second and third embodiment, respectively, wherein the actuator 13 comprises a plurality of blades. Referring to FIG. 3 , a first blade 18 may be offset from a second blade 31 by up to 180 degrees around the axle 17 . The second blade 31 has a leading edge 14 b and a trailing edge 15 b disposed in the same arrangement as those of the first blade 18 to increase the surface area of the actuator 13 for receiving molecular impacts. Preferably, the second blade 31 is disposed opposite the first blade 18 and has the same properties as the first blade 18 to maintain symmetry of the actuator 13 . However, the second blade 31 may have a different size or mass, or may be composed of different materials, if the implementation calls for it. For example, the second blade 31 may have a magnet attached to it as described below, and the mass of the second blade 31 is lower than that of the magnet-free first blade 18 , so that the sum of the masses of the second blade 31 and the magnet are equal to the mass of the first blade 18 . A four-bladed actuator 13 is illustrated in FIG. 4 . The blades 18 , 31 , 41 , 42 may be spaced at 90-degree intervals around the base 16 . As shown, one or both of the leading face 14 a - d and trailing face 15 a - d of each of the blades 18 , 31 , 41 , 42 may be angled away from the opposite face, the angle a being between 180 and 360 degrees. The angle a may be chosen so that each blade 18 , 31 , 41 , 42 ends in a point. The angular design provides for a longer trailing face 15 a - d on each blade than if the trailing face 15 a - d were parallel to the leading face 14 a - d, for a blade with the same length. This provides more surface area for molecular impacts, which in turn may increase the efficiency with which the Brownian motion of the molecules is converted into rotational motion of the actuator 13 .
[0025] In other embodiments, rather than being fixed in a stationary position at its center, the actuator 13 may be substantially untethered within the chamber 12 . Referring to FIGS. 5 and 6 , the actuator 13 may be a freely-moving vehicle with a leading face 14 e and a trailing face 15 e having the properties described above. The actuator's 13 movement may be constrained by the width and depth of the chamber 12 , so that on average the molecular impacts upon the actuator 13 will cause it to move in the direction of the leading face 14 e. Referring to FIG. 5 , the chamber 12 may comprise a channel 50 in which the actuator 13 is contained, the channel 50 having a start point 51 and an end point 52 . The channel 50 may be substantially linear or may define an otherwise regular or irregular path along which the actuator 13 may travel toward the end point 52 . The housing 11 may be configured to release the actuator 13 , such as by comprising a portal 53 positioned near the end point 52 . Referring to FIG. 6 , the chamber 12 may be configured as a closed loop around which the actuator 13 travels. The loop is preferably circular as shown, and may alternatively have any shape and comprise any number of bends provided the actuator 13 is able to navigate them. The actuator 13 may have a shape that conforms to the shape of the chamber 12 . The actuator 13 may be used to transport a material, such as a molecule that is heavier than the molecules of the enclosed gas or fluid, along the path of the chamber 12 . For example, the actuator 13 may comprise, carry, push, or pull a drug to be delivered to a cell or one or more magnetic materials that may cooperate with an external magnet, inductor, or other device for generating a magnetic flux, which may then be converted into electric current. In other embodiments, the actuator 13 may engage a lever or a rotating device such as a turnstile as the actuator 13 travels along a loop. This engagement may mechanically extract energy from the actuator's 13 movement.
[0026] Referring to FIGS. 7 and 8 , the device 10 may further comprise a track 70 disposed within the chamber 12 and attached to a wall of the housing 11 . The actuator 13 travels along the track 70 , which is preferably circular but may be oblong, irregular, or any other shape suitable for the actuator 13 to travel along. The track comprises at least one rail 71 that defines the path of the track 70 . The actuator 13 comprises one or more guides 73 that cooperate with the rails 71 to keep the actuator 13 on the track 70 as the actuator 13 is propelled by the molecular impacts. In one embodiment, shown in FIG. 7 , the actuator 13 comprises a plurality of guides 73 disposed on either side of a single rail 71 . In another embodiment, shown in FIG. 8 , two concentric rails 71 are spaced apart to create a channel 81 , and the actuator 13 comprises one or more guides 73 disposed within the channel 81 . The dimensions of the chamber 12 are selected so that the actuator 13 cannot drift off of the track 70 . The actuator 13 may be used to transport a material, such as a molecule that is heavier than the molecules of the enclosed gas or fluid, along the path of the chamber 12 . For example, the actuator 13 may comprise, carry, push, or pull one or more magnetic materials that may cooperate with an external magnet, inductor, or other device for generating a magnetic flux, which may then be converted into electric current. The device 10 may further comprise other components as described above to mechanically extract energy from the moving actuator 13 .
[0027] As described above, the net kinetic energy of the actuator 13 can be used to do work through various methods such as direct mechanical coupling to the actuator 13 or by using the motion and magnetic materials to generate an electrical current. It will be understood that a net motion in the desired direction is achieved, but at any particular point in time the actuator 13 may stop or move backwards due to the random Brownian motion of the molecules. Further, it will be understood that the materials and media chosen affect a net force upon the actuator 13 that is greater than any forces imparted by friction, gravity, or drag. The specific implementation and operational characteristics desired will control the primary dimensions and mass of the housing 11 , housing walls, chamber 12 , and actuator 13 , and will also determine the desired pressure of the fluid or gas contained in the chamber 12 . Further as explained, the components of the device 10 may be made of a variety of substances. The convenience of silicon as used in integrated circuit manufacturing makes it a good choice for much of the material.
[0028] The device 10 may be manufactured using presently known or later developed methods, including those used in MEMS and integrated circuit production, nanoscale metal and carbon manipulation, and biological functions used as a manufacturing template. A single device 10 may be produced at, for example, the nano scale and used to power another piece of nano-scale machinery. Many devices 10 may be physically or electrically connected, functioning as an array that generates an aggregated electrical current or performs work on a macro scale. For example, an array of several million devices 10 may be deposited on the surface of a 1 mm-square microchip. In another example, the array of devices 10 may be etched into a silicon substrate using MEMS construction techniques. In this example the housing 11 is essentially a pit in the substrate, defining a chamber that may have a regular or irregular shape. Electrical design of such an array may include connections and components for stepping up a produced voltage, increasing the current, or modulating or normalizing the current, as is known in the art of electrical circuit design. The microchip may be placed proximate to a computer processor, where waste heat from the processor may excite the molecules in the devices' 10 chambers 12 , producing an electric current that then powers a fan, a light-emitting indicator diode, or another electrical component. It is estimated that an array of devices 10 may have a power density of about 5% to 10% that of an alkaline battery.
[0029] The device 10 extracts kinetic energy from the molecules in the enclosed gas or fluid, which in turn decreases the average temperature of the gas or fluid. It is estimated that the device will extract about 2% of the initial kinetic energy in the enclosed gas or fluid for every six degrees Celsius lost. After a certain amount of energy is extracted, the gas or fluid may be too cold to move the actuator 13 . However, the actuator 13 will move substantially continuously if the device 10 is contained in a gas or fluid having a temperature that is higher than 17 degrees Celsius, due to heat transfer through the housing 11 into the chamber 12 . The device 10 may thus be used to dissipate heat contained in its environment, as the kinetic energy of molecules outside the housing 11 is transferred into the device 10 .
[0030] While there has been illustrated and described what is at present considered to be the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made and equivalents may be substituted for elements thereof without departing from the true scope of the invention. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
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A device for converting the kinetic energy of molecules into useful work includes an actuator configured to move within a fluid or gas due to collisions with the molecules of the fluid or gas. The actuator has dimensions that subject it to the Brownian motion of the surrounding molecules. The actuator utilizes objects having multiple surfaces where the different surfaces result in differing coefficients of restitution. The Brownian motion of surrounding molecules produce molecular impacts with the surfaces. Each surface then experiences relative differences in transferred energy from the kinetic collisions. The sum effect of the collisions produces net velocity in a desired direction. The controlled motion can be utilized in a variety of manners to perform work, such as generating electricity or transporting materials.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/401,073, entitled “SYSTEM AND METHOD FOR DISTRIBUTING KEYS IN A WIRELESS NETWORK,” filed Mar. 10, 2009, (now U.S. Pat. No. 8,161,278), which is a continuation of U.S. application Ser. No. 11/377,859, filed Mar. 15, 2006 (now U.S. Pat. No. 7,529,925), which claims priority to and the benefit of U.S. Provisional Application No. 60/661,831, filed Mar. 15, 2005, all of which are incorporated by reference herewith in their entireties.
BACKGROUND
Consumer demand for wireless local area network (WLAN) products (e.g. smart phones) grew rapidly in the recent past as the cost of WLAN chipsets and software fell while efficiencies rose. Along with the popularity, however, came inevitable and necessary security concerns.
The Institute of Electrical and Electronics Engineers (IEEE) initially attempted to address wireless security issues through the Wired Equivalent Privacy (WEP) standard. Unfortunately, the WEP standard quickly proved inadequate at providing the privacy it advertised and the IEEE developed the 802.11i specification in response. 802.11i provides a framework in which only trusted users are allowed to access WLAN network resources. RFC 2284, setting out an in-depth discussion of Point-to-Point Protocol Extensible Authentication Protocol (PPP EAP) by Merit Network, Inc (available at http://rfc.net/rfc2284.html as of Mar. 9, 2006), is one example of the 802.11i network authentication process and is incorporated by reference.
A typical wireless network based on the 802.11i specification comprises a supplicant common known as a client (e.g. a laptop computer), a number of wireless access points (AP), and an authentication server. In some implementations, the APs also act as authenticators that keep the WLAN closed to all unauthenticated traffic. To access the WLAN securely, an encryption key known as the Pairwise Master Key (PMK) must first be established between the client and an AP. The client and the AP then exchange a sequence of four messages known as the “four-way handshake.” The four-way handshake produces encryption keys unique to the client that are subsequently used to perform bulk data protection (e.g. message source authentication, message integrity assurance, message confidentiality, etc.).
A handoff occurs when the client roams from one AP to another. Prior to 802.11i, it was necessary for the client to re-authenticate itself each time it associates with an AP. This renegotiation results in significant latencies and may prove fatal for real-time exchanges such as voice data transfer.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention are illustrated in the figures. However, the embodiments and figures are illustrative rather than limiting; they provide examples of the present invention.
FIG. 1 is a block diagram illustrating an example of a WLAN system.
FIG. 2 is a block diagram illustrating an example of a WLAN system including one or more authenticators.
FIG. 3 is a block diagram illustrating an example of a WLAN system including one or more authentication domains.
FIG. 4 depicts a flowchart of an example of a method for secure network communication.
FIG. 5 depicts a flowchart of another example of a method for secure network communication.
FIG. 6 depicts a flowchart of a method to obtain an encryption key for secure network communication.
The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
DETAILED DESCRIPTION
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without one or more of these specific details or in combination with other components or process steps. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the present invention.
FIG. 1 is a block diagram illustrating an example of a Wireless Local Area Network (WLAN) system 100 . In the example of FIG. 1 , the WLAN system 100 includes an authentication server 102 , switches 104 - 1 to 104 -N (referred to collectively hereinafter as switches 104 ), Access Points (APs) 106 - 1 to 106 -N (referred to collectively hereinafter as APs 106 ), and clients 108 - 1 to 108 -N (referred to collectively hereinafter as clients 108 ).
In the example of FIG. 1 , the authentication server 102 may be any computer system that facilitates authentication of a client in a manner described later with reference to FIGS. 4-6 . The authentication server 102 may be coupled to one or more of the switches 104 through, for example, a wired network, a wireless network, or a network such as the Internet. The term “Internet” as used herein refers to a network of networks which uses certain protocols, such as the TCP/IP protocol, and possibly other protocols such as the hypertext transfer protocol (HTTP) for hypertext markup language (HTML) documents that make up the World Wide Web (the web). The physical connections of the Internet and the protocols and communication procedures of the Internet are well known to those of skill in the art. In an alternative embodiment, the authentication server 102 may reside on one of the switches 104 (or, equivalently, one of the switches 104 may reside on the authentication server).
In the example of FIG. 1 , the switches 104 may be any computer system that serves as an intermediary between a subset of the APs 106 and the server 102 . In an alternative, the APs may include the functionality of the switches 104 , obviating the need for the switches 104 .
In the example of FIG. 1 , the APs 106 typically include a communication port for communicating with one or more of the clients 108 . The communication port for communicating with the clients 108 typically includes a radio. In an embodiment, at least some of the clients 108 are wireless clients. Accordingly, APs 108 may be referred to in the alternative as “wireless access points” since the APs 106 provide wireless access for the clients 108 to a network, such as a Local Area Network (LAN) or Virtual LAN (VLAN). The APs 106 may be coupled to the network through network interfaces, which can be Ethernet network or other network interfaces. The network may also be coupled to a gateway computer system (not shown) that can provide firewall and other Internet-related services for the network. This gateway computer system may be coupled to an Internet Service Provider (ISP) to provide Internet connectivity to the clients 108 . The gateway computer system can be a conventional server computer system.
In the example of FIG. 1 , the clients 108 may include any wireless device. It should be noted that clients may or not be wireless, but for illustrative purposes only, the clients 108 are assumed to include wireless devices, such as by way of example but not limitation, cell phones, PDAs, laptops, notebook computers, or any other device that makes use of 802.11 or other wireless standards. When the clients 108 are authenticated, they can communicate with the network. For illustrative purposes, clients 108 are coupled to the APs 106 by lines 110 , which represent a secure connection.
In the example of FIG. 1 , in operation, to communicate through data traffic in the WLAN system 100 , the clients 108 typically initiate a request to access the network. An authenticator (not shown) logically stands between the clients 108 and the network to authenticate the client's identity and ensure secure communication. The authenticator may reside in any convenient location on the network, such as on one, some, or all of the APs 106 , on one, some, or all of the switches 104 , or at some other location. Within the 802.11i context, the authenticator ensures secure communication by encryption schemes including the distribution of encryption keys. For example, the authenticator may distribute the encryption keys using existing encryption protocols such as, by way of example but not limitation, the Otway-Rees and the Wide-Mouth Frog protocols. The authenticator may distribute the encryption keys in a known or convenient manner, as described later with reference to FIGS. 4-6 .
In the example of FIG. 1 , a client may transition from one authenticator to another and establish secure communication via a second authenticator. The change from one authenticator to another is illustrated in FIG. 1 as a dotted line 112 connecting the client 108 -N to the AP 106 -N. In a non-limiting embodiment, the secure communication via the second authenticator may be accomplished with one encryption key as long as both the first and second authenticators are coupled to the same authentication server 102 . In alternative embodiments, this may or may not be the case.
FIG. 2 is a block diagram illustrating an example of a WLAN system 200 including one or more authenticators. In the example of FIG. 2 , the WLAN system 200 includes authenticators 204 - 1 to 204 -N (referred to hereinafter as the authenticators 204 ), and a client 208 . As was previously indicated with reference to FIG. 1 , the authenticators 204 may reside on APs (see, e.g., FIG. 1 ), switches (see, e.g., FIG. 1 ) or at some other location in a network.
In the example of FIG. 2 , in a non-limiting embodiment, the client 208 scans different channels for an access point with which to associate in order to access the network. In an alternative embodiment, scanning may or may not be necessary to detect an access point. For example, the client 208 may know of an appropriate access point, obviating the need to scan for one. The access point may or may not have a minimum set of requirements, such as level of security or Quality of Service (QoS). In the example of FIG. 2 , the client 208 determines that access point meets the required level of service and thereafter sends an association request. In an embodiment, the access request includes information such as client ID and cryptographic data. The request may be made in the form of a data packet. In another embodiment, the client 208 may generate and later send information including cryptographic data when that data is requested.
In the example of FIG. 2 , the authenticator 204 - 1 authenticates the client 208 . By way of example but not limitation, the authenticator 204 - 1 may first obtain a session encryption key (SEK) in order to authenticate the client 208 . In one implementation, the authenticator requests the SEK and relies on an existing protocol (e.g. 802.1X) to generate a PMK as the SEK. In an alternative implementation, the SEK is pre-configured by mapping a preset value (e.g. user password) into a SEK. In the event that a preset value is used, convenient or well-known methods such as periodically resetting the value, or remapping the value with randomly generated numbers, may be employed to ensure security. In this example, once the authenticator 204 - 1 obtains the SEK, it proceeds to a four-way handshake whereby a new set of session keys are established for data transactions originating from client 208 . Typically, the client 208 need not be authenticated again while it communicates via the authenticator 204 - 1 . In the example of FIG. 2 , the connection between the client 208 and the server 204 - 1 is represented by the line 210 .
In the example of FIG. 2 , the client 208 roams from the authenticator 204 - 1 to the authenticator 204 -N. The connection process is represented by the arrows 212 to 216 . In an embodiment, when the client 208 roams, the server 202 verifies the identity of the (new) authenticator 204 -N and the client 208 . When roaming, the client 208 sends a cryptographic message to authenticator 204 -N including the identity of the client 208 (IDc); the identity of the server 202 (IDs); a first payload including the identity of the authenticator 204 -N (IDa) and a randomly generated key (k) encrypted by a key that client 208 and the server 202 share (eskey); and a second payload including the SEK encrypted by the random key k. This cryptographic message is represented in FIG. 2 as arrow 212 . In an alternative embodiment, the client 208 sends the cryptographic message along with its initial association request.
In the example of FIG. 2 , in an embodiment, once authenticator 204 -N receives the cryptographic message, it keeps a copy of the encrypted SEK, identifies the server 202 by the IDs, and sends a message to the server 202 including the identity of the client IDc and the first payload from the original cryptographic message having the identity of the authenticator IDa and the random key k encrypted by the share key eskey.
In the example of FIG. 2 , when the server 202 receives the message from authenticator 204 -N, it looks up the shared key eskey based on the identity of the client IDc and decrypts the message using the eskey. The server 202 then verifies that a trusted entity known by IDa exists and, if so, constructs another message consisting of the random key k encrypted with a key the server 202 shares with authenticator 204 -N (askey) and sends that message to the authenticator 204 -N. However, if the server 202 can not verify the authenticator 204 -N according to IDa, the process ends and client 201 cannot access the network through the authenticator 204 -N. In the event that the authenticator 204 -N cannot be verified the client may attempt to access the network via another authenticator after a preset waiting period elapses.
Upon receipt of the message from the server 202 , the authenticator 204 -N decrypts the random key k using the shared key askey and uses k to decrypt the encryption key SEK. Having obtained the encryption key SEK, the authenticator 204 -N may then proceed with a four-way handshake, which is represented in FIG. 2 for illustrative purposes as arrows 214 and 216 , and allow secure data traffic between the client 208 and the network.
Advantageously, the authentication system illustrated in FIG. 2 enables a client 208 to roam efficiently from authenticator to authenticator by allowing the client 208 to keep the same encryption key SEK when transitioning between authenticators coupled to the same server 202 . For example, the client 208 can move the SEK securely between authenticators by using a trusted third party (e.g. the server 202 ) that negotiates the distribution of the SEK without storing the SEK itself.
FIG. 3 is a block diagram illustrating an example of a WLAN system 300 including one or more authentication domains. In the example of FIG. 3 , the WLAN system 300 includes a server 302 , authentication domains 304 - 1 to 304 -N (referred to hereinafter as authentication domains 304 ), and a network 306 . The server 302 and the network 306 are similar to those described previously with reference to FIGS. 1 and 2 . The authentication domains 304 include any WLANs, including virtual LANs, that are associated with individual authenticators similar to those described with reference to FIGS. 1 and 2 .
The scope and boundary of the authentication domains 304 may be determined according to parameters such as geographic locations, load balancing requirements, etc. For illustrative purposes, the client 308 is depicted as roaming from the authentication domain 304 - 1 to the authentication domain 304 -N. This may be accomplished by any known or convenient means, such as that described with reference to FIGS. 1 and 2 .
FIGS. 4 to 6 , which follow, serve only to illustrate by way of example. The modules are interchangeable in order and fewer or more modules may be used to promote additional features such as security or efficiency. For example, in an alternative embodiment, a client may increase security by generating and distributing a unique random key to each authenticator. In another alternative embodiment of the present invention, the authenticator employs a known or convenient encryption protocol (e.g. Otway-Rees, Wide-Mouth Frog, etc.) to obtain the encryption key.
FIG. 4 depicts a flowchart of an example of a method for secure network communication. In the example of FIG. 4 , the flowchart starts at module 401 where a client sends an association request to an access point. The flowchart continues at decision point 403 where it is determined whether a preconfigured encryption key is used. If it is determined that a preconfigured encryption key is not to be used ( 403 -NO), then the flowchart continues at module 405 with requesting an encryption key and at decision point 407 with waiting for the encryption key to be received.
In the example of FIG. 4 , if a preconfigured encryption key is provided at module 403 , or an encryption key has been received ( 407 -YES), then the flowchart continues at module 409 with a four-way handshake. The flowchart then continues at module 411 where data traffic commences, and the flowchart continues to decision point 413 where it is determined whether the client is ready to transition to a new authentication domain.
In the example of FIG. 4 , if it is determined that a client is ready to transition to a new authentication domain ( 413 -YES), then the flowchart continues at module 415 when the client sends a cryptographic message to the new authenticator. In an alternative embodiment, the client sends the cryptographic message along with its initial association request and skips module 415 .
The flowchart continues at module 417 , where once the new authenticator receives the cryptographic message, the new authenticator sends a message to the server. If at decision point 419 the authenticator is not verified, the flowchart ends. Otherwise, the server sends a message to the authenticator at module 421 . The flowchart continues at module 423 where the authenticator obtains an encryption key, at module 424 where the client and the authenticator enter a four-way handshake, and at module 427 where data traffic commences.
FIG. 5 depicts a flowchart of another example of a method for secure network communication. In the example of FIG. 5 , the flowchart begins at module 501 where a client makes an association request. The flowchart continues at decision point 503 , where it is determined whether a preconfigured encryption key is available. If it is determined that a preconfigured encryption key is not available ( 503 -NO) then the flowchart continues at module 505 , where an encryption key is requested, and at decision point 507 where it is determined whether an encryption key is received. If it is determined that an encryption is not received ( 507 -NO), the flowchart continues from module 505 . If, on the other hand, it is determined that an encryption key is received ( 507 -YES), or if a preconfigured encryption key is available ( 503 -YES), then the flowchart continues at module 509 with a four-way handshake. In the example of FIG. 5 , the flowchart continues at module 511 , where data traffic commences, and at decision point 513 , where it is determined whether a client is ready to transition. If it is determined that a client is not ready to transition ( 513 -NO), then the flowchart continues at module 511 and at decision point 513 until the client is ready to transition ( 513 -YES). The flowchart continues at module 515 , where an authenticator obtains an encryption key using an established cryptographic protocol. The flowchart continues at module 517 with a four-way handshake, and at module 519 where data traffic commences.
FIG. 6 depicts a flowchart of a method to obtain an encryption key for secure network communication. In one embodiment, a client transitions from a first authenticator to a second authenticator, both of which coupled to the same server, and establishes secure communication with the first and the second authenticator using one encryption key.
At module 601 , a client generates a first key. In one embodiment, the first key is randomly generated. In an alternative embodiment, the first key is generated according to a preset value such as by requesting a value (e.g. password) from a user. In yet another alternative embodiment, the first key is a constant value such as a combination of the current date, time, etc.
At module 603 , the client obtains a second key. In one implementation, the generation of the second key relies on an existing protocol (e.g. 802.1X). In an alternative implementation, the second key is pre-configured (e.g. user password). In yet another alternative implementation, the second key is a combination of a pre-configured value and a randomly generated value.
At module 605 , the client constructs a first message using the first key and the second key. In one embodiment, the message is a data packet comprising cryptographic data using the first and the second key. Furthermore, in one embodiment, the first message comprises the second key encrypted with the first key.
At module 607 , the client sends the first message to an authenticator. In one embodiment, the authenticator is a second authenticator from which the client transitions from a first authenticator.
At module 609 , the authenticator constructs a second message using data from the first message. In one implementation, the authenticator constructs the second message comprising the client's identity, and an encrypted portion having identity of the authenticator and the first key.
At module 611 , the authenticator sends the second message to a server with which the authenticator is coupled. At module 613 , the server decrypts an encrypted portion of the second message. In one implementation, the encrypted portion of the second message comprises the identity of the authenticator and the first key.
Subsequently at module 615 , the server verifies the authenticator with the decrypted identity information extracted from the second message. If the server cannot verify the authenticator according to the identification information, as shown at decision point 617 , the client cannot communicate through the authenticator. If, on the other hand, the server verifies the authenticator, the server constructs a third message with the first key that it extracted from the second message at module 619 . In one implementation, the third message comprises the first key encrypted with a third key that the server shares with the authenticator. The server then sends the third message to the authenticator at module 621 .
After receiving the third message, the authenticator extracts the first key from the message at module 623 . In one implementation, the authenticator extracts the first key using a third key it shares with the server. With the first key, the authenticator then decrypts the cryptographic data in the first message and extracts the second key at module 625 . Having obtained the second key, the authenticator establishes secure data traffic/communication with the client using the second key. In one embodiment, the authenticator is a second authenticator to which the client transitions from a first authenticator coupled to the server, and the client communicates securely with both the first and the second authenticator using the second key.
As used herein, the term “embodiment” means an embodiment that serves to illustrate by way of example but not limitation. It may be noted that, in an embodiment, timestamps can be observed to measure roaming time.
It will be appreciated to those skilled in the art that the preceding examples and embodiments are exemplary and not limiting to the scope of the present invention. It is intended that all permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the true spirit and scope of the present invention. It is therefore intended that the following appended claims include all such modifications, permutations and equivalents as fall within the true spirit and scope of the present invention.
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A technique for improving authentication speed when a client roams from a first authentication domain to a second authentication domain involves coupling authenticators associated with the first and second authentication domains to an authentication server. A system according to the technique may include, for example, a first authenticator using an encryption key to ensure secure network communication, a second authenticator using the same encryption key to ensure secure network communication, and a server coupled to the first authenticator and the second authenticator wherein the server distributes, to the first authenticator and the second authenticator, information to extract the encryption key from messages that a client sends to the first authenticator and the second authenticator.
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BACKGROUND OF THE INVENTION
As discussed in our copending application Ser. No. 727,072 filed Sept. 27, 1976, now U.S. Pat. No. 4,061,810, a number of metal compounds have been reported in the literature as flame retardants for various substrates. These have included antimony oxide, antimony chloride, phosphates and borates of alkali metals and alkaline earth metals, aluminum hydrate, titanium salts, tin salts and double salts such as potassium hexafluorozirconate and potassium hexafluorotitanate. However, when applied to carpets, the flame retardancy provided is not durable to usual cleaning procedures.
Also, as discussed in application Ser. No. 727,072, various patents have issued on compositions reporting flame retardancy; however, investigations have continued to develop improved flame-retardant carpet wherein the flame retardancy is particularly durable. The present invention is concerned with such improved flame-retardant carpets and methods of preparing same.
BRIEF DESCRIPTION OF THE INVENTION
The present invention includes a flame-retardant carpet having a relatively pliable primary backing and a tufted surface, said surface being comprised of fibers selected from the group consisting of polyester and polyamide fibers, said carpet having from about 1 to about 15 weight percent of a composition added thereto, said composition comprising:
(a) about 10 to about 80 weight percent of a polyvalent metal compound selected from the group consisting of the dispersible and soluble salts, oxides and hydroxides of aluminum, antimony and the alkaline earth metals;
(b) about 5 to about 85 weight percent of boric acid; and
(c) 0 to about 85 weight percent of a hydroxy carboxylic acid selected from the group consisting of maleic acid, citric acid, tartaric acid, gallic acid and 2,4-dihydroxybenzoic acid. The present invention also includes a process of producing a carpet which comprises adding to the carpet from about 1 to about 15 weight percent of the above composition and curing said composition on the carpet at a temperature of about 100° C. to about 150° C., whereby said carpet has improved flame retardancy and said flame retardancy has improved durability to carpet cleaning procedures.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a flame-retardant carpet which retains its aesthetic properties and is surprisingly flame retardant even after repeated cleanings. By "flame retardant carpet" is meant that the carpet burns very slowly when exposed in air to a direct flame or its equivalent. The preferred method of testing for flame-retardant properties is the modified United States Department of Commerce test, DOC FF1-70 described in our application Ser. No. 727,072 and in the present examples. Using this test, a pass and fail face fiber temperature can be determined for a treated carpet sample before any washings and after any given number of washings.
The untreated carpets are well-known materials, as described in our application Ser. No. 727,072 which is incorporated herein by reference for a more detailed description. In general, such carpets have a primary backing, a secondary backing, a latex binder and various polyester or polyamide fibers tufted therethrough. The preferred polyamides include polycaprolactam and condensation products of a dicarboxylic acid with a diamine such as polyhexamethylene adipamide and polyhexamethylene sebacamide or copolymers thereof. The preferred polyesters are the linear terephthalate polyesters, i.e. polyesters of a glycol containing from 2 to 20 carbons and a dicarboxylic acid component containing at least about 75% terephthalic acid. The remainder, if any, of the dicarboxylic acid component may be any suitable dicarboxylic acid such as sebacic acid, adipic acid or isophthalic acid. The glycols may be, for example, ethylene glycol, diethylene glycol, butylene glycol, or decamethylene glycol. Preferred examples are poly(ethylene terephthalate) and poly(butylene terephthalate).
Preferably, the composition comprises at least 5 weight % hydroxy carboxylic acid and more preferably between about 20 and about 85 weight percent of hydroxy carboxylic acid. Preferably, if the hydroxycarboxylic acid is citric acid (or tartaric acid), then boric acid and citric acid (or tartaric acid) are present in substantially equimolar amounts and complexed as borocitric acid (or borotartaric acid) or a salt thereof. Even more preferably, the polyvalent metal compound is also present in substantially equimolar amounts (based on moles of metal cation) and is complexed as the metal borocitrate (or metal borotartrate). Preferred are the antimony and magnesium borocitrates (or borotartrates).
In treating the carpet in accordance with the process of this invention, from about 1 to about 15 weight percent of the treating composition is applied to the carpet, as previously described. The metal complexes formed by the combination of ingredients are all essentially insoluble in water. In practicing the invention, the composition is dispersed or suspended in a solvent, preferably water, to make a pad bath of preferably about 0.5 to about 12 weight percent dispersion in a solvent such as water. The carpet is then soaked by the pad bath, which may also contain other additives commonly used in finishing carpets to improve properties of the carpet or to facilitate finishing. The carpet is then squeezed with any suitable apparatus such as pad rollers to remove excess solution. The squeezing apparatus, such as the rollers, is adjusted to give from about 25 to about 300 weight percent wet pick-up. The carpet is then dried and cured in a dryer or oven, preferably at a temperature of 100° to 150° C. The dispersion may be applied to the carpet in numerous ways. For example, the carpet may be immersed in the dispersion or the dispersion may be sprayed upon the carpet or applied to the carpet by means of pad rollers.
In accordance with another preferred procedure, after padding, the wet carpet is exposed to steam at atmospheric pressure for several minutes, rinsed with water and dried at 100° to 150° C. The steamed carpet is superior to unsteamed carpet in appearance and softness of hand.
Preferred forms of the treated carpet and method include those wherein the treating composition is as follows. It is preferred that the composition contain between about 20 and about 50 weight percent of the polyvalent metal compound, between about 20 and about 60 weight percent boric acid and between about 20 and about 60 percent of the hydroxy carboxylic acid. Preferred polyvalent metal compounds include aluminum hydroxide, antimony oxide, barium hydroxide and magnesium hydroxide. Preferred hydroxycarboxylic acids include gallic, tartaric and citric acids. With citric acid it is most preferred that the boric and citric acids be provided in substantially equimolar amounts. With tartaric acid, it is most preferred that the boric and tartaric acids be applied in substantially equimolar amounts. By substantially equimolar is meant those ratios that will cause most of each acid to be in the complex acids borocitric acid, borotartaric acid or their salts. It is also most preferred that the polyvalent metal compound be provided in a proportion where most of it will be in a complex salt such as a borocitrate or borotartrate.
The polyvalent metal can be provided in any form that will permit formation of complexes with the boric acid and hydroxycarboxylic acid, if the latter is included. For most of the above metals, soluble salts, hydroxides or oxides may be used such as the more soluble of the hydroxides, oxides, chlorides, fluorides, nitrate, sulfates and the like. In general, it is preferred to use the more soluble of the above forms, such as the barium chloride rather than the barium sulfate. Nevertheless, insoluble hydroxides, oxides and salts may be used under conditions (such as with a surfactant) that will suspend the metal compound, such as antimony oxide, finely enough to permit complexing with the boric acid (and organic acid if present) to form a highly insoluble material which may be deposited on the fibers.
The above discussion is phrased primarily in terms of water as the prefered solvent or dispersant, but the same rules would apply to other solvents or dispersants. When water is used, surfactants of conventional types may be used to promote solubility or dispersion.
In many preferred forms "substantially equimolar" amounts of boric acid, hydroxycarboxlic acid and polyvalent metal complex are used. By this is meant that about one mole of boric acid is provided for each mole of hydroxycarboxlic acid so as to form the complex acids borocitric acid, borotartaric acid and the like. Similarly a substantially equimolar or stoichiometric amount of the polyvalent metal oxide, hydroxide or salt is used to form the corresponding borocitrate, borotartrate or the like, with the complex acid apparently only linked to one of the metal valences. Small excess amounts of certain ingredients may promote formation of the insoluble complex acid or salt and thus are within the range of "substantially equimolar" amounts. Excesses of any component that do not promote complex acid or salt formation are less preferred.
EXAMPLE 1
Four-inch by four-inch carpet test specimens having polycaprolactam fibers in a jute primary backing were treated with 3.0% by weight of fibers boric acid and 6.5% by weight of fibers of antimony oxide suspended in a pad bath of distilled water. The specimens were then squeezed through a padder and dried in an oven at 125° C. They were then given a secondary backing with a latex binder having no flame retardant.
For testing by the "Aggravated Pill Test" described in our application Ser. No. 723,072, several samples were placed in a draft free box made of one-inch thick cement asbestos board. A 31/2 inch inner diameter iron ring was placed over the carpet to hold it down and to prevent buckling or other distortion during the test. A methenamine pill was placed in the center of the test specimen and three thermocouples placed gently resting in the pile to give representative values, continuously and automatically, of the face fiber temperature. The carpets were heated by infrared heat modules to the desired temperature after about five minutes of heating. Then the heat modules were turned off and the methenamine pill lit with a match. After the test sample had stopped burning, the maximum average burn diameter and time of burning were noted. Any sample having a maximum burn diameter of 5 centimeters or larger or a burn time of 3 minutes or longer was scored a failure. Multiple samples of similarly treated carpet were heated to various temperatures before lighting the pill and the lowest fail and highest pass temperature noted. Before any washings, these first samples passed at 202° C.
Similar samples were laundered following procedure 124-1973 in the Technical Manual of the American Association of Textile Chemists and Colorists. The laundered test pieces, after drying, were conditioned at ambient conditions for 48 hours before testing by the "Aggravated Pill Test". After one such washing and then conditioning, the samples failed at 201° C., but passed at 195° C. After three such washings, and then conditioning, the samples failed at 198° C. After 5 such washings and then conditioning, they passed at 190° C. These results are summarized in Table 1.
COMPARATIVE EXAMPLES 2, 3 AND 4
Example 1 was repeated separately with carpets treated with 10% of weight of fibers of boric acid, 10.2% of weight of fibers of citric acid and 10% of weight of fibers antimony oxide. The results are summarized in Table 1. As shown in Table 1, none of the three components alone gave the flame retardant properties and durability of flame retardance of the combinations in Example 1 and in Examples 6-10, discussed below.
COMPARATIVE EXAMPLE 5
Padding baths were prepared with borocitric acid, a complex acid, by method described in S. Prasad and N. P. Singh, J. Indian Chemical Society, Vol. 44 (3), page 219 (1967). Briefly, the process consisted of adding 19.2 gms of citric acid and 6.2 gms of boric acid in 400 gms of distilled water for complete solution. This provided borocitric acid which was highly water soluble and could not be readily isolated. It was, however, not necessary to do so when treatment of the carpet samples with borocitric acid was desired, since a dispersion could be prepared without isolation. The results of treatment with this bath are displayed in Table 1.
EXAMPLES 6 AND 7
Highly water insoluble polyvalent metal salts were prepared by first completely neutralizing the above borocitric acid with sodium hydroxide and then converting the water soluble sodium borocitrate into the desired insoluble compound. For example, the above borocitric acid was neutralized with 12.0 grams of sodium hydroxide and the reaction mixture was stirred for about 30 minutes and a non-ionic surface active agent (Mykon NRW-3 from Sun Chemical Corp.) was added to provide 0.5% on the weight of the total solution. Now, with vigorous and continuous stirring, a stoichiometric amount of antimony chloride was added, small quantities at a time. Continuous and vigorous stirring and the presence of surface active agent produced a very fine dispersion of the insoluble antimony borocitrate. Such a fine dispersion is highly desirable in preparing these flame retardant pad baths. This composition is then applied to the test specimens as in Example 1 at levels of 5.0% and 9.2% by weight of fibers and subjected to the Aggravated Pill Test described in Example 1. The results of these Examples 6 (at 5%) and 7 (at 9.2%) are displayed in Table I.
EXAMPLES 8-10
Example 6 is repeated for the magnesium, aluminum and barium borocitrates prepared by substituting magnesium chloride, aluminum chloride and barium chloride for the antimony trichloride in Examples 6 and 7, but applied at levels of 9.0%, and 10.0% and 10.0%, respectively. The results of the "Aggravated Pill Test" are displayed in Table 1. These complex salts all gave good flame retardance and durability, but not as good as the antimony borocitrate.
CONTROL
Example 1 was repeated using no flame retardant composition. The results are displayed in Table 1 as a base for showing the flame retardancy of the compositions and components.
Table 1__________________________________________________________________________Aggravated Pill TestMaterial Level Flame Retardance (After No. of Launderings)Ex. Applied % OWF 0 1 3 5 10__________________________________________________________________________1 Boric Acid 3.0 Antimony 6.5 202/-- 195/201 191/198 190/-- 190/197 Oxide2 Boric Acid 10.0 147/163 --/146 --/146 --/147 --/--3 Citric 10.2 207/-- 191/200 178/184 --/152 --/152 Acid4 Antimony 10.0 174/184 --/-- --/161 --/-- --/-- Oxide5 Borocitric 10.0 203/-- 184/192 178/185 179/185 153/165 Acid6 AnBC 5.0 195/204 183/191 181/193 180/-- 171/1807 AnBC 9.2 205/-- 200/N.T. 200/N.T. 199/-- 201/2118 MgBC 9.0 173/180 N.T. 172/180 159/169 158/1709 AlBC 10.0 181/192 --/-- 137/148 138/148 140/14910 BaBC 10.0 144/152 147/153 --/-- --/-- --/157- Control 0.0 141/151 131/139 127.sup.m /139 115/123 --/--__________________________________________________________________________ AnBC = Antimony Borocitrate; MgBC = Magnesium Borocitrate; AlBC = Aluminu Borocitrate; BaBC = Barium Borocitrate; = not tested; m = marginally passed.
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Combinations of boric acid with certain dispersible or soluble metal salts, oxides and hydroxides, preferably also with certain hydrocarboxylic acids, provide unexpectedly enhanced flame retardancy to carpets, said flame retardancy being durable to usual carpet cleaning procedures. Such combinations may take the form of certain metal borocitrates or borotartrates.
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BACKGROUND OF THE INVENTION
The invention relates to a process for the automatic adaptation of the data to be transferred to a data-requesting device, to the capabilities of this terminal.
In today's data communication networks there exist terminals with different displays, input apparatuses and computer performances. Displays differ above all in the color depth, resolution, and size. Input apparatuses can be, for example, keyboards or contact-sensitive surfaces. When data are transferred from a data-preparing device to a terminal, it is important, for as short as possible a transfer time of the data, that the data volume to be transferred at a given band width be as small as possible. Since, however, it is not known to the sending device what properties the end terminal possesses, the data and therewith the data volume are not adapted to the properties of the end terminal. To an end terminal with a display with a low resolution and black-and-white representation there are sent, for example, the same data as to an end terminal with a high resolution and a plurality of representable colors.
This leads to the result that data are transferred which cannot be processed in the end terminal by reason of the latter's capabilities. Resources of the transfer media, of the sending devices, and of the receiving end terminal are wasted.
In WO-A-98 37698 an adaptable data transfer system is disclosed, in which a data-preparing server is provided which, either by software or suitable hardware, executes an algorithm for the generation and storage of a plurality of hierarchically ranked video data streams, in which it is covered, which multimedia characteristics a data-requesting device has, and on the basis of this information there is transmitted a special selection of the available video-data stream to the data-requesting device.
WO-A-98 43177 teaches a system for the dynamic recording of data transmitting between computers. A so-called proxy-server is provided, which comprises devices for the dynamic adaptation of data transmitted from a network server to a network client, in which system the adaptation occurs in dependence on a selection criterion delivered from the network client. The selection criterion can be, for example, the hardware configuration of the network client.
The problem of the present invention lies, therefore, in giving a process for the automatic adaptation of the data to be transferred from a data-preparing device to a data-requesting device, to the capabilities of the data-requesting device, which process can react very flexibly to the capabilities of the data-requesting device.
SUMMARY OF THE INVENTION
The solution of the problem is achieved by transmitting a list of usable display formats to the data-preparing device which then selects the best suited display format.
According to the invention, in the data transmission a reduction of the resource expenditure becomes possible by the means that the data-preparing device receives information data about the capabilities of the receiving terminal, in order to transmit the data to be transferred in correspondence to the pre-determined capabilities.
The advantage of this process for the operator of the data preparing device lies, inter alia, in lower needed computing performance of the sending device and therefore in lower acquisition and maintenance costs. According to the transmission technique, the operator's transmission costs are reduced.
The advantages of this process for the user of the data-requesting device lie, inter alia, in shorter data transmission time and in lower transmission costs. Since according to this process the sending device can also adapt the data to the display of the receiving device, the user can also receive a representation of the data adapted to the display. For example, textual information data which otherwise are contained in graphics can, with end terminals with pure text representation, be sent as text to the end terminal and there brought into display.
BRIEF DESCRIPTION OF THE DRAWING
In the following the invention is described in detail with the aid of an example of execution with reference to a drawing FIGURE. From the drawing and its description, there are yielded further features and advantages of the invention.
In FIG. 1 a scenario is described in which this process is used for the automatic adaptation of the data to be transferred from a data-preparing device to a data-requesting device, to the capabilities of this end terminal; and
FIG. 2 is a flow chart illustrating the method steps.
DETAILED DESCRIPTION
By means of three different apparatuses 1 , 2 and 3 , a user requests information from a WWW-server 5 . In each end terminal there is installed a WWW-browser for this.
In the end terminal 1 , in this case the data-receiving device, there is a Personal Digital Assistant (PDA). The display of the PDA has a resolution of 160×160 pixels, in a black-and-white representation with pure text representation possibility. The end terminal 2 is a Notebook with a display with the resolution of 640×480 pixels, which can represent 256 colors and graphics.
The display of the desktop computer 3 has a resolution of 1600×1200 pixels, which can represent about 16 million colors and graphics.
EXAMPLE 1
The user, over a user interface such as, for example, a keyboard, enters the address www.info.com of the WWW-server 5 (data-preparing device) into the WWW-browser, to request the information data belonging to this address from the server 5 . The WWW-browser establishes a connection to the WWW-server 5 , and communicates to the WWW-server by which address information data are requested.
According to the invention there are further conveyed to the WWW-server 5 information data as to which capabilities the end terminal 1 possesses. To these capabilities there belong, inter alia, the resolution of the display and the number of representable colors. In the present case the end terminal 1 will instruct the WWW-server 5 that it should communicate the information data with a resolution of 160×160 pixels in black-and-white and in pure text representation. The standard resolutions and color depths can be correspondingly coded for this, for example with 2-place numbers so that, for example, only one byte suffices for the transmission of the information.
The WWW-server 5 reports/communicates the address and capabilities of the utilization device 6 . The utilization device 6 requests from the information data bank 7 the information data belonging to the address www.info.com and formats these in correspondence to the capabilities of the end terminal 1 . Since the end terminal 1 can represent only text, the application device generates only textual information in black-and-white representation. Graphics are not generated or cannot be read from the information data bank. The application device 6 delivers the data to the server 5 which sends these to the WWW-browser in 1 . The WWW-browser interprets the formatting and makes the information data available in the display of the end terminal 1 .
EXAMPLE 2
The user uses, in contrast to example 1, a notebook 2 . As described in example 1, the WWW-server 5 obtains the information data about the capabilities of the end terminal 2 and forwards these data to the utilization device 6 . Since the end terminal can represent graphics with a maximum of 256 colors, the utilization device 6 generates or conveys from the information data bank 7 , graphics with a maximal color depth of 256 colors, which insofar as possible do not exceed 640×480 pixels. For the coloration of text information data, there are chosen only colors from a given color pallet with 256 colors standing for selection. The utilization device 6 delivers the data to the server 5 , which sends these to the WW-browser in the end terminal 2 . The WWW-browser interprets the formatting and represents the information data in the display of the notebook 2 . In comparison to example 1, because of the color information data and of the graphics, a larger data volume must be transmitted between the WWW-server and the end terminal. However, the size and color depth (256 colors) are utilized.
EXAMPLE 3
In contrast to examples 1 and 2, the user uses a desktop computer 3 . Since, as in examples 1 and 2, the capabilities of the end terminal 3 are known by the utilization device 6 , the utilization device 6 generates or conveys from the information data bank 7 graphics with a maximal color depth of 16 million colors, which insofar as possible do not exceed 1600×1200 pixels. For the coloration of text information data, there are chosen colors from a color pallet with 16 million colors standing for selection. The utilization device 6 delivers the data to the server 5 , which sends these to the WWW-browser in the end terminal 3 . The WWW-browser interprets the formatting and represents the information data in the display of the desktop computer 3 . In comparison to examples 1 and 2, because of the color and graphics information data, a greater data volume must be transmitted between the WWW-server and the end terminal. The size and color depth (16 million colors) of the display, however, are utilized.
Obviously the invention also comprises end terminals that can process several different display formats. In this case, for example, a list of usable display formats can be communicated to the data-preparing device. The latter then, and according to availability, selects the best-suited display format.
Further, the invention is not restricted to a utilization in the internet, but is usable for every type of data transfer in arbitrary data networks, thus, for example, also in the data transfer between subscribers of the digital mobile radio network.
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A method for automatically adapting to the capabilities of a data transmitting terminal a device supplying data to said terminal requesting the data. The method is characterized in that the data supplying device receives information concerning the capabilities of the device requesting data to send to the latter the data to be transmitted in accordance with the specified capabilities.
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BACKGROUND
1. Field of the Invention
The field of the invention pertains to building construction paper such as that often called Builder's Felt.
2. Related Art and Other Considerations
Many building construction professionals have used the various forms of a nonwoven continuous web, often impregnated with asphalt, as a layer to place underneath other building products such as shingles, sheathing, and flooring. Because of the usual location of the nonwoven web, i.e., underneath other products, it has been called “underlayment” or “underlay”.
For many years prior art webs have served in building construction as a base material that is converted into roofing, siding, and flooring felt. In addition, various types of nonwoven continuous web sheets have also been used as a “facer” material for foamed insulation board laminates. In these foamed insulation board laminates, facer materials typically form a sandwich panel where the core material is comprised of polyisocyanurate foam. These foamed insulation laminates are typically utilized as side-wall or roofing insulation. The two facers of a laminated roof insulation board can be a glass fiber reinforced felt. One such facer material is made by Atlas Roofing Corporation, and is called “GRF (Glass-Reinforced-Felt) Facer”.
A recently developed and popular nonwoven web is described in U.S. Pat. No. 6,572,736 to Bush et al. Prior art facer webs are listed in U.S. Pat. No. 6,572,736 and in U.S. patent application Ser. No. 09/971,771, both of which are incorporated herein by reference in their entirety.
Outside of the building construction arena, the practice of treating nonwoven web materials with anti-microbial chemicals has become more widespread as health standards have improved worldwide. For example, U.S. Pat. No. 6,734,157 treats nonwoven web materials with anti-microbial chemicals. However, the field of anti-microbial treated nonwoven webs for building products is relatively barren.
The principal biology responsible for the health problems in many buildings are fungi rather than bacteria or viruses. Reports have indicated that Stachybotrys chartarum, Aspergillus versicolor , and several toxigenic species of Penicillium are potentially hazardous, especially when the air-handling systems have become heavily contaminated.
Perhaps the most hazardous of the toxigenic fungi found in wet buildings is Stachybotrys chartarum , a fungus known to produce the very potent cytotoxic macrocyclic trichothenes along with a variety of immunosuppressants and endothelin receptor antagonists mycotoxins. This fungus was investigated for its association with the serious health problems of a family living in a water-damaged home in Chicago and has been implicated in several cases of building-related illness. Also, a cluster of cases of acute pulmonary hemorrhage/hemosiderosis was reported in Cleveland, Ohio.
While there has been some progress in nonwoven webs in personal hygiene technology, the control of molds and fungus in building construction nonwoven web products has yet to be substantially addressed. What is needed, therefore, and an object of the present invention, is a nonwoven web for building products that resists growth of fungi and molds, and a method of making the same.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, and advantages will be apparent from the following more particular description of preferred embodiments as illustrated in the accompanying drawings in which reference characters refer to the same parts throughout the various views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is a schematic view of web making apparatus according to a first example embodiment of the technology.
FIG. 2A , FIG. 2B , and FIG. 2C are diagrams illustrating a differing configurations of a size press which can be utilized for application of a biocide in the embodiment of FIG. 1 .
FIG. 3 is a schematic view of web making apparatus according to a second example embodiment of the technology.
FIG. 4 is a schematic view of web making apparatus according to a third example embodiment of the technology.
FIG. 5 is a schematic view of web making apparatus according to a fourth example embodiment of the technology.
FIG. 6 is a schematic view of web making apparatus according to a fifth example embodiment of the technology.
BRIEF SUMMARY
A nonwoven web has a weight sufficient for construction industry use and comprises at least forty percent (40%) recycled waste paper. At least one surface of the web bears a biocide, e.g., has a biocide applied thereto or is treated with a biocide. Preferably the weight of the web is greater than fifteen pounds per thousand square feet (15-lbs/MSF). Preferably the biocide is zinc pyrithione. The web bears (on each side) at least 50-grams of biocide per thousand square feet of said web per web side to which it is applied. Depending on nature of web use, the biocide can be applied to one or both sides of the nonwoven web. The biocide-bearing nonwoven web is specifically directed to use in building construction. One example use of the web is as builders felt, with other uses including as a facer for a laminate board and for asphalt-impregnated webs. Because building construction products must be tough, but priced as low as possible, this web is made largely from recycled waste paper (as opposed to virgin cellulose fiber, as a cost-reducing measure), and optionally clarifier sludge.
DETAILED DESCRIPTION
In the following description, for purposes of explanation and not limitation, specific details are set forth such as particular compositions, techniques, etc. in order to provide a thorough understanding. However, it will be apparent to those skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well known substances and methods are omitted so as not to obscure the description of the present invention with unnecessary detail. It will be further understood that in the ensuing description and claims that the terms “web” and “mat” are employed interchangeably, and in the sense that the mats and webs can be used as “facers”, all three terms may be utilized interchangeably. Likewise, the terms “biocide,” “bactericide,” and “fungicide” are employed interchangeably.
Described herein are nonwoven webs which are treated with one or more biocides to resist the growth of fungi and molds, and methods of making such webs. The nonwoven webs are largely comprised of recycled cellulose fiber, usually in the form of purchased waste paper. For the purpose of describing this technology, the term “recycled cellulose fiber” means either (1) post-consumer recycled waste paper and cardboard, or (2) pre-consumer but post-industrial recycled waste paper and cardboard, which is obtained from factories, or a combination of (1) and (2). An example of pre-consumer but post-industrial recycled waste paper and cardboard is the side-trim and clippings that come from paper converters. Preferably the non-woven webs are continuously produced in a conveyor-type paper forming machine.
Optionally, as described in U.S. Pat. No. 6,572,736 to Bush et al, untreated clarifier sludge may be added. Also optionally, either virgin or recycled glass fibers may be added. With or without glass fibers being added, the web can be subsequently saturated with asphalt and used as shingle underlayment, or used as either facer for laminated foam board or for unsaturated Builder's Paper, and sometimes used as flooring underlayment.
Many biocides are being phased out due to harmful side effects, and only a few new ones being considered for long term use. For example, ortho-Phenyl Phenol is rated by one of California's many hazardous materials watchdog organizations as a human carcinogen; however, the National Institute for Occupational Safety and Health (NIOSH) does not draw that conclusion. Thus the environmental concerns of the 21 st century have reduced the number of biocides that can be seriously considered for use.
Evaluations were performed to ascertain some appropriate biocides for use with a nonwoven web. A preliminary screening resulted in a list which included twenty-four (24) compound groups, further collected into seven (7) different categories. They are listed in TABLE 1.
TABLE 1
Biocides
1. Metal containing compounds
a. Copper and zinc naphthenate and quinolinolate
b. Copper and zinc dimethyl dithiocarbamate
c. Tributyl tin oxide, fluoride, chloride and naphthenate
d. Phenylmercuric acetate
e. 10,10 1 -oxybisphenoxarsine
f. Organoborons
2. Phenolics
a. Phenol and homologues such as orthophenyl phenol, cresol and thymol
b. Trichlorophenol, pentachlorophenol, para-chloro-meta cresol,
dichloro dihydroxy-diphenyl-methane
c. Parahydroxybenzoic acid and its salts, pentachlorphenyl laurate
d. Para-nitro-phenol, salicylanilide
3. Quaternary ammonium compounds
a. Dialkyl dimethyl ammonium chloride
b. Alkyl dimethyl benzyl ammonium chloride
4. Nitrogen containing compounds
a. 1,3,5-hexahydrotriazine and derivatives
b. Dodecylamine salicylate
c. Oxazolidines
d. Imidazolines
5. Sulphur containing compounds
a. Bis(2 hydroxy-5-chloro-phenyl)sulphide
b. Hexachlorodimethyl sulphone
6. Nitrogen and sulphur containing compounds
a. Tetramethylthiuram disulphide
b. N-(trichloromethyl)thiophthalimide (Folpet) and fluorine derivative
c. 8-hydroxyquinoline sulphate
d. Pyrithiones, Zinc and Sodium
e. Isothiazoline range
7. Inorganic compounds
a. Metallic salts of copper, zinc, copper/chrome, potassium and mercury
Further screening found a few commercially successful products that covered a broad range of biocides. Four such products (or series of products) are briefly describing in the ensuing paragraphs. These products can be utilized in differing embodiments of the present technology.
The Dow-Corning silicone quaternary amine, now called Microbe Shield, has broad-spectrum antimicrobial activity. The active ingredient (3-trimethixysilylpropyldimethyloctadecyl ammonium chloride) is a special version of Category 3 above, and controls a broad range of bacteria and fungi responsible for odors, rot, and mildew. This compound destroys microorganisms by disrupting the delicate cell membranes, and therefore, does not need to be absorbed in solution to be effective. In addition, the compound bonds to inert surfaces. This means that Microbe Shield remains effective after the substrate is cleaned. In one embodiment, a nonwoven web treated with this material holds the promise of long lasting effectiveness.
The Vancide® series of products from R. T. Vanderbilt Company, Inc., of Norwalk, Conn. 06855, are quite effective. However, at least two of them, Vancide MZ-96 (zinc dimethyldithiocarbamate) and Vancide 89, are rated “Highly Toxic” by the OSHA Hazard Communication Standard. They are also a Level 4 Health Hazard by both the Hazardous Material Information System and the NFPA standards. This means they must be handled with extreme care, especially if used in a manufacturing facility.
Troy Corporation makes zinc naphthenate and proprietary mixtures called Polyphase®. These products have a long, successful history with cellulose-based products.
A Dow Chemical product called Dowicide® is an ortho-phenyl-phenol This solid material can be used in another embodiment, such as in any number of dispersions, for implementing in an application to a nonwoven web such as described herein.
Five biocides were chosen for a comparative evaluation for inhibition activity against three common mold fungi. The evaluation was performed at the Forest Research Labs of Mississippi State University in Starkville, Miss. (“MSU”) using a substantially modified version of ASTM G-21, termed the “The Agar-Plate Test Method”. This method provides a rapid screening test for the evaluation of biocides against a wide variety of microorganisms.
Five (5) biocide compositions (“biocides”) were evaluated using the Agar-Plate Test Method: (1) Microbe Shield, (2) Zinc Pyrithione (ZPT), (3) ortho-Phenyl Phenol, (4) Borogard ZB, and (5) a mixture evaluated of 50% Zinc Pyrithione with 50% Borogard ZB. These biocide compositions were added to autoclaved fungal media at different concentrations. The biocides do not have to be dissolved in the agar, only suspended. Plugs of specific fungi were inoculated onto agar plates containing the different biocides/concentrations. According to this method, the lowest biocide level that totally inhibits fungal growth is reported as the Minimal Inhibitory Concentration (MIC).
For terminology, “hypha” (singular) and “hyphae” (plural) is/are a loose network of delicate filaments in a fungus. “Mycelia” (singular) and “mycelium” (plural) (plus the adjective form “mycelial”) is/are the main part of fungus, consisting of the feeding and reproducing hyphae, that forms the body of a fungus. Radial growth of a mycelia is measured and plotted against concentration. A linear regression is run to estimate the biocide concentration that inhibits radial growth by 50%. This Inhibitory Concentration is called the IC 50 .
The five (5) different biocides that were involved in the comparative evaluations were tested at four (4) concentrations per biocide composition, plus a control (no biocide). The biocides were tested against three common mold fungi ( Aspergillus niger, Cladosporium cladosporioides , and Penicillium funiculosum ) with five (5) replicates for every treatment combination. The biocides that were tested and their concentrations were (1) Microbe Shield at 0, 3, 15, 75 and 375 ppm (“Parts Per Million”) ai (“Active Ingredient”); (2) Zinc Pyrithione at 0, 3, 15, 75 and 375 ppm ai; (3) ortho-Phenyl Phenol (“OPP”) at 0, 3, 15, 75 and 375 ppm ai; (4) Borogard ZB at 0, 10, 50, 250, and 1250 ppm ai; and (5) the 50:50 mixture of Zinc Pyrithione and Borogard ZB at 0, 1.5/5.0, 7.5/25, 37.5/125, and 187.5/625 ppm ai.
Stock concentrations of each biocide were dissolved or suspended in water or acetone (only OPP was dissolved in acetone) to a concentration that allowed 1 ml of stock to be added to 250 ml of media in order to provide the highest required biocide concentration. Stocks were diluted in a 5 fold series to match the concentrations required. For each biocide concentration, 250 ml of Sabouraund Dextrose Agar in water was autoclaved and then cooled to 50° C. Then 1 ml of the appropriate biocide concentration was added to each flask. Control flasks received 1 ml of water or acetone (for OPP). Media was mixed, dispensed into Petri dishes and allowed to cool. Each biocide test used 90 agar plates including controls.
A 0.7 mm plug of agar was removed from every plate at the time of each study. A plug from an agar plate containing one of the fungi was inserted into the hole. The plug of fungi was taken from the leading edge of a fungal colony. Several plates of fungi were required for each study. The studies were grouped by fungi. The Cladosporium cladosporioides study began first; the Aspergillus niger study began next; and the Penicillium funiculosum study began last. Mycelial growth was measured for every plate in each study. Fast growing species were measured daily and slower growing species were measured every 2-3 days. All studies were carried for at least two weeks or until growth leveled out. Digital photographs were taken at different times during each fungal study.
The average for the five replicates of each biocide concentration was determined and the averages plotted as growth over time for each biocide. The growth at the measurement just prior to the control samples reaching full plate growth (maximum growth) was used to plot these growth averages against concentration on a semi-log scale. The linear portion of these lines was used in a linear regression to estimate the IC 50 and MIC for each biocide and fungal species. These results are shown in TABLE 2.
TABLE 2
Data Comparing Biocide Effectiveness
Cladosporium
Aspergillus
Penicillium
cladosporioides
niger
Funiculosum
Biocide Used
IC 50 (ppm)
MIC (ppm)
IC 50 (ppm)
MIC (ppm)
IC 50 (ppm)
MIC (ppm)
Microbe Shield
2025 a
5575 a
286
625 a
670 a
1289 a
OPP
203.8 b
375 b
16.3
84.5
212.6 b
375 b
Zn Pyrithione
1.8 b
15 b
9.2
21.2
8.0
16.2
Borogard
1347 a
3158 a
2276 a
5336 a
557
1396 a
50:50
4.8/16.1
9.6/32.1
13.2/43.9
32.5/108.4
3.5/11.5
8.0/26.7
In Table 2, the numbers denoted as “a” are an extrapolation outside of the test concentration range. For numbers denoted as “b”, the IC 50 and MIC are probably less than the reported numbers. There was mycelial growth at the lower concentration, but no mycelia grew at the upper concentration. Therefore, inhibition could have actually occurred at a concentration somewhere in between. Since these estimates are only based on two points, it is impossible to estimate where true inhibition occurred without repeating the experiment at intermediate concentrations.
The data collected and shown in Table 2 indicates, surprisingly, that Zinc Pyrithione was most suitable for further studies and for use in manufacture of a nonwoven web. Zinc Pyrithione was more powerful than even ortho-Phenyl Phenol (OPP), which has long been a standard fungicide in the preservation of cellulose, especially wood. Ortho-Phenyl Phenol (OPP) is, at best, suspected of being harmful to humans, while Zinc Pyrithione is the active ingredient in most anti-dandruff shampoos.
In view of the foregoing evaluation, it was decided to continue work utilizing either Sodium Pyrithione or Zinc Pyrithione. The major USA producer of these products is Arch Chemicals, Inc. of Cheshire, Conn. 06410, whose “Zinc Omadine®” brand zinc pyrithione product is hereinafter referred to hereinafter as “ZPT”. The basic formula for ZPT (zinc pyrithione) is C 10 H 8 N 2 O 2 S 2 Zn. For use in a coating, the product is supplied as a 48% solids content aqueous dispersion. The particle size is 100% at 5-microns or less, and 90% at 1-micron or less. This dispersion is very stable, having a long shelf-life.
FIG. 1 shows a first example embodiment of apparatus for forming a nonwoven web to which a biocide such as ZPT can be applied. As illustrated in FIG. 1 , a typical batch of paper-making stock can be made by utilizing a large type waste paper disintegrator 20 , as used by any waste paper mill (such as a Hydrapulper® type waste paper disintegrator, for example). This “Pulper” is charged with about 5000 gallons of water, to which is added about 1900 pounds of OCC (Old Corrugated Container). The water/OCC mixture is pulped until the big clumps are disintegrated. To the pulped mixture is added about 1200 pounds of Mixed Waste paper and another 5000 gallons of water. The resulting stock is now at about 3.6% consistency (% solids).
As soon as this blend is well mixed, it is passed through cleaning and clump removal screens 22 into a first holding chest 24 . This is followed by a stock refiner 26 , and then the stock is pumped to a second holding chest 28 . From the second holding chest 28 , the stock is diluted somewhat before passing through a Selectifier® screen to remove smaller clumps, and then several cleaners to remove foreign objects such as metal (the Selectifier® and subsequent screens being illustrated as 30 in FIG. 1 ). The stock is further diluted at a fan-pump 32 to about 0.8% consistency, and then introduced to a paper-forming machine 40 . A paper forming machine 40 can comprise any suitable apparatus, such as a Fourdrinier, a single cylinder, or a multiple cylinder vat machine, for example. After initial stock dilution, various processing aids such as retention aids, drainage aids, and defoamers may be added as needed to the paper forming machine.
Following the forming apparatus of a paper forming machine 40 , the sheet formed is pressed by a standard mechanical paper wet-press section 42 , and then the web is introduced to a typical steam-heated dryer section 44 . After the web is dried, it is fed as a flexible web to a reel forming winder 46 , followed by a more precise reel forming device known as a rewinder 48 . Thus the web has flexibility sufficient for the web to be wound on a roll. The re-winder 48 can perform various functions, such as trim web edges and slit web width (Often the wide web is slit into narrower rolls during the re-winding process).
In the apparatus of FIG. 1 , the steam-heated dryer section 44 comprises a size press 50 and multiple steam-can driers 52 . The size press 50 is typically located downstream from the entrance to the steam-heated dryer section 44 and is situated at about 66% to 75% of the length of the steam-heated dryer section 44 from the entrance. The size press 50 can be realized in several configurations. In a first mode and embodiment, biocide is applied to one surface of a nonwoven web at the size press 50 , as shown in FIG. 1 . The biocide for treating a nonwoven mat can be any suitable biocide, such as (for example), the ZPT (zinc pyrithione), OPP (ortho-Phenyl Phenol), or Microbe Shield, or the Vancide® series of products from R. T. Vanderbilt Company, Inc., or the Troy Corporation's proprietary mixtures called Polyphase®, all mentioned above.
As shown in FIG. 2A , an example size press 50 includes two cylindrical rotatable rollers 53 , 54 positioned with their major axes being parallel and separated to form a nip 55 between which the nonwoven web substrate 56 is transported or conveyed. In the example configuration of FIG. 2A , a header 57 or the like discharges biocide onto one roller 53 . The biocide is applied to one surface of the web 56 as the roller 53 rotates. In another example configuration of FIG. 2B , the bottom roller 54 laps up biocide from a pan or reservoir 58 which is situated beneath bottom roller 54 , with the biocide being applied to an underside of web 56 as roller 54 rotates. In yet another example configuration of FIG. 2C , a nozzle or fountain sprays biocide on a surface of the web 56 proximate the nip 55 . The nip 55 is accurately set so that the biocide application is uniform over the applied surface of web 56 . It will be appreciate by those skilled in the art that further apparatus and structures can be employed in conjunction with one or more of these example configurations, such as a blade or scraper positioned downstream of the rollers 53 , 54 to remove excess biocide, for example.
As mentioned above, the example apparatus of FIG. 1 and any suitable biocide can be used for treating a nonwoven mat. Such biocides include but are not limited to those mentioned and evaluated, e.g., ZPT (zinc pyrithione), OPP (ortho-Phenyl Phenol), and Microbe Shield. One particular set of trials for producing a biocide-treated nonwoven felt product which utilized the example apparatus of FIG. 1 and the procedures and inputs described in conjunction therewith were conducted at the Herty Research Foundation in Savannah, Ga., utilizing a paper machine's “Size-Press” to apply various levels of biocide ZPT (zinc pyrithione) to nonwoven web which had been produced essentially in the manner described above. A large number of differing levels of treatment were made and samples of each dosage rate retained.
In order to establish a range of dosage levels that might quantify their effectiveness, four (4) dosage levels were utilized: (a) 62-grams/MSF; (2) 86-grams/MSF; (3) 116-grams/MSF, and (4) 123-grams/MSF; plus a zero grams/MSF(0) control. The unit of measure: “per MSF” or per “Thousand Square Feet”, rather than a unit of weight; e.g., “per Ton”, is the most common unit of sale for many special nonwoven webs.
After the biocide was applied to the nonwoven web at the varying dosage levels, two different testing facilities were used to evaluate these samples: The Forest Research Labs of Mississippi State University (MSU), and the laboratory of Arch Chemicals, Inc. (“Arch”). MSU evaluated the treated samples for resistance to mold using testing procedures of, e.g., ASTM D 6329-98, “Standard Guide for Developing Methodology for Evaluating the Ability of Indoor Materials to Support Microbial Growth Using Static Environmental Chambers,” and Arch Chemicals utilized ASTM G 21-96 (Re-approved 2002), “Standard Practice for Determining Resistance of Synthetic Polymeric Materials to Fungi”, both from ASTM International, PA, USA.
The MSU testing used the fungus Stachybotrys chartarum , but allowed “other molds” to enter the chamber. The Stachybotrys chartarum (ATCC 9182) was grown on Potato Dextrose Agar (“PDA”) and Sabouraud Dextrose Agar and allowed to sporulate (i.e., produce spores). This procedure followed ASTM C 1338-00, Standard Test Method for Determining Fungi Resistance of Insulation Materials and Facings. ASTM International, PA., USA. The solution was adjusted with additional sterile water until a spore count of approximately 940,000 cells per ml was obtained. This solution was the inoculum. A portion of this solution was also plated onto PDA to confirm the viable cell count. In the test, the nonwoven felt pieces were laid out with their treated side up, and inoculated with the spore suspension by an atomizer (ASTM C 1338-00). The pieces were allowed to air dry for several hours before being placed into the static environmental chambers. There were five replicates for each sample set (62-grams/MSF; 86-grams/MSF; 116-grams/MSF, and 123-grams/MSF; plus a zero (0) control) for each sampling period (2 weeks, 4 weeks, and 6 weeks).
While this testing project was designed to evaluate only one specific mold type; i.e., Stachybotrys chartarum (ATCC 9182), the accidental inclusion of “other molds” provided an opportunity to see how the biocides reacted to these intruders; e.g., the “other molds” proved to be much harder to kill than the Stachybotrys chartarum.
The results of the MSU test is shown in TABLE 3. The numbers in Table 3 are in colony forming units (CFUs), a well known standard of measure prescribed, e.g., by ASTM 6329-98.
Results of the Arch Chemicals, Inc. study are shown in TABLE 4 for five samples, with results shown for both top and bottom surfaces of the nonwoven web. The numbers in Table 4 are explained in terms of a Growth Rating Scale for the mold wherein 0=No growth; 1=Trace growth (<10% coverage); 2=Light growth (10 to 30% coverage); 3=Medium growth (30 to 60% coverage); 4=Heavy growth (60 to 100% coverage).
TABLE 3
The Evaluation Conducted by MSU; ASTM D 6329-98
Week
Week
Number 2
Number 4
Week Number 6
Stachy -
Other
Stachy -
Other
Stachy -
Other
botrys
Mold
botrys
Mold
botrys
Mold
Control
2760
4870
2830
6660
9640
48040
(No ZPT)
62-g/MSF
0
880
680
3360
3710
19730
86-g/MSF
0
530
390
3450
1110
4100
116-g/MSF
0
67
0
125
0.2
7540
123-g/MSF
0
0
0.4
54
0
5380
TABLE 4
The Evaluation Conducted by ARCH; ASTM G 21
Sample ID and ZPT Content
Sample Number &
ZPT, g/MSF
ASTM G-21 Rating
Orientation
of paper
Week 1
Week 2
Week 3
Week 4
1 - Top
26
1, 1
1, 1
1, 1
1, 2
1 - Bottom
0
2, 1
2, 2
3, 3
3, 3
2 - Top
62*
0, 0
0, 0
0, 0
0, 0
2 - Bottom
0
1, 1
2, 2
3, 3
3, 3
3 - Top
84
0, 0
0, 0
0, 0
0, 0
3 - Bottom
0
4, 4
4, 4
4, 4
4, 4
4 Top
116*
0, 0
0, 0
0, 0
0, 0
4 Bottom
0
1, 1
2, 2
2, 3
2, 3
5 Top
128
0, 0
0, 0
0, 0
0, 0
5 Bottom
0
1, 1
2, 3
2, 3
2, 3
The Arch results of Table 4 show that, with the exception of the sample having the lowest biocide dose at 26 grams ZPT per MSF (and had growth on both sides), all the nonwoven felt samples were resistant to fungal growth via ASTM G 21 on one side (the top side), but not on the opposite side (the bottom side). However, the MSU results showed that mold DOES grow at the biocide dose of 62-grams ZPT per MSF. The Arch study, where both sides were tested, reflects the fact that some biocide was inadvertently applied to the bottom side of the nonwoven continuous web.
From Table 3 and Table 4 it appears that significant mold resistance is imparted when 50-grams or more of biocide, e.g., ZPT, is applied per MSF per side to the nonwoven continuous web. Mold resistance is optimum when 100-grams or more of biocide (e.g., ZPT) is applied per MSF (per side) to the nonwoven continuous web. However, the amount of biocide added may be controlled in accordance with manufacturing and application objectives. For example, minimum amount of added biocide will resist the growth of fungi, while a higher dose of the same biocide may actually kill already formed fungi. Killing already formed fungi can be particularly important when the recycled paper or cellulose has been obtained from a dirty waste paper source.
While stock preparation systems have used biocides for many years to control unwanted mold inside the whole paper-mill, treatments designed to resist mold growth in the end-use market should not be added prior to web formation. Chemicals that modify the performance of this nonwoven web can be introduced to the sheet during fabrication anywhere, but preferably are added to an already-formed web after the wet-press section. In this regard, the example embodiment of FIG. 1 shows the biocide (e.g., ZPT) being added at a size-press 50 . In place of a typical low-solids size-press, a high-solids on-machine coater can be utilized in approximately the same position. The example embodiment of FIG. 3 shows biocide (e.g., ZPT) being added at a shower 60 . The shower 60 is situated in a similar location to size press 50 and just upstream from multiple steam-can driers 52 . The example embodiment of FIG. 4 shows biocide (e.g., ZPT) being added at a waterbox on a calender stack (illustrated as 62 in FIG. 4 ). The waterbox on a calender stack 62 is positioned between the steam-heated dryer section 44 and the reel forming winder 46 . The waterbox is a trough on a nip roller of the stack of calender rolls, with the web extending in serpentine configuration through the calender rolls.
Modifying chemicals such as the biocide (e.g., ZPT) can also be added in a subsequent process, such as by a so-called “off-machine” coater 66 as illustrated in FIG. 5 . The web is taken from reel forming winder 46 , and then introduced into an unwinder 64 and then through coater 66 where the biocide is applied. The web is then fed to rewinder 48 .
Generally, for optimum effectiveness, biocide treatment is best added to the nonwoven web after it has been formed. However, it is possible to add biocides to the papermaking stock just prior to, or during, web formation, as illustrated in FIG. 6 . For example, the makers of Microbe Shield claim that it will “bond” to cellulose fibers, and remain bonded and effective throughout washings or rain storms. Still, a lot of fibers leave the paper mill in the effluent water, and will carry biocide with them. Any biocides in the effluent water may kill microbial action, which is undesirable in some cases. Some water clarifying systems require certain microbial activity to be effective. Therefore, adding the biocides during, or before, web formation is a possible embodiment for those who do not want microbial activity in their water clarification system. Furthermore, since this addition point will always split the total biocide dose added into some ratio between staying with the nonwoven web and staying with the effluent water, this method would be the preferred embodiment if the manager wanted to kill microbial activity in the water clarifying process.
A biocide such as ZPT can be added during the web fabrication process or (more preferably and depending, e.g., on type of biocide and environmental or waste concerns) after such process. In the most preferred mode, a biocide is added at a size-press or “on-machine” coater Another preferred mode comprises a well-designed spray system such as made by V-I-B Systems of Atlanta, Ga. The major control mechanism for the amount of biocide added will usually be the concentration of the liquid material.
Another distinguishing feature of the present technology is that the nonwoven web is, on average, heavier than prior art biocide treated nonwoven webs. By “heavier”, it is meant that the “Basis Weight” of the nonwoven web of the current technology is generally in excess of thirty (30) pounds per one-thousand (1000) square feet (abbreviated 30-lbs./MSF). Most nonwoven webs currently in service as biocide-treated sheets weigh about half of that; e.g., 15-lbs/MSF.
The nonwoven web of the present technology may contain some virgin cellulose fiber. However, as a distinctive difference over the nonwoven webs of the prior art, the webs of the present technology utilize at least 40% of the low quality waste paper, e.g., Mixed Waste and “OCC” (Old Corrugated Container). While some of the white, or at least the light-colored, webs of the prior art do use recycled scrap paper, they do not use “Mixed Waste” or “OCC”. The recycled scrap paper furnish used by the prior art webs may be “Office Waste” or even “De-Inked” stock, but they do not use as much as forty percent (40%) of the low quality recycled cellulose.
While in the examples illustrated above a biocide is applied only to one surface of a nonwoven web, the technology herein described also encompasses modes wherein the biocide is applied to both opposed surfaces of a nonwoven web. Such may be desirable, for example, when the nonwoven web serves as builders felt or the like, particularly when not treated with asphalt. On the other hand, in some utilizations such as a facer for a polyisocyanurate lamination board, the foam-adhered surface of the web need not have the biocide, with the result that only one surface of the web need have the biocide applied.
Thus, described herein are nonwoven webs having a biocide and methods of making the same. The webs may be employed for all forms of building construction products to impart at least some resistance to molds and fungi growth. The web can be (for example) a facer for continuously laminated foam board, or a “Builder's Paper” (a.k.a. “Dry Felt”), or a nonwoven web felt underlayment, that has at least a measurable level of resistance to molds and fungi growth. In addition to web ingredients already described, it should be understood that the web may also comprise glass fibers, either recycled glass and/or virgin glass.
Although various embodiments have been shown and described in detail, the claims are not limited to any particular embodiment or example. None of the above description should be read as implying that any particular element, step, range, or function is essential such that it must be included in the claims scope. The scope of patented subject matter is defined only by the claims. The extent of legal protection is defined by the words recited in the allowed claims and their equivalents. It is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements.
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A nonwoven web has a weight sufficient for construction industry use and comprises at least forty percent (40%) recycled waste paper. At least one surface of the web bears a biocide, e.g., has a biocide applied thereto. Preferably the weight of the web is greater than fifteen pounds per thousand square feet (15-lbs/MSF). Preferably the biocide is zinc pyrithione. The web preferably bears at least 50-grams of biocide per thousand square feet per side of said web. One example use of the web is as builders felt, with other uses including as a facer for a laminate board and for asphalt-impregnated webs. The biocide-bearing nonwoven web is specifically directed to use in building construction. One example use of the web is as builders felt, with other uses including as a facer for a laminate board and for asphalt-impregnated webs. Because building construction products must be tough, but priced as low as possible, this web is made largely from recycled waste paper (as opposed to virgin cellulose fiber, as a cost-reducing measure), and optionally clarifier sludge.
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BACKGROUND OF THE INVENTION
This invention relates to an improved precipitation process for the production of alumina hydrate from Bayer process sodium aluminate liquors. More particularly, it relates to a precipitation process which produces coarse and strong alumina hydrate at high yields while simultaneously achieving energy savings, as well as reduced equipment and operating costs.
The Bayer process production of alumina hydrate has been practiced since 1888, and the process involves digestion of bauxite with an aqueous caustic medium at elevated temperatures and pressures. Digestion results in a slurry consisting of a liquor containing the alumina values dissolved from the bauxite in the form of sodium aluminate and a caustic-insoluble digestion residue, the so-called "red mud". The red mud is generally separated from the liquor and the alumina content of the liquor is recovered by precipitation. Precipitation is usually induced by seeding the sodium aluminate liquor with solid alumina hydrate and the precipitated alumina hydrate is recovered. Precipitation of alumina hydrate from the sodium aluminate liquor is an involved operation due to the many process variables and the product quality requirements. The process variables involved in the precipitation step, such as temperature, seed charge, holding time, alumina and caustic concentrations, impurity content, etc., affect product quality and yield, and, consequently, this operation requires close control, as well as a thorough understanding of the precipitation process.
The desired characteristics of the alumina hydrate produced by the Bayer process include suitable particle size distribution which is typically measured by screen analysis. To reduce dusting and improve aluminum reduction cell operations, the +325 mesh screen fraction (+44 microns) is used as an industry standard for comparing alumina hydrates for suitability. Generally, only a small quantity of less than 44 micron size particles is allowed. Another factor is strength, which is represented by resistance to abrasion during handling and particularly during calcination, again to avoid excessive dusting. In addition to these quality requirements, it is also important that the alumina hydrate produced by precipitation should be recovered at high yields at a minimum of energy input and at the lowest possible capital equipment cost requirement. Energy savings can be achieved, for example, by conducting the precipitation at relatively low temperatures, i.e., below about 68° C. (155° F.) and equipment costs can be minimized by eliminating the need of a cooling stage between precipitation stages and also by reducing the need for costly precipitators and classifiers which separate the coarse alumina hydrate fraction from the fines.
Over the years, many efforts were made to improve the precipitation stage of the Bayer process to achieve the above-stated goals. In the American Bayer process practice, major emphasis was placed on obtaining a coarse, "sandy" product of high strength. The yield of alumina hydrate, however, was unsatisfactory. In the European Bayer process practice, the yield of alumina hydrate was relatively high in comparison to the American Bayer process; however, the product was too fine and required overcalcination to reduce dustiness. Overcalcination reduces the surface area of the alumina and makes it unsuitable for dry scrubbing in state of the art aluminum reduction facilities. Both processes, the American and the European, had certain advantages, but these advantages were always accompanied by unavoidable difficulties and disadvantages.
During the past few years, several proposals were made to combine the advantages of both of these processes without the accompanying disadvantages. Thus, U.S. Pat. No. 4,234,559 (1980) describes a two-stage precipitation method, each stage proceeding within defined temperature ranges, and to each stage, seed alumina hydrate of different particle size distribution is added to induce precipitation. In the first stage, fine seed is added in such an amount as to provide a defined seed surface area to aluminate liquor ratio, expressed in g/l supersaturation per m 2 seed surface area in the range of 7-25. In the second stage, a larger quantity of coarser seed is added to complete the precipitation. The first precipitation stage is accomplished in a temperature range of 66°-77° C. (151°-171° F.), then the second seeding and precipitation stage is carried out at about 40° C. (104° F.). The process as shown produces a relatively coarse material wherein the fine fraction produced (less than 45 micron size) is less than 15% by weight and under certain process conditions, can be within the range of 4-8% by weight of the produced hydrate. The yield of the alumina hydrate produced according to this patent varies widely depending upon the weight fraction of the fine (less than 45 micron size) alumina hydrate. Thus, a product yield of 71.1 grams Al 2 O 3 /l of liquor is reported at a 14.9% by weight fine fraction, an 83 g/l Al 2 O 3 yield is obtained with an 18.6% by weight fine fraction, and the highest reported Al 2 O 3 yield is 91.7 g/l at a 16.5% by weight fine content. The process disclosed in this patent, although capable of producing higher than conventional yields, is still hampered by the production of an unacceptably high fine fraction as indicated by the examples in the patent. In addition, the temperature drop required between the first and second stages requires extensive interstage cooling, and the use of different size seed materials necessitates the extensive use of expensive classifying equipment.
In U.S. Pat. No. 4,305,913 (1981), a three-stage process is disclosed for the production of coarse and strong alumina hydrate with yields in the range of 70-80 g/l. The process also produces a high percentage of coarse material, at least 90% by weight of the product has a size in excess of 45 microns. The process disclosed in this patent provides a significant advance in the precipitation art, since it is applicable to both the American and European Bayer processes. The need for three distinct but interconnected stages requires significant capital expenditure; in addition, classification associated with each stage adds to processing costs.
In German Offenlegungsschrift No. 3,324,378 (published Jan. 12, 1984), a precipitation process is described wherein coarse alumina hydrate is obtained at reported Al 2 O 3 yields within the range of 77-85 grams/liter. The process shown involves the addition of large seed charges (800-1500 grams seed/liter of sodium aluminate solution) to the supersaturated sodium aluminate solution. The particle size distribution of the product alumina hydrate is controlled by the particle size distribution of the seed charge. Thus, if the fine fraction of the seed charge (less than 44 micron size) constituted 19% by weight of the total charge, the recovered product alumina hydrate also contained 19% by weight of fine fraction. Avoidance of the production of such large quantities of fine alumina hydrate as shown is only achieved by recycling major quantities of the slurry to a classification stage. This process, although capable of increasing Al 2 O 3 yields, does not eliminate the production of large quantities of fines. It also involves the addition of very large seed charges which lead to operational difficulties and requires extensive classification if reduction of the fine content of the product hydrate is desired.
German Patentschrift No. 3,030,631 (first publication Feb. 19, 1981) provides a precipitation process wherein the supersaturated sodium aluminate solution is separated into two streams and each of these streams are separately seeded. Extensive recycling to allow sufficient residence time and, consequently, production of coarse agglomerates, is essential in this process, together with the use of a large number of classifiers to reduce the fine fraction in the product alumina hydrate. While the process allows production of coarse alumina hydrate product, it does so at the cost of yield and it also involves increased operating and capital costs.
It has now been found that alumina hydrate can be produced at high yields in the form of coarse and strong product from supersaturated sodium aluminate liquors resulting from both the American and European Bayer processes. The novel process utilizes a single, relatively small seed charge, which, when added to the entire liquor stream, will allow production of alumina hydrate of desired quality and yield without requiring the extensive recycle systems of the prior art or the need for large-scale use of interstage cooling and classification equipment.
BRIEF SUMMARY OF THE INVENTION
Coarse, strong alumina hydrate is recovered in high yields from Bayer process supersaturated sodium aluminate liquors by seeding the entire liquor in a first precipitation line with a relatively small seed charge, the charge being selected to provide a seed surface area-to-liquor volume ratio in the range from about 1 to 3 m 2 /liter. The seeded liquor is kept at a temperature below about 68° C. to allow precipitation of alumina hydrate. The formed slurry containing from about 30-40 grams/liter precipitated solids is then transferred to a second precipitation line where the solids content of the slurry is allowed to increase without addition of more seed to a level in the range from about 250-700 g/l by accumulating solids from the transferred slurry. After sufficient residence time in the second line of precipitators under predetermined temperature conditions, the accumulated solids are subjected to a size classification stage to obtain a product wherein at least 95% by weight exhibits a particle size in excess of 44 microns and a fine fraction having an average particle size below 44 microns. The alumina hydrate product is recovered in yields of about 80 g/l or more and the fine fraction constituting only a very minor fraction of the total alumina hydrate production is recycled after washing as seed to the first precipitation line for the production of additional alumina hydrate. The process, due to the relatively low temperatures utilized, may dispense with the use of interstage cooling and thus can result in significant energy savings. Extensive recycle of alumina hydrate is also eliminated, as well as the need for large-scale use of classification equipment and additional precipitators.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of the novel precipitation process employing a simple, relatively small seed charge for the precipitation of alumina hydrate from supersaturated Bayer process sodium aluminate liquors.
FIG. 2 shows a variation of the process, where a relatively small seed charge is utilized in a first precipitation stage and a conventional seed charge is used in a second precipitation stage to improve the yield and avoid formation of excessive fines in precipitation systems using existing conventional precipitation practices.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to the production of strong, coarse alumina hydrate at high yield from Bayer process sodium aluminate liquors. More particularly, it concerns a process wherein one relatively small, single seed charge is added to relatively cool supersaturated sodium aluminate liquors in a first precipitation line to precipitate a limited quantity of coarse alumina hydrate. The alumina hydrate containing slurry is then transferred to a second precipitation line, where the solids content of the slurry is allowed to increase during a predetermined residence time. In the second precipitation stage, growth and strengthening of the solids take place, resulting in the production of a coarse, strong alumina hydrate product which is recovered at high yield.
For the purposes of this invention, the terms "supersaturated sodium aluminate liquor" or "pregnant liquor" refer to a sodium aluminate solution which, under the conditions of the present precipitation process temperature, caustic and Al 2 O 3 concentrations contains the maximum quantity of alumina dissolved which can be kept in solution without autoprecipitation.
The terms "alumina-to-caustic ratio" or "A/C" refer to the quantity of Al 2 O 3 in grams/liter dissolved in a caustic solution, wherein the caustic concentration of the solution is expressed in Na 2 CO 3 grams/liter.
The terms "precipitation line 1" or "first precipitation stage" refer to one or several parallelly arranged precipitation vessels, each of which is charged with pregnant liquor and also charged with seed to induce precipitation.
The terms "precipitation line 2"1 or "second precipitation stage" refer to at least one, preferably several, precipitation vessels connected in series.
In the process of the present invention, the pregnant liquor utilized in the precipitation system is generated by the digestion of bauxite. The bauxite employed in the digestion can be of any desired source, thus bauxites mind in the United States, the Caribbean, South America, Africa, Australia, Asia, and Europe, can be equally employed for the generation of pregnant liquors. The digestion conditions utilized for the production of the pregnant liquor can be the conventionally used American or European Bayer process conditions. With regard to the A/C ratios and caustic concentrations employed in the digestion stage, the conventionally utilized alumina and caustic concentrations are acceptable. Thus, the entire range of A/C ratios commonly used in both the American and European practices apply, i.e., A/C ratios within the range of 0.575 and 0.700, at caustic concentration values within the limits from about 165 to about 300 g/l can be utilized for the generation of the pregnant liquor employed in the precipitation system of the present invention.
In the following, the novel aspects of the precipitation process of the present invention will be explained in detail and with reference to the Figures. It is to be understood, however, that the schematic flowsheets shown in the Figures are for illustrative purposes only. It is not intended to limit the scope of the invention by simply referring to these.
As shown in FIG. 1, pregnant liquor from the digestion stage of the Bayer process is charged to a first precipitation stage. This first precipitation stage can consist of a single precipitation vessel, or if desired, of several precipitator vessels arranged in parallel relationship to each other. The pregnant liquor charged to the first precipitation line has an A/C ratio within the range from about 0.575 to about 0.700 and its caustic concentration is within the limits from about 165 g/l to about 300 g/l, preferably from about 175 g/l to about 250 g/l. The liquor charged to the first precipitator line is seeded with a charge of alumina hydrate seed to induce precipitation of dissolved alumina from the pregnant liquor.
The seed to be charged to the first precipitation stage has to meet certain specifications in accordance with the present invention. In the first instance, the seed should have a large fraction of fine particles, preferably up to about 50-70% by weight of the seed to be charged to the first precipitation stage should have a particle size below about 44 microns (0.044 mm).
The seed surface area to the pregnant liquor volume ratio is of prime importance for the purposes of this invention. While in conventional Bayer process precipitation practice the seed surface area to pregnant liquor volume is kept as high as possible and at not less than 6 m 2 /liter of liquor and preferably up to about 15 m 2 /l or more, it has now been found that for best results in the present process, seed areas from about 1 to about 3 m 2 /l of pregnant liquor, preferably 1-2.5 m 2 /l, should be employed for the liquor A/C ranges referred to above. Since the surface area of alumina hydrate seed having the particle size referred to above varies within the range of about 800-1500 m 2 /g, the quantity of seed to be added to the pregnant liquor should be calculated based on the measured seed surface area and the seed surface area/liter of pregnant liquor ratio requirement. In the present process, the quantity of seed charge is generally 80-85% less than seed charges utilized by the prior art precipitation processes.
The temperature, where the seeding of the pregnant liquor is accomplished in accordance with the present process, is kept below about 68° C. (155° F.) and generally within the range from about 40° C. to about 68° C. The average residence time of the seeded pregnant liquor in the first precipitation stage is usually in the range from about 90 minutes to about 300 minutes. This average residence time at the given seed charge-to-liquor ratio and temperature range results in the precipitation of about 30 to 40 g/l alumina hydrate. During the time period referred to hereinabove, the precipitation vessel(s) may be agitated in a conventional manner, for example, by mechanical or air agitation, to achieve maximum contact of the low seed charge with the pregnant liquor.
From the first precipitation stage, the produced slurry is then introduced into the second precipitation line or stage. This precipitation stage can, as shown, consist of several precipitation vessels all arranged in series. Also, depending upon the number of first stage precipitation vessels employed in parallel, a number of second precipitation lines may be used in parallel, each line consisting of several vessels in series. The number of precipitation vessels used in both the first and second stages depends upon the Bayer process liquor volumes generated by the plant, the availability of vessels and other economic and operational considerations. This facet of the precipitation process is within the skill and knowledge of the practitioner. For the sake of ready understanding, this description, as indicated in FIG. 1, will only consider a single first stage precipitation vessel and a second precipitation stage consisting of several precipitation vessels connected in series.
Slurry from the first precipitation stage is charged to the second precipitation stage where the solids content of the slurry is allowed to increase from the initial 30-40 g/l to 250-700 g/l by the dual effect of further precipitation and accumulation of hydrate from the first stage. This is suitably accomplished by well-known techniques employed in the Bayer process. The average residence time of the solids in the second precipitation stage is within the range from about 30 to 90 hours. During this residence time, agglomeration and coarsening of the alumina hydrate takes place resulting in a strong, coarse product. The temperature in the second precipitation stage is kept within the range from about 40° to about 55° C. If the temperature in the second precipitation stage approximates the temperature maintained in the first stage, cooling will not be required when slurry is being transferred from one vessel to another within the second precipitation stage. If a significant temperature drop is desired between the individual precipitation vessels of the second precipitation line for optimization of the process, then so-called interstage cooling may be employed. However, the instant invention operating at relatively low precipitation temperatures allows, if so desired, the elimination of the need for interstage or intervessel cooling and thus can result in significant energy savings.
From the last precipitation vessel of the second precipitation stage, the high solids content slurry is introduced into a classifier where classification of the solids by particle size takes place. Due to the novel use of low seed charge in the first precipitation stage, in combination with the high solids second stage precipitation line, the process results in an alumina hydrate product which consists of at least about 90%, preferably 95%, by weight of coarse, strong particles having a particle size in excess of 44 microns in a yield (based on the Al 2 O 3 content of the supersaturated sodium aluminate liquor) of about 80 g/l.
From the classification stage, the overflow, containing the fine fraction, is introduced into a clarifier-settler where the slurry is allowed to settle in order to separate the finely divided alumina hydrate particles from the spent Bayer process liquor. The spent liquor, having an A/C ratio in the range from about 0.350 to about 0.375 is recycled to the Bayer process after its caustic concentration is increased, for example, by evaporation and/or addition of caustic. The fine alumina hydrate discharged in the underflow from the settler is subjected to a washing treatment to remove adhered impurities therefrom. The washed hydrate is then employed as seed for precipitation of alumina hydrate in the first precipitation stage of the instant process.
The process of the present invention involving the use of a relatively small seed charge in the first precipitation stage can also be advantageously employed in conventional batch or continuous precipitation systems where under the known precipitation conditions excessive production of finely divided alumina hydrate occurs. As mentioned hereinbefore, many conventional precipitation processes produce a large fraction of fines and/or weak alumina hydrate which necessitates extensive recycling of the slurry and the large-scale utilization of classification apparatus, both of which result in operational difficulties and significantly increased operating and capital expenditures. To minimize these disadvantages, it has been found that the process of the invention can be adapted to conventional precipitation systems where multiple seeding is utilized. Thus, as shown in FIG. 2, in a first precipitation stage, only a small quantity of seed is added to the pregnant liquor and then the produced slurry is introduced into a second precipitation line as taught by the present invention. In the second precipitation stage, accumulation of the solids content is achieved in accordance with the invention, however, reduction of fine particle generation and production can be achieved by recycling a portion of the medium sized alumina hydrate particles to at least one, preferably to more, precipitation vessels in the second precipitation stage. These particles are cemented and strengthened along with the coarse agglomerates generated in the second stage, thus producing strong alumina hydrate products in addition to reducing the overall quantity of fines. As shown in FIG. 2, in the event the inventive process is employed in combination with conventional precipitation systems, the high solids content slurry discharged from the second precipitation line is subjected to a classification step (primary thickener) to separate the product alumina hydrate from the fine fraction. The overflow slurry from the thickener containing the finer fraction is then subjected to a second thickening step and the underflow containing slightly coarsened but still fine alumina hydrate is recycled to the second precipitation stage as seed to aid in precipitation and accomplish cementation. The overflow slurry is charged to a third thickener from where the underflow, consisting of alumina hydrate of fine particle size, is subjected to a washing step and the washed hydrate is used as seed in the first precipitation stage in accordance with the process of the present invention.
The following examples are given to further facilitate the understanding of the invention.
EXAMPLE 1
Pregnant Bayer process liquor having an A/C ratio of 0.675 and a caustic concentration (expressed as g/l Na 2 CO 3 ) of 266 g/l was continuously charged to a first precipitation stage at a rate of 12.6 m 3 /min (3300 gpm) where it was contacted with alumina hydrate seed. The alumina hydrate seed employed had a particle size distribution wherein particles having a particle size below 44 microns constituted about 45% by weight of the seed charge. The amount of seed charge to this precipitation stage was selected to provide a seed surface area of approximately 2 m 2 /liter of pregnant liquor and the average surface area of the seed was in the range of about 800-1500 m 2 /g. The temperature of the seeded pregnant liquor was maintained within the range from about 60° to about 65° C. (140°-150° F.) and the average residence time of the seeded liquor in the first precipitation stage was kept within the limits of about 120-180 minutes. The produced slurry containing approximately 34-36 g/l solids was then continuously charged to a second precipitation stage consisting of eleven precipitators connected in series. The solids content of the slurry in each of these precipitator vessels was increased to about 400-450 g/l by allowing solids to accumulate in each of these vessels. Transfer of slurry from one vessel to another was accomplished by gravity. The temperature in the second precipitation stage was so controlled as to achieve an approximate temperature drop across the eleven precipitator vessels of about 20°-24° C., resulting in a final temperature of about 40°-42° C. in the last precipitation vessel of the series. The average residence time of the slurry in each vessel of this stage was about 3-4 hours. From the last precipitation vessel of the second precipitation stage, the slurry of high solids content was charged to a classifier where the product alumina hydrate was removed with the underflow and the overflow containing the fine fraction was charged to a clarifier. From the clarifier, the separated fine alumina hydrate was charged to a washing stage to remove adhered and adsorbed impurities, such as organics, and the washed fine hydrate was then used as seed to initiate precipitation in fresh Bayer process pregnant liquor introduced in the first precipitation stage. The overflow spent liquor had an A/C finishing ratio of about 0.375 and it was recycled to the Bayer process.
The product hydrate recovered from the classification stage was analyzed for particle size distribution and strength. It was found that about 95% by weight of the product hydrate consisted of particles having a size in excess of 44 microns and the attrition test of the product hydrate indicated high strength. Only a very small portion of the hydrate suffered attrition when subjected to an attrition test. The yield of product hydrate from the precipitation was 80.5 g/l based on the alumina (Al 2 O 3 ) content of the pregnant liquor from which it was recovered. The fine fraction removed from the classifier was also analyzed for particle size distribution, and it was found that about 45% by weight of the fine fraction had a particle size below 44 microns.
EXAMPLE 2
In this example, the beneficial effects of the process of the invention on a conventional precipitation system are shown. In the conventional system, unacceptable quantities of fine, weak alumina hydrate particles (less than 44 micron size) are produced unless the produced fine hydrate is recycled in large quantities to the precipitation stage to allow agglomeration and growth. To avoid the need for such extensive recycle and associated operational and capital costs, the conventional precipitation system, involving addition of seed in more than one stage, was combined with the precipitation process of the present invention. The novel process utilizing a single, relatively small seed charge in a first precipitation stage in contact with the entire pregnant liquor stream is established, as shown in FIG. 2, ahead of the conventional system. Thus, pregnant liquor having an A/C ratio of 0.700 and a caustic concentration of 215 g/l was contacted with a charge of fine alumina hydrate seed. The fine alumina hydrate seed contained about 45% by weight particles having an average particle size below 44 microns. The pregnant liquor kept at 68° C. (155° F.) was seeded in a first precipitation stage with sufficient seed to obtain an approximately 2 m 2 seed surface area per liter of pregnant liquor. The contact between the seed and the liquor was maintained for an average time period within the range from about 150-200 minutes, then the produced slurry containing from about 30 to about 40 g/l solids was transferred into a second precipitation stage consisting of eleven precipitation vessels in series. A solids content of about 250 g/l was established in each of the vessels by the addition of seed derived from the secondary thickener shown in the Figure. The seed surface area to pregnant liquor volume in this second stage seeding was established at 4 m 2 /l and the solids in the precipitators were allowed to strengthen and grow during a 2-3 hour average residence time in each vessel of the second precipitation stage. From the last precipitator vessel of the series, the slurry was discharged into a primary thickener where separation of the product hydrate from the fine fraction took place. The product hydrate was recovered and its average particle size distribution showed that particles in excess of 95% by weight had a size in excess of 44 microns. The overflow from the primary thickener was charged to a secondary thickener where classification took place by size. The coarser particles recovered from the underflow were used as seed for the second precipitation stage, while the overflow was charged to a tertiary thickener. From the underflow of the tertiary thickener, fine particles (average particle size 44μ or less) were recovered and after washing, used as seed for the first precipitation stage. The overflow spent liquor was recycled to the Bayer process after reestablishment of its caustic concentration.
The product hydrate recovered from the primary thickener was obtained in a yield in excess of about 75 g/l; the major improvement observed by the combination described resulted in the reduction of the overall fine particle generation. It was found that the fine particle generation of the combined process was substantially less in comparison to the conventional precipitation process. The combination shown resulted in a total fine particle content reduction of about 10%. In addition, the produced product hydrate had high strength characterized by at least about a 10% increase in attrition resistance.
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An improved precipitation system is provided for the Bayer process production of alumina hydrate. In order to produce coarse and strong alumina hydrate at high yield, supersaturated Bayer process sodium aluminate liquor is seeded with a relatively small seed charge in a first precipitator at a relatively low temperature and the produced slurry is transferred to a second precipitator where without additional seeding, the solids content of the slurry is allowed to increase to about 250-700 g/l by accumulating solids in the line until the desired solids content is reached. After a suitable residence time, a coarse, strong product hydrate can be recovered in yields of or exceeding 80 g/l based on the alumina (Al 2 O 3 ) content of the supersaturated sodium aluminate liquor subjected to precipitation. The process not only produces the desired product at high yield but also, due to the use of a single, small seed charge, the precipitation system requires fewer precipitators and classifiers for a given residence time. Additionally, it allows significant energy savings by eliminating the need for cooling during the precipitation cycle due to the lower than conventional temperatures which can be utilized in the first precipitator.
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