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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a camera mounting device for an endoscope which enables an operator to easily attach and detatch a camera to and from an ocular portion of an endoscope.
2. Description of the Prior Art
When a coelom is examined by means of an endoscope, it is very important to take at any required time photographs of the affected parts of the coelom for the diagnosis and treatment of intra-coeliac deseases.
Conventional camera mounting devices for an endoscope are also detatchably connected to the ocular portion of the endoscope. However, attaching and detatching of the prior art devices are achieved in a relatively complicated manner such as screw engagement, and thus cannot be undertaken by an operator alone. The operator, therefore, needs an assistant.
Since the intra-coeliac photographing must be conducted in any positions and at any time, it is strongly desired that a camera be attached to the ocular portion of an endoscope speedily and easily as well as by a single-handed operation of an operator without any assistant's help.
SUMMARY OF THE INVENTION
An object of this invention is to provide a camera mounting device for an endoscope enabling an operator to accomplish speedy and easy single-handed attaching and detaching of a camera to and from the ocular portion of an endoscope.
Another object of the invention is to provide a camera mounting device for an endoscope which would not easily come off the ocular portion even if it is exerted by any force to separate it from the ocular portion coupled therewith.
A camera mounting device for an endoscope according to this invention comprises a hollow connecting tube having one end fitted with a camera mount, a cavity defined in the other end portion of the tube for locating an ocular portion of the endoscope, engaging elements pivoted to said other end portion of the tube, each normally engaged at an engaging surface thereof with a conical rear surface of the ocular portion by an urging means so as to hold the ocular portion in the cavity, and a releasing means disposed at said other end portion of the tube to rock the engaging elements to the outside of the cavity against the urging means. In this construction, the device can be attached to the endoscope only by pressing the ocular portion against a wall of the cavity, and can be easily removed from the endoscope by actuating the releasing means, so that an operator can unfailingly handle the device by a single hand.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be fully understood from the following detailed description with reference to the accompanying drawings, in which:
FIG. 1 is a sectional view of the principal portion of an embodiment of a camera mounting device for an endoscope according to this invention, and
FIG. 2 is an explanatory sketch illustrating the operation of an engaging element of the camera mounting device of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a camera mounting device for an endoscope is provided with a hollow cylindrical connecting tube 1 fitted at one end thereof with a camera mount (not shown). An ocular portion or an eyepiece 2 provided on the proximal end portion 3 of an endoscope is inserted in a cavity 4 formed in the other end portion of the tube 1. The cavity 4 is defined by a truncated-cone-shaped wall surface 5 diverging outward and a cylindrical inner wall surface 6 with its innermost portion complementary to an outer peripheral edge portion 7 of the ocular portion 2. The cylindrical inner wall surface 6 is continuous to a flange 8 extending inward from the inner wall surface of the tube 1. The front of the outer peripheral edge portion 7 of the ocular portion 2 is brought in contact with the opposite surface of the flange 8. In a cylindrical adapting portion 9 whose inner surface defines the wall surfaces 5 and 6 of the cavity 4, there are formed a plurality of (e.g., three) slits 10 (only one shown in FIG. 1) extending along the central axis l of the tube 1 (which is also an optical axis thereof) and arranged in circumferential spaced relation with each other. In each of the slits 10 is disposed an engaging element 11 rockable about a pivot 12 fixed to the adapting portion 9. Each of the elements 11 is urged clockwise in FIG. 1 by an urging means such as a tension spring 13. A convex cam surace or engaging surface 14 formed at that end of the element 11 which faces the central axis l is pressed against a conical rear surface 15 of the ocular portion 12, thereby bringing the front end surface of the edge portion 7 of the ocular portion 2 into close contact with the end surface of the flange 8 opposed thereto and holding the ocular portion 2 in a prescribed position in the cavity 4. Formed at the other end or outer end of the engaging element 11 is a projecting portion 16 extending toward the camera mount. A ring-shaped end member 17 is fixed at its end wall to the end of the adapting portion 9 of the tube 1 so as to surround and protect the portion 9 and the engaging elements.
A cylindrical cam or cylindrical member 18 surrounds said other end of the tube 1. A slot 19 extending along the central axis l of the tube 1 is formed in the wall of the tube 1 within the range covered by the cam 18, and a pin 20 protruding inward from the cam 18 is inserted in the slot 19 so that the cam 18 can reciprocate axially of the tube 1. A rim 21 is formed on the outer periphery of the tube 1, and a tension spring 23 is disposed in a chamber 22 defined by the rim 21 so as to normally urge the cam 18 toward the camera mount portion.
Disposed between the end member 17 and the rim 21 is a rotatable actuation ring 24 surrounding the cylindrical cam 18. A knob 25 is fixed to the outer periphery of the ring 24. A pin 26 extends inward from the actuation ring 24 and engages a helical groove 27 formed in the outer peripheral surface of the cylindrical cam 18. The stroke of the cylindrical cam 18 is selected as follows. As the actuation ring 24 is rotated clockwise as viewed from the camera mount in FIG. 1, the cam 18 is moved leftward in FIG. 1 under the guidance of the pin 26 engaging the groove 27. The left end surface of the cam 18 first hits against the projecting portion 16 of the engaging elements 11, and thereafter pushes the portion 16 to the left hand in FIG. 1 to rotate the engaging elements 11 counterclockwise. The elements 11 are rocked out of the cavity 4, i.e., out of the passage of the ocular portion 2 before the pin 26 reaches the right end of the groove 27 in FIG. 1. The cylindrical cam 18, slot 19, spring 23, actuation ring 24, pins 20 and 26, groove 27, and knob 25 constitute a releasing means.
In an embodiment as shown in FIG. 2, the cam surface 14 of each engaging element 11 is arcuate, and its center of curvature O 1 is separated toward the cylindrical cam 18 (i.e., toward the camera mount) from the center of rotation (or pivotal point O 2 of the element 11 or the pivot 12 so that the distance between the center of rotation O 2 and the cam surface 14 increases toward the cylindrical cam 18.
When the ocular portion 2 is not inserted in the cavity 4, the engaging elements 11 are further rotated clockwise from the position of FIG. 1 and protrude more towards the central axis l. As the ocular portion 2 is inserted into the cavity 4 it rocks the engaging elements 11 counterclockwise in FIG. 1 against the urging force of the springs 13. Then, the edge portion 7 of the ocular portion 2 engages the cylindrical inner wall surface 6 of the adapting portion 9 of the tube 1, and at the same time the front end surface of the edge portion 7 is brought into contact with the end surface of the flange 8 opposed to the front end surface of the edge portion 7. Thus, the ocular portion 2 is set in position in the cavity 4. At this time the cam surfaces 14 of the engaging elements 11 contact the conical rear surface 15 of the ocular portion 2, and thrust the ocular portion 2 into the tube 1 by means of the urging force of the springs 13, thereby keeping the ocular portion 2 in position.
When a pulling-out force is applied to the ocular portion 2, the conical rear surface 15 acts as a wedge on the cam surfaces 14 of the engaging elements 11. The pulling-out force is divided into component forces F which act perpendicularly to the conical rear surface 15 of the ocular portion 2 at a point P of the engaging elements 11 contacting the surface 15 and are directed to the center of curvature O 1 , as shown in FIG. 2. The force F can be divided into two component forces F 1 and F 2 , the component force F 1 being directed from the point P to the center of rotation O 2 of the engaging element 11, and the component force F 2 acting from the point P to the cylindrical cam 18 perpendicularly to the component force F 1 . The component force F 2 tends to rotate the engaging element 11 counterclockwise about the center of rotation O 2 . The materials of the engaging elements 11 and the rear surface portion of the ocular portion 2 are so selected as to provide the undermentioned coefficient of friction μ, thereby to prevent the rotation of the engaging element 11 resulting from the component force f 2 .
μ≧sin θ· cos θ=(1/2) sin 2θ.
where θ is defined as an angle between the component forces F 1 and F 2 . Thus, the ocular portion 2 would not be pulled off the camera mounting device, even if a large pulling force is exerted on the ocular portion 2.
Subsequently, when the knob 25 or actuation ring 24 is manually turned counterclockwise as viewed from the camera mount in FIG. 1, the cylindrical cam 18 is moved to the left hand under the guidance of the pins 20, 26 engaging the slot 19 and helical groove 27, respectively, and pushes with its left end the projecting portions 16 of the engaging elements 11 to thereby rock the elements 11 counterclockwise out of the cavity 4. Thus, the ocular portion 2 is disengaged from the cavity 4 without any interference with the elements 11.
As will be clear from the above description, attaching and detaching of the ocular portion 2 to and from the camera mounting device is quite easily and unfailingly accomplished by a single-handed operation of an operator.
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A camera mounting device for an endoscope consists of a hollow connecting tube provided at one end with a camera mount and at the other end with a cavity for receiving an ocular portion of the endoscope having a conical rear surface, engaging elements pivoted to the other end of the connecting tube and circumferentially spaced from each other in the cavity so as to normally press the conical rear surface of the ocular portion thereby to hold the ocular portion in the cavity, and a releasing mechanism for rotating the engaging elements out of the cavity, whereby connection and disconnection of the camera mounting device to and from the ocular portion of the endoscope can be made by a single-handed operation of an operator.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is being filed simultaneously with copending application having disclosure number 92-084.1 entitled A WORDLINE DRIVER CIRCUIT HAVING A DIRECTLY GATED PULL-DOWN DEVICE.
TECHNICAL FIELD
This invention relates generally to memory device technologies and more particularly to a circuit and method for driving a wordline to a desired potential.
BACKGROUND OF THE INVENTION
A DRAM consists of an arrangement of individual memory cells. Each memory cell comprises a capacitor capable of holding a charge and a field effect transistor, hereinafter referred to as an access transistor, for accessing the capacitor charge. The charge is referred to as a data bit and can be either a high voltage or a low voltage. Therefore, the memory has two states; often thought of as the true logic state and the complementary logic state. There are two options available in a DRAM memory: a bit of data may be stored in a specific cell in the write mode, or a bit of data may be retrieved from a specific cell in the read mode. The data is transmitted on signal lines, also called digit lines, to and from the Input/Output lines, hereinafter known as I/O lines, through field effect transistors used as switching devices and called decode transistors. For each bit of data stored, its true logic state is available at an I/O line and its complementary logic state is available at a line designated I/O*. For purposes of this discussion, I/O and I/O* lines are often referred to as just I/O lines. Thus, each cell has two digit lines, referred to as digit line pairs.
Typically, the memory cells are arranged in an array and each cell has an address identifying its location in the array. The array comprises a configuration of intersecting rows and columns and a memory cell is associated with each intersection. In order to read from or write to a cell, the particular cell in question must be selected, also called addressed. The address for the selected cell is represented by input signals to a row decoder and to a column decoder. The row decoder activates a wordline in response to the row address. The selected wordline activates the access transistor for each of the memory cells in electrical communication with the selected wordline. Next the column decoder activates a column decoder output in response to the column address. The active column decoder output selects the desired digit line pair. For a read operation the selected wordline activates the access transistors for a given row address, and data is latched to the digit line pairs. The column decoder output selects and activates the decode transistors such that the data is transferred from the selected digit line pair to the I/O lines.
The row decoder comprises decode circuitry for determining which wordline is selected for a desired address and for determining which wordlines are non-selected. The row decoder also comprises driver circuitry for driving the selected and the non-selected wordlines to potentials having active and inactive logic states respectively. The active wordline has a potential capable of activating the access transistors in electrical communication with the active wordline and the inactive wordline has a potential capable of deactivating the access transistors in electrical communication with the non-selected wordlines. For this discussion the selected wordline will have a high potential and the non-selected wordlines will have low potentials.
Typically the decode circuitry comprises a primary decoder and a secondary decoder for generating a primary select signal, S 1 *, and at least one secondary select signal, S 2 , respectively. The asterisk indicates that the signal is active low. The primary and secondary select signals are used as inputs to a driver portion of the row decoder. The driver portion typically comprises an inverter portion and a latch portion. The primary select signal is typically inverted to the wordline by the inverter portion, and the secondary select signal regulates the switching of the primary select signal to the inverter portion. The latch portion latches a non-selected wordline to the inactive logic state.
Typical decoder circuitries can comprise either MOS decodes utilizing NAND circuitry or NOR circuitry, or tree decode circuitry. FIGS. 1, 2 and 3 are examples of a portion of the NAND, NOR, and tree decode circuitries respectively. The decode circuitries of the row decoder provide predecoded addresses to select the driver portion of the row decoder circuit. MOS decode circuitry provides predecode signals comprising the primary select signal, S 1 *, and the secondary select signal, S 2 . Although the specific decode circuitry determining the values of S 1 * and S 2 can vary, the variations are well known in the art. FIGS. 1-3 have been included to provide examples of portions of possible decode circuitries. FIG. 1 is an example of a portion of a CMOS NAND decode circuit wherein each of the secondary select signals, S 2A , S 2B , S 2C and S 2D , is a one of four decode having four phases, and wherein S 1 * (not shown) comes from a one of 64 CMOS NAND decode used to decode 256 wordlines. FIG. 2 is an example of a portion of a CMOS NOR decode circuit wherein each of the primary select signals, S 1A *, S 1B *, S 1C * and S 1D *, is a one of four decode using four phases, and wherein secondary select signal S 2 , (not shown), comes from a one of 64 CMOS NOR decode used to decode 256 wordlines.
In the circuits of FIGS. 1 and 2, the secondary select signal controls the activation of a single pass transistor. The decode circuitry may employ the tree decode configuration wherein a plurality of serially connected pass transistors are activated in order to drive the selected wordline to a high logic level. In the example depicted by FIG. 3 predecode address signals activate three serially connected pass transistors. For example if predetermined address signals RA56(0), RA34(0), and RA12(1) are high and the remaining predecode addresses are low, transistors 1,2, and 3 are activated providing an electrical path between points 4 and 5. These decode circuitries are well known to those skilled in the art.
FIG. 4 is a simplified schematic of the driver circuit of the related art. Each wordline in the array has a similar driver circuit. In FIG. 4, a MOS decode has been utilized to provide a primary select signal S 1 * at primary select node 4 and a secondary select signal S 2 at secondary select node 6. The select signals S 1 * and S 2 control the potential of the wordline 8. The primary select signal is transmitted through NMOS transistor 9 and continually gated transistor 10 to an inverter/latch portion 11 when the secondary select signal is high. When select signal S 2 is high, NMOS transistor 9 activates and the select signal on S 1 * is inverted to the wordline 8.
FIG. 5 is a simplified schematic of a portion of the decode circuitry of a typical row decoder of the related art. Primary select signals S 1 * and S 1 '* and secondary select signals S 2 and S 2 ' are generated by decode circuitry (not shown). The purpose of this discussion is to provide an understanding of the final mechanism for activating and deactivating the wordlines and to provide an understanding of the relationship between the select signals and the driver circuit. At the onset of each read or write cycle, all of the wordlines are typically reset to a low potential. In this case, select signals S 1 *, S 1 '*, S 2 , and S 2 ' have a high potential which take the potentials of the wordlines 12, 14, 16, and 18 low.
During the selection of a wordline the secondary select signals go low except for the secondary select signal which activates the pass transistor in electrical communication with the selected wordline. All of the primary select signals remain high except for the primary select signal which must be inverted to the selected wordline.
Still referring to FIG. 5, assume the desired address selects wordline 14. In this case select signal S 2 goes low and select signal S 2 ' is high; and select signal S 1 '* goes low, and select signals S 1 * is high. The low select signal S 1 '* is inverted to wordline 14 through activated transistor 22. Although transistors 21 and 23 are deactivated the wordlines 12 and 16 remain at the initial low potential due to a latching of the low potential by the inverter/latch portion 11 of the driver circuits. Wordline 18 is driven low when the high potential of S 1 * is driven through activated transistor 24 and inverted to wordline 18.
FIG. 6 is exemplary of a driver portion of a row decoder circuit wherein the decode portion is implemented with tree decode circuitry having a plurality of pass transistors 25.
Serial nodes 26 and 27 tend to float to unknown potentials between cycles of cell selection. Since it is important to know the potential of serial nodes 26 and 27 the serial nodes 26 and 27 are typically reset to a known potential prior to the selection of the active wordline. During reset transistors 25 are actuated thereby precharging the serial nodes 26 and 27 to a high potential. Initial precharging presents a problem since there is a significant power consumption associated with precharging all of the serial nodes at the onset of each cycle.
In some circuits there have been problems with latch up. Latch up occurs when node 40 in FIGS. 4 and 6 has latched to the high supply potential through a transistor component (not shown) of the driver circuit. Latch up occurs when the potential of node 40 is greater than the supply potential, V ccp . This can occur during power up when the supply potential is increasing. In order to eliminate latch up, a transistor device 10 is continually gated by a V ccp supply potential as shown in FIGS. 4 and 6. Transistor device 10 keeps the potential at node 40 less than the supply potential as long as the potentials at nodes 42 and 27 are less than the supply potential. Therefore, as long as the potentials at nodes 42 and 27 are less than V ccp , the part will not latch up since the n-well of the transistor component of the driver circuit will never be forward biased. The function of the continually gated device will become clear when analyzed with respect to subsequent schematics of the present invention.
V ccp is a high voltage pump potential typically equal to the supply potential, V cc , of the memory device plus a threshold voltage, V t , of the access transistor, V cc +V t equals V ccp . The threshold voltage of the access transistor is the potential that must be overcome in order for the access transistor to conduct current.
In order to conserve power, supply potentials of many memory devices have been decreased from the typical 5 volt V cc . A low supply voltage of 3.3 volts is increasingly replacing the 5 volt operation. There is a disadvantage associated with the lower supply potentials. Often the potentials driven to a node are marginal. They often do not meet the minimum low potentials for a high logic state. Thus, circuits can experience erroneous outputs potentials. For example, in FIG. 6 when the supply voltage is approximately 3 volts, the select signal on S 1 * may be 3 volts. Considering that the NMOS transistor doesn't pass high potentials with minimal loss, we must expect a threshold voltage drop across the NMOS transistors 25. The input voltage to the inverter/latch 11, FIGS. 4-6, may drop from 3 volts to 2 volts due to the threshold loss. There exists the increased probability that the inverter/latch 11 will see the 2 volts as a low logic state rather than the high logic state desired, or that the threshold voltage loss will be greater thereby decreasing the potential at the input of the inverter/latch. A need therefore exists to provide a row decoder that consistently drives the wordline to the inactive low state for a high primary select signal regardless of the supply potential used. Therefore, memory device circuits need to be redesigned in order to successfully drive wordlines to low logic levels for circuits utilizing supply potentials less than the typical 5 volts.
Further understanding of the DRAM circuitry can be gleaned from the DRAM DATA BOOK, 1992, published by Micron Technology and herein incorporated by reference.
SUMMARY OF THE INVENTION
An object of the invention is to conserve power, increase speed, and provide one hundred percent error free wordline selection.
The invention features an automatic precharge circuit for precharging serial nodes of a driver portion of a row decoder circuit.
The automatic precharge circuit features precharge devices each of which is interposed between a high voltage node, connectable to a supply potential, and a serial node. The precharge devices are gated automatically by a primary predecode signal of a decode portion of the row decoder. Power is conserved since the serial nodes are passively pulled to the supply potential through the precharge devices when automatically gated.
Details of the present invention will become clear from the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a portion of a MOS NAND decoder for row decoder circuitry.
FIG. 2 is a schematic of a portion of a MOS NOR decoder for row decoder circuitry.
FIG. 3 is a schematic of a portion of a tree decoder for row decoder circuitry.
FIG. 4 is a schematic of a driver circuit of a row decoder of the related art.
FIG. 5 is a portion of a row decoder circuit for providing a simplified example of wordline selection.
FIG. 6 is a schematic of a driver circuit of a row decoder of the related art.
FIG. 7 is a simplified schematic of a driver circuit of the invention.
FIG. 8 is a detailed schematic of the driver circuit of the invention.
FIG. 9 is a detailed schematic of a further embodiment of the invention.
FIG. 10 is a detailed schematic of a further embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 7 represents a driver portion of a row decoder. A decode portion of the row decoder is not shown. The decode portion generates predecode signals S 1 * and S 2 . S 1 * is a primary select signal and controls the actuation and deactuation of pull-down NMOS transistor 50. S 2 is a secondary select signal and controls the actuation and deactuation of pass NMOS transistor 55. When a high primary select signal actuates pull-down transistor 50, a low reference potential at reference node 59 is rapidly driven to the wordline 60 through the pull-down transistor 50. Since the high primary select signal is not driven through a pass transistor to the inverter/latch portion 62 and then inverted to the wordline, but instead directly drives the transistor that pulls the wordline low, there is a significant time savings realized over the circuit of the related art as shown in FIG. 4.
In a case where wordline 60 is selected the primary select signal S 1 * goes to a low potential and the secondary select signal goes to a high potential. The low is then driven through transistors 55 and 65 to the input of inverter/latch 62 where the primary select signal is inverted and driven as a high potential to the wordline 60. The low primary select signal deactuates transistor 50 thereby isolating wordline 60 from the reference potential.
In the case where the primary select signal goes to a low potential but wordline 60 is not selected, the secondary select signal remains low, and the wordline is latched to its initial low potential by inverter/latch circuitry 62.
FIG. 8 is a more detailed schematic of the circuit of FIG. 7. A high primary select signal, S 1 *, gates transistor 50 rapidly pulling the wordline 60 to a low potential. The low on wordline 60 activates transistor 90 thereby pulling the gate node 95 to the high supply potential at high voltage node 96. This high supply potential at gate node 95 is actually a latch signal. The latch signal actuates transistor 97 which in turn pulls wordline 60 to the reference potential. Thus even if the primary select signal transitions low thereby deactuating transistor 50, the initial low potential on the inactive wordline is latched to the wordline by the inverter/latch circuitry, as long as transistor 55 remains deactuated.
In a case where wordline 60 is selected the primary select signal, S 1 *, transitions low and the secondary select signal, S 2 , transitions high. The low primary select signal is then transmitted to node 95 through transistors 55 and 65. The low at 95 actuates transistor 98 and deactuates transistor 97 thereby pulling the wordline to a high supply potential and isolating the wordline from the reference potential.
In the circuit of FIG. 8 transistor 50 is relatively large when compared to transistor 97. Directly driving the wordline to the low potential through transistor 50 ensures the that the wordline is driven to the low potential quickly in the case where the supply potential is lower than the typical 5 volts. This is accomplished without the use of complicated PMOS circuitry and the more cumbersome layout methods necessitated in the manufacture of PMOS-NMOS circuits.
Continually gated NMOS transistor 65 is utilized to prevent the n-well of transistor 90 from forward biasing during powerup when V ccp is less than V cc .
FIG. 9 is an alternate embodiment of the circuit of FIG. 8. In FIG. 9 the gate node 99 of transistor 97 is the serial connection of transistors 55 and 65. Both placements of nodes 95 and 99, as shown in FIGS. 8 and 9, are equally viable and the final configuration may well be determined from a manufacturing standpoint where layout design restrictions are weighted against circuit performance.
In FIG. 10 a tree decode is implemented as the decode portion of the row decoder. The circuit of FIG. 8 performs similar to the circuits of FIGS. 9 and 10. When the primary select signal S 1 * is high transistor 50 is actuated and wordline 60 is pulled to the low reference potential. When the primary select signal transitions low the wordline is latched low by the inverter/latch circuit 62 in a case where the wordline is not selected. In this case at least one of the pass transistors 100 is deactuated. When wordline 60 is selected the secondary select signals S 2 , S 2 ', and S 2 '' transition high thereby actuating pass transistors 100. The low primary select signal is then transmitted to node 95 and the primary select signal then actuates transistor 98 thereby pulling the wordline to the high supply potential. Transistors 50 and 97 are deactuated by the low primary select signal.
Serial nodes 110 provide the electrical connection between the pass transistors and between one of the pass transistors and the continually gated transistor 65. The automatic precharge circuit of the invention eliminates the need for the precharge circuit of the related art. The automatic precharge circuit of the invention provides quick response and large power saving without increasing cell size. The precharge circuit of the invention comprises the serial node pull-up transistors 105. Each serial node pull-up transistor 105 is interposed between high voltage node 106 connected to a supply potential, and a serial node 110. The serial node pull-up transistors are gated by a high primary select signal. Therefore when the primary select signal is high the serial node pull-up transistors are automatically actuated thereby automatically precharging the serial nodes by pulling them passively to the high potential.
When using the present invention the pass transistors 100 do not have to be actuated at the start of each cycle in order to precharge the nodes. A significant power savings is realized using the implementation of the invention over the previous implementation of the related art wherein all of the pass transistors were actuated before each cycle. Since the precharge occurs automatically the access speed is increased. The serial node pull up transistors are fabricated with existing silicon and there is no increase in cell size.
The automatic precharge circuit of the invention can also be utilized in a case wherein a MOS decode has been utilized. In this case the automatic precharge circuit is particularly useful during power up.
It can be seen that the invention quickly drives a non-selected wordline to an inactive logic state having a low potential through the pull-down transistor gated directly by the primary select signal. The low potential is latched to the wordline through an inverter/latch circuit which also drives the wordline to the low potential. The inverter/latch circuit drives a selected wordline high in response to a low primary select signal. Serial node charging transistors can be configured to automatically charge the serial nodes when the primary select signal is high thereby conserving power by eliminating the necessity of actuating all of the pass transistors for every wordline at the beginning of each cycle.
Although the invention has been described in terms of an automatic precharge circuit and method for charging the serial nodes of a wordline driver circuit, the circuit and method have utility in other circuits where an automatic precharge is desired. Modification to the circuitry may also be implemented without detracting from the concept of the invention. Accordingly, the invention should be read as limited only by the claims.
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The invention is an automatic precharge circuit featuring precharge devices each of which is interposed between a high voltage node, connectable to a supply potential, and a serial node. The precharge devices are gated automatically by a primary predecode signal of a decode portion of the row decoder. Power is conserved since the serial nodes are passively pulled to the supply potential through the precharge devices. The invention increases speed and provides error free wordline selection.
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This application is a national stage application, according to Chapter II of the Patent Cooperation Treaty. This application claims the priority date of Nov. 19, 1993 for Great Britain Patent Application No. 9323954.9.
This application is a national stage application, according to Chapter II of the Patent Cooperation Treaty. This application claims the priority date of Nov. 19, 1993 for Great Britain Patent Application No. 9323954.9.
FIELD OF THE INVENTION
The invention described here relates to improvements in drying webs and is applicable with particular advantage although not limited to a process carried out in a paper making machine, that of the application of "size" or "coating".
Such coatings are normally aqueous based and need to be dried by evaporation of the aqueous content. One particular problem associated with the application of "on machine" size/coating is that unless it is sufficiently dried before contact with the drying cylinders a phenomenum known as "picking" takes place. "Picking" results in areas of size/coating building up on the after-drying cylinders causing cylinder contamination, and leading to product quality problems. Hence there is a requirement for a device that will adequately dry the size or coating once applied to the paper web which can be positioned within the area of the paper making machine under consideration. Furthermore the area in question is very often limited in terms of space and thus the required device must be extremely compact and of high intensity in terms of its evaporation potential.
In recent times the approach to this problem has been to position a non contact "air turn" device between the size/coating application and the first "after-drying" cylinder, thereby setting up the correct sheet geometry through the size press/coater and creating a long uninterrupted length of web path into which an infra red radiation heating unit could be positioned. The purpose of the infra red unit is to achieve the required evaporation of water from the coated paper web.
There are problems however which can be attributed to the application of infra red radiation devices, namely:
1 Fire risk.
2 Sheet instability caused by turbulence within the unit leading to contamination, poor quality and risk of sheet creasing.
3 Hostile environment surrounding the unit due to the very high radiation temperatures and consequent heat loss, with attendant inefficiencies.
4 Typically in gas fired infra-red systems, there is high thermal inertia i.e. slow response on both start-up and shut-down.
5 Poor mass transfer capability resulting from the predominance of radiation heat transfer with low air movement.
Thus, it is desirable to identify an improved method of web drying. Typically webs coated with `wet` size or coating are handled by air flotation systems. Such systems allow a web to be supported in a cushion of gas, usually air, without contact, and therefore damage to the coated surface.
A typical air flotation system comprises two air bar assemblies, between which a web travels. Each air bar assembly includes a plurality of parallel and spaced apart air bars, each air bar being elongate and arranged such that its longitudinal axis is transverse to the direction of travel of the web. Each air bar has a web facing surface through which gas, typically air, flows from the air bar.
Although the gas used in air flotation systems is often air, at times different gases need to be used to support the web. In the specification the term `air bar` and `air flotation system` will be used to encompass systems which could also operate with gases other than air.
In one form of air bar, each air bar includes an air inlet and on the web facing surface, a pair of parallel linear nozzles through which air passes to impinge on the web to support it. The nozzles are arranged such that they are aligned with the longitudinal axis of the air bar so that the nozzle lies transverse to the direction of travel. Many such air bars operate using the Coanda effect which causes the air flow to converge. This is arranged by providing a central top plate lying between the nozzles where each edge of the top plate forms one edge of a respective nozzle which is radiused such that air flowing from the nozzle flows over the radius and across towards the centre of the top plate. A typical air bar operating using these principles is described in UK patent specifications 1 302 091 and 1 302 092.
An alternative form of air bar also operates using the Coanda effect, and is known as an `air foil`. Here the air bar is elongate but is asymmetric about its longitudinal axis. Each air foil includes one linear nozzle. The nozzle is arranged such that it is not along the centre of the air bar but is closer to the edge which the web first meets when travelling over the air bar. The nozzle is arranged to feed a jet of air in a diagonal direction towards the web, the air bar including a sloped plate which slopes in a direction away from the nozzle and towards the web and then to a top plate substantially parallel to the web. By the Coanda effect, the air fed out of the nozzle adheres to the sloping plate and then to the top plate to form an air cushion to support the travelling web.
The terms `coanda effect` and `coanda air bars` will be well known to the skilled addressee of the specification, and the term `coanda air bar` will here be used to encompass any air bar from which air may flow exhibiting a coanda effect, as opposed to a jet impingement air bar from whose web facing surface air is blown to impinge upon the web, with no exhibition of coanda effect. The term `jet impingement air bar` will be used to encompass any such air bar exhibiting no coanda effect. Such jet impingement air bars typically have a perforate upper surface with a series of spaced small orifices, but may equally include slots or nozzles through which the air flows.
To satisfy the evaporative requirement for drying within a small dimension in machine direction, it was necessary to develop an air impingement system which would support the web being processed in a stable manner as well as deliver extremely high heat transfer rates. Standard air flotation systems could not be configured to achieve this in the confined space available.
This is because a standard air flotation system's ability to evaporate is based on the temperature and velocity of the air it is discharging to the surface of the web. It will be clear to the skilled addressee of the specification that the use of extreme temperatures could cause problems in material selection and machine design (e.g. thermal expansion).
There are problems also when operating conventional air flotation nozzle systems at high air velocities of circa more than 70 m/second with accompanying low web tensions of circ 5 kg/m width. Under these high air velocity and low web tension conditions the nozzle to paper web distance in operation could be typically of the order of 40 mm and too high to maintain the positive web stability characteristics and maintain the heat transfer capability of a standard flotation system.
U.S. Pat. No. 3,982,328 (Aktiebolaget Svenska Flaktfabriken) discloses a web dryer comprising two air bar assemblies between which a web travels, each air bar assembly comprising a plurality of parallel and spaced apart air bars, each air bar being elongate and arranged such that its longitudinal axis is transverse to the longitudinal axis of the dryer, each of the air bar assemblies including at least two sets of air bar, a first set comprising coanda air bars, each having at least two air nozzles, and a second set comprising jet impingement air bars and in which the air bar assemblies are arranged such that in use each coanda air bar from one assembly faces a jet impingement air bar from the other assembly.
The present invention is characterised in that air flows flowing from each of the air nozzles of a coanda bar converge towards the centre of this bar.
Air exiting from the jet impingement air bars causes their velocity pressure to be transferred into static pressure on the web. The air flows flowing from each of the air nozzles of a coanda bar converge towards the centre of the bar and exert a cushion pressure on the other side of the web. The effect of these opposed pressure regions has the action of suppressing the amplitude of the sine wave generated by the coanda air bars and it maximises the heat transfer capability of the nozzle system and ensures web stability.
As already explained, the term "Coanda air bar" shall include any air bar which includes nozzles and upper surfaces arranged such that air passing through the nozzles exhibits the Coanda effect.
The term "jet impingement air bar" will be taken to include an air bar exhibiting no coanda effect, in which the upper surface is perforate and air is blown through the upper surface to impinge upon the web.
The preferred embodiment of the dryer includes each of the air bar assemblies being arranged with alternating coanda air bars and jet impingement air bars, such that between each pair of coanda air bars lies a jet impingement air bar, and between each pair of jet impingement air bars lies a coanda air bar.
In addressing the aforementioned problems this invention offers the following.
1 Capability of achieving a variable evaporation requirement up to the maximum demand conditions as dictated by the process requirements.
2 Ability to process a web by supporting it on air or other gas with complete stability.
3 Energy efficient operation.
4 Low thermal inertia facilitating rapid response.
5 Compatability with the paper machine, its operation and its surroundings.
6 Greatly reduced fire risk (compared to infra red).
The nozzle system comprising coanda nozzles opposed by jet impingement nozzles gives high heat transfer coefficient, complete web stability and non-contact operation.
The jet impingement air bar, in addition to contributing considerably to the heat transfer capability of the system, also has the direct influence of suppressing a high amplitude sine wave. Because of this the system is able to utilise high air velocities at low tensions and retain complete web stability and non-contact operation.
In this manner the invention guarantees the required high evaporation rates, complete web stability and non-contact operation, irrespective of web tension which hitherto was not possible.
The coanda air bar preferred is that sold by Spooner Industries Ltd of Moorland Engineering Works, Railway Road, Ilkley LS29 8JB under the trade mark SPOONERFLOAT.
Preferably the jet impingement air bar includes a web facing surface which is perforate, preferably including a plurality of relatively small orifices.
Preferably each of the coanda, and jet impingement, air bars has mounted within it a diffuser plate to ensure even air flow.
In this system it is preferred that the air that is delivered to the nozzle system is delivered in a uniform manner with respect to the cross-machine and machine direction, in terms of both temperature and velocity of the impinging air. Preferably each air bar assembly includes at least one air feed duct capable of feeding air to the air bars, where each air bar is fed via a plurality of feed inlets spaced along the air bar, the air feed duct extending substantially along the length of the air bar and coupled to a source of pressurised air (or other gas) in the region of one end of the air bar, the air feed duct tapering along the length of the air bar, such that the cross-section of the duct is greater at the end of duct at the region of the gas source, and least at the end of the duct remote from the gas source.
This serves to ensure that gas of substantially constant pressure is fed to the air bar along its length in the cross machine direction.
The dryer preferably also includes flow regulators positioned in the air feed duct and in a gas return duct. Such flow regulators may comprise dampers, vanes, diffuser plates or valves.
The tapered duct feed and return systems with such flow regulator devices gives uniform cross-machine nozzle velocity and uniform movement of the "spent" return air.
To achieve the high evaporation rates demanded of the device it displays a very high heat transfer coefficient at elevated temperatures and impingement velocities. Typically the temperature will be in the region of 450° C. and the impingement velocity will be in the region of 70 m/s.
However, it should be noted that the apparatus can operate across a wide range of temperatures and velocities, from standard lower temperatures (as used in conventional air flotation systems) to temperatures well in excess of 450° C.
To achieve the envisaged elevated operating temperatures mentioned above the system would normally be heated by direct gas firing but the design is not limited to this method of heating and other fuel sources may well be employed (e.g. steam, oil, electricity, turbine exhaust etc).
Preferably the region of the air bars and the web will have its internal environment isolated from the surrounding environment by the use of a specially designed single slot nozzle (positioned either side of the web at entry and exit) acting as a dynamic seal curtain. Such nozzles are known in the art as `anti-overspill` nozzles, and the choice of an appropriate nozzle will be apparent to the skilled addressee of the specification. Web positioning may be achieved at entry and exit by controlling the available cushion pressure to the coanda air bars and/or the jet impingement air bars at said positions.
Preferably at least one of the air bars positioned at each of the entry and exit ends of the assembly includes a flow regulator to control the flow of gas into that air bar. Typically such flow regulator comprises a manually operable damper. Preferably both air bars at each of the exit and entry ends of the assembly include such flow regulators to give maximum control. The antispill nozzles preferably include such dampers.
To minimise dryer volume requirements only the feed ducts/chambers/nozzles etc may be housed between the paper machine frames. The external equipment such as fans, combustion chamber etc typically will be sited away from the machine and a series of ducts will convey the necessary gas movement. However, it may be possible to site them within the dryer frame in some cases.
Preferably the dryer is capable of being positioned in a confined space. Although the space available is a variable from machine to machine, in general the area into which the invention is to fit is of the order of 2 meters in machine direction and 1 meter from the web to the top of the dryer shell (i.e. 2 meters in total). However, the invention is equally applicable to larger or smaller dryers.
In many air flotation systems, it is known to have one or both of the air bar assemblies mounted to move towards and away from the other air bar assembly. This allows web feeding, inspection, repair and changing of one or more of the air bars without needing to dismantle the entire machine. It is possible for the present web dryer to include air bar assemblies movable towards and away from each other.
In this case it is preferred that at least one of the air bar assemblies is pivotably mounted with respect to a pivot axis substantially parallel to the web, at or adjacent one end of the air bars, the air bar assembly being mounted within a shell of tapered construction with its dimension in a direction perpendicular to the plane of the web tapering from a maximum in the region of the pivot axis to a minimum in the region of the end of the assembly remote from the pivot axis.
Preferably both of the air bar assemblies are pivotably mounted, about respective parallel axes and are mounted within respective shells which taper in the same direction.
Preferably the pivot point is at the drive side of the machine with the narrowest part being the front or operator side of the machine.
When access to the dryer is required, the upper and lower halves are moved apart, by pneumatic cylinders or similar actuators. It is evident that the dryer housing will not occupy any more headroom when open than when closed, and in this way the available space is maximised.
The combination of the preferred features of the tapered shell construction with a tapered air feed duct is particularly advantageous. Here the tapered duct may fit within the tapered shell, such that the gas source is at the same end of the air bar assembly as the pivot axis.
The nozzle system and duct system being housed within a tapered shell construction permits good access to the internals of the dryer for purposes of cleaning etc as well as maximising the space available.
This invention allows the dryer to fit in a very confined space on a paper machine following the size press/coater and to render the paper dry enough for intimate contact with the after-drying cylinders and thus eliminate the possibility of "picking" which leads to product quality problems.
The dryer preferably operates with a high energy efficiency.
The completed unit must be compatible with the paper machine, its operation and its surroundings.
The unit preferably possesses low thermal inertia, thus facilitating rapid response to changes in process conditions.
The use of these higher than average air temperatures dictates the use of heat resistant materials as well as design and construction techniques that will accommodate the demands imposed by high temperature operation and rapid changes thereof (e.g. thermal expansion).
The invention also encompasses a paper machine including a web dryer in accordance with the first aspect of the invention.
The invention may advantageously comprise a method for ensuring compatibility with operation of the paper machine. On start up, a paper tail is threaded via "threading ropes" and "threading wheels" mounted on or adjacent to the invention and during operation the invention is controlled by an externally mounted control panel.
A further development of the dryer will be to integrate within the dryer housing infra-red emitters, in a manner such that the positive benefits of both the Infra-Red and the forced convection flotation dryer system are realised.
BRIEF DESCRIPTION OF THE DRAWINGS
A web dryer in accordance with the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a cross-sectional view of the nozzle arrangement;
FIG. 2 is a cross-sectional side elevation of the dryer concept;
FIG. 3 is an end elevation of the dryer concept in the open position showing the proposed tapered chamber arrangement;
FIG. 4 is a diagram detailing the "air-circuit" layout.
FIG. 5 is a schematic cross-section of a coanda air bar; and,
FIG. 6 is a schematic cross-section of a jet impingement air bar.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A web dryer 1 comprises two air bar assemblies 3,5 between which a web 7 travels. Each air bar assembly 3,5 comprises a plurality of parallel and spaced apart air bars 9. Each air bar 9 is elongate and arranged such that its longitudinal axis 11 is tranverse to the direction of travel A of the web 7. Each of the air bar assemblies 3,5 includes two sets of air bar. A first set 13 comprises coanda air bars and the second set 15 comprises jet impingement air bars.
Only one of the coanda air bars 13A illustrates the web facing surface 17. FIG. 5 illustrates the air bar in more detail. The air bar is one sold under the trade mark SPOONERFLOAT by Spooner Industries Limited. The dimensions of the bar are that the bar is 104 mm wide and 130 mm in height. The length of the air bar is chosen dependant on the web width to be handled. The air bar includes an inlet 19 of dimension 300 by 75 mm through which air is fed to the air bar. On its face 17 which in use faces the web 7 a pair of parallel linear nozzles 21 through which air passes to impinge on the web to support it. The nozzles are arranged such that they are aligned with the longitudinal axis of the air bar such that the nozzles are transverse to the direction of travel of the web. A central top plate 23 lies between the nozzles 21 where each edge of the top plate 23 forms one edge of a respective nozzle 21. The edges of the plate 23 are radiused such that air flowing from the nozzle is caused to flow over the radius surface 21 and therefore towards the centre of the bar. The bar includes a series of holes 24 at its base of dimension 300 by 75 mm which act as air inlets to the bar.
Each jet impingement bar 15, only one of which 15A is illustrated in FIG. 6, includes as its web facing surface 25 a perforate plate including a plurality of small orifices through which air may be blown to impinge upon the web 7 with no exhibition of coanda effect. The dimensions of the air bar are 104 mm in width and a height of 115 mm. The perforations 26 are of diameter 5 mm.
The air bars 13,15 are arranged in each air bar assembly 3,5 such that between each pair of coanda air bars 13 lies a jet impingement air bar 15 and between each pair of jet impingement air bar 15 lies a coanda air bar 13. Moreover each coanda air bar 13 faces a jet impingement air bar 15 and each jet impingement air bar 15 faces a coanda air bar 13. At the dryer entry and exit the coanda air bars 27 and jet impingement air bars 29 have positioned in their air feed system regulating dampers 31.
Also at the environment interface at entry and exit there are positioned above and below the web anti-overspill nozzles 33 in which are also fitted regulating dampers 35. The nozzles 33 are those sold under the trade mark ANTI-OVERSPILL by Spooner Industries Limited.
Regulating dampers 31 and 35 could be electrically or electronically controlled but here are manually independently adjustable.
Within each of the air bars 13,15,27 and 29 is a diffuser plate 37 which ensures an even air flow within the air bars.
The air bars are coupled to an air distribution chamber system 39 which is connected to the air feed duct system 41. At the interfaces between the air distribution chamber 39 and the air feed duct system 41 are positioned flow regulators 43. At the interface where the air flow enters return air duct 47 are positioned flow regulators 45. As can be seen air flows from the environment in the region of the web by outlets 49.
Alongside the air feed duct system 41 the air return duct system 47 is positioned. All of the foregoing is housed within an insulated shell 51.
Regulating plates or dampers 53 are positioned at the entrance to the air feed duct system 41. The ducts conveying the gas to and from the dryer are terminated at the dryer interface. The stationary part of this interface is a substantial heavy duty membrane known as a backframe 56. The method of sealing between the backframe 56 and the air feed duct is a material to material seal, typically a metal flanged face seal 55. Alternatively a compressible gasket-type seal may be used. The flanges are adjusted such that the area for leakage between the backframe 56 and the air feed duct is minimal. This seal at this interface takes this form because the use of flexible ducts at this point would quickly result in material degradation due to high temperatures. It is possible however where space constraints permit, to use a high temperature flexible duct typically stainless steel
A seal 58 between the backframe and the insulated shell 51 is a compressible seal and as such isolates the dryer body form the surrounding atmosphere. Pneumatic cylinders 57 (or similar actuators) move the top and bottom shells 51 of the dryer to pivot them about the pivot axes 59. The shell 51 is of tapered construction with its dimension perpendicular to web travel tapering gradually from the end at which it is pivotally mounted to its other end. This means that when the air bar assemblies are in their `open` position shown in FIG. 3, the headroom required by the apparatus does not increase. This is sufficient for web threading and many maintenance operations. However if greater access is required than is afforded by movement of the shells 51 about pivot axes 59 then, provided that headroom is available, the original pivot axes 59 may be locked and the shells 51 moved about new pivot axes 60 to permit greater access. This facility would typically be utilised for extensive maintenance work. The apparatus relating to the external ancillary equipment is of standard design and is discussed in the Operation Procedure with reference to FIG. 4.
Operation of the Preferred Embodiment
With reference to FIG. 4 the operation of the air circuit layout is as follows:
When the dryer is in operation the by-pass damper 61 is closed, the air feed damper 63 and the air return damper 65 are open. The flow dampers 67 are typically adjusted to establish equal flow in the top and bottom compartments. Air is fed at a given temperature and pressure into the external air feed duct 69 and hence to the web 7.
Having impinged upon the web 7 the hot air causes the web to give up moisture. This moisture-laden airstream is drawn into the external air-return duct 71 and consequently back into the combustion chamber 73 where its temperature is raised again before being drawn into the fan 75 and recycled to the air-feed duct 69.
Combustion air and fuel 77 is supplied to the combustion burner 79 thus bringing about the temperature rise. If this alone were the air circuit then the humidity would build up to the point of saturation and, because of the introduction of the combustion air, the system would be out of balance and hence hot humid air would spill out uncontrollably into the surrounding environment.
To prevent this from happening a portion of the humid air flow in duct 71 is drawn off by an exhaust fan 81. The quantity drawn off is controlled by the exhaust damper 83 and is set to maintain the required humidity level within the dryer.
A quantity of air is introduced as "fresh" air, the cleanliness of which is guaranteed by the inlet filter 85. The amount of fresh air introduced to the system is controlled by the fresh air damper 87.
To "mass balance" the system the dampers are arranged as follows, the fresh air damper 87 is set such that the flow of fresh air and combustion air is balanced by the exhaust flow when the exhaust damper 83 is set to maintain the correct humidity conditions. To maximise the energy efficiency of the system the fresh air brought into the circuit can be raised in temperature by passing through an air to air heat exchange 89 and thereby transfer heat from the exhaust stream.
More specifically the air movement in the region of the nozzle arrangement is as follows:
The air reaches the nozzles types 13,15,27,29 & 33 in a substantially uniform manner with reference to cross machine and machine direction.
This is achieved by the following method. When considering the volumetric flow rate requirements in a cross-machine direction from back side to front side, it is clear to a person skilled in the art, that from back side to front side the volumetric flow rate required decreases as the nozzles demand for air is incrementally satisfied.
The air feed duct 41 is of a tapered cross-section to mirror this decrease in flow rate requirement, thus the velocity of the air in the duct 41 is kept to a constant, and because the air bars themselves cause a constant and uniform pressure drop on the system the air stream is discharged at a uniform velocity.
To further improve the substantially uniform nozzle velocity, internal flow regulators 43 are positioned at the interface between the air feed duct 41 and the air distribution chamber system 39 (known as fingers). These can take the form of vanes, damper blades diffuser plates, valves or a combination thereof. The purpose of the flow regulator 43 is to further equalise the flow of air from the air feed duct 41 into the finger (or plurality of fingers) 39. In this case the flow regulator is a diffuser plate. The uniformity of the nozzle velocity is further improved by the diffusers 37 located within the air bar bodies.
It is the coanda air bars 13 which have the most profound effect on the flotation characteristics displayed by the system. However if the coanda air bars were considered in isolation and the unit was operating on a web at low tension of circa 5 kg/m width, then at an operating velocity of circa 70 m/second the prevalent nozzle to material distances could be circa 40 mm and as such the heat transfer capability and the web stability would be impaired.
But when considering the system in full including the jet impingement air bars 15, the air flow is normally delivered substantially uniformly to both the coanda air bars 13 and the jet impingement air bars 15, the action of the air entering the air bars is to establish a high magnitude cushion pressure region.
The air exiting the jet impingement air bars 15 impinges on the web 7 with the effect that they contribute greatly to the heat transfer coefficient on the opposite side to that on which the coanda cushion is established. When the jet streams of air from the jet impingement air bars 15 come into contact with the web 7 they are effectively stopped and as such their velocity pressure is transferred into static pressure. The effect of these localised static pressure regions is to establish an average static pressure region above the face of the jet impingement air bars 15.
This secondary static pressure region is applied to the web 7 in opposition to the coanda cushion, which has the action of suppressing the amplitude of the sine wave generated by the coanda air bars, such that when operating the unit at 70 m/s air velocity on a web at 5 kg/m width tension, the nozzle to material distance would be circa 5-10 mm, thus maximising the heat transfer capability of the nozzle system and ensuring web stability. The standard air bars 13,15 are surrounded by other air bars and hence the forces acting upon the web are in equilibrium. However the air bars at entry and exit 27,29 have the nozzle system on one side and the external environment on the other and hence the web 7 registers a force imbalance.
Dampers 31 are adjusted such that the magnitude of the cushion generated above the coanda air bar 27 is sufficient to maintain the web 7 in the equilibrium position. The exhaust damper 83 can be adjusted such that the ambient pressure level within the dryer body is very slightly negative. However because air bars 27,29 are sited very close to the entry and exit there is still a tendency for these nozzles to cause overspill of the dryer atmosphere to the surrounding environment. To prevent this from happening dampers 35 in the anti-overspill nozzles 33 are adjusted until the internal atmosphere is prevented from escaping from the dryer enclosure.
Once the high temperature high velocity air stream has impinged upon the web 7 and caused evaporation there is a requirement for this "spent" air to be returned to the recirculating circuit. This must be achieved in a ially uniform manner in the cross-machine direction because high levels of air movement across the sheet surface could impair the product quality and in the extremes can cause the web to move or track sideways.
Substantially uniform return flow is brought about regulating the air flow at the interface into the air return duct 47 with flow regulator 45. These can be dampers,vanes,diffuser plates, valves or a combination thereof. Here they are diffuser plates. In this manner the returning flow is made to be substantially uniform across the width of the web. The dimensions of this dryer are 2 meters long by 4.8 m wide by 2 m (i.e. 1 meter at either side of the web 7.
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The invention relates to improvements in drying webs and is applicable with particular advantage, although not limited to, a process carried out in a paper making machine; that of the application of `size` or `coating`.
A web dryer (1) comprises two air bar assemblies (3,5) between which a web (7) travels, each air bar assembly (3,5) comprises a plurality of parallel and spaced apart air bars (9), each air bar (9) being elongate and arranged such that its longitudinal axis is transverse to the direction of travel (A) of the web (7), in which each of the air bar assemblies (3,5) includes at least two sets of air bar, a first set (13) comprises coanda air bars, and the second set (15) comprises jet impingement air bars.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 09/433, 593 filed on Nov. 2, 1999 now abn.
FIELD OF THE INVENTION
This invention relates to a single very light tubular building element for the construction of reinforced concrete intermediate floors/ceilings and roofs. The single building element provides the formwork for the casting in place of the structural concrete and also provides for a high quality finished ceiling at the same time. It is intended for simple installation without heavy equipment into building parts. A series of members are often intended to form an exposed surface when used as a floor or ceiling.
A series of members are constructed and often arranged to be the primary means of containing and supporting a panel or slab of concrete as it cures. An interconnected series of members, according to the present invention, also form a continuous mortar impervious formwork for a concrete slab, and presents an attractive permanently exposed ceiling surface.
PRIOR ART
There have been many suggestions for use of either or both temporary or permanent form members to construct building parts of concrete. These form members can be temporary in nature since they are removed after concrete cures, or can be contained in concrete as permanent parts.
For example:
U.S. Pat. No. 4,742,660 teaches a modular building system of extruded hollow thermoplastic structural components of rectilinear cross-section. These members are made of a special thermoplastic mixture said to resist the elements and are characterized by a fire-resistant outer skin. The concrete is poured inside the thermoplastic components which have internal apertures through which the concrete can flow from one member to another member in a group when they are joined as a wall panel, for example. When the members are to be used in construction of a roof, concrete cannot be used, and metal inserts are called for to assist in stiffening.
U.S. Pat. No. 5,729,944 discloses the use of thermoplastic structural components as permanent formwork. The forms can be used in a series to construct various structures. Concrete is poured inside the thermoplastic components which have internal apertures through which the concrete can flow from one member to another member when they are joined as a wall panel.
U.S. Pat. No. 5,397,096 is illustrative of conventional concrete forming techniques to manufacture a ribbed, reinforced concrete slab. The forming system utilizes concrete displacement pans supported on temporary framework. The patent discloses the problem of concrete leaking out of joints. The leaking material normally is without aggregate, and is sometimes referred to as mortar. When the concrete slab or slab cures, workers must remove the hardened mortar with a chisel, or the like, providing an unsatisfactory surface finish. The bottom surface is neither planar nor finished. The patent suggests the use of additional members to forestall the leakage of mortar.
U.S. Pat. Nos. 4,557,031 and 5,216,863 are illustrative of other expedients to join extruded plastic form members for use in containing concrete inside. The members are normally a part of the cured concrete structure or building component.
U.S. Pat. No. 5,535,565 is illustrative of a containment including a plurality of panels that are interconnected by connector columns and fused together by the passing of electrical current through conductors received within such elements at their points of intersection. The panels are interconnected by sliding one adjacent panel over another panel. A gasket is interposed between a pair of panels to create a watertight environment.
U.S. Pat. No. 5,535,565 is illustrative of a highly sound insulating clay tile for the construction of floors that has an outer substantially parallelepiped shape with symmetrical, laterally projecting portions that act as shoulders for the support of each tile by prefabricated reinforced concrete floor beams.
While the field of reinforced concrete formwork is well-developed, there is still the need for a relatively inexpensive easy-to-use system to form ribbed-concrete slabs with structural formwork components. The system should not be as labor intensive as prior art arrangements. It should use components that are lightweight and yet will control elastic deformation such as is often encountered when steel and aluminum alloy formwork is used to make such ribbed structures. Moreover, each element should be easily aligned with an adjacent member, the alignment means providing an impermeable alignment between adjacent members. Thus, eliminating the need of additional members (e.g. gaskets) or fusing of the adjacent members to accomplish impermeability.
Further, the members making up the formwork should not be filled with concrete, to create the slab. Similarly, the members should include an easy device for placement of reinforcement bars without the need of manual tying or securing of the reinforcement bars together.
It is also desirable to have the ability to incorporate the formwork into the slab and have it serve as an impervious formwork base, eliminating cumbersome cleaning during construction and leakage afterward, and saving the common need of a costly waterproofing membrane over the slab. The formwork should serve for the casting in place of the structural concrete and also should provide for a high quality finished ceiling at the same time, eliminating the need to plaster and otherwise enhance the aesthetic appeal of the ceiling. Finally, the formwork should facilitate hung ceiling installations and also be easily penetrable to hold threaded screws and the like.
BRIEF DESCRIPTION OF THE INVENTION
There is provided an elongated tubular member arranged to be interconnected in a series. Each member is constructed of extruded thermoplastic material, is relatively thin walled, and light in weight. In a preferred embodiment, it will weigh less than four pounds per square foot, i.e., the individual members weigh about 2 pounds per linear foot, so that a 5 meter long member weighs about 32 pounds and can be handled by only one laborer without need of special equipment. It is intended to be incorporated in structural, reinforced ribbed concrete slabs used in roofs and floors.
The members serve as a continuous mortar impervious formwork on the bottom of a poured concrete slab while it is curing. It thus avoids the leakage of concrete mortar through formwork joints during concrete pouring and cure time which leakage can result in honeycomb void defects that cause the structure to be prone to possible future corrosion of steel reinforcement contained in the concrete slab. Such corrosion is often difficult and costly to repair.
The formwork permanently serves as the bottom of the slab. It is an impervious barrier of the type essential for roof construction and thus eliminates the need for an exterior waterproofing membrane. The formwork has transverse, flexural strength and stiffness sufficient to resist vertical and lateral construction loads without significant deformation. It can bear the weight and pressure of wet concrete, needing but few transverse intermediate temporary supports directly under the hollow elements which make up the formwork. For example, a line of 4×4 wooden purlines, spaced about five feet apart over 4×4 wooden shores, also spaced about five feet apart, or equivalent simple systems of metal purlines and shores can be used.
The members are generally formed of a PVC (polyvinyl chloride) alloy conforming with Uniform Building Code (UBC). Any UBC conforming extrudable and light weight similar material of equal or better strength and durability will be suitable. This general type of theremoplastic is lightweight and easily formed by extrusion with many integral convenient features, but has lower modulus of elasticity (stiffness) than most other construction materials. For example, the modulus of elasticity of steel is more than sixty times more than in thermoplastic and the modulus of elasticity for aluminum is more than thirty times more than in thermoplastic.
The center section is like the hat crown and the wings are like a hat brim. A member is defined by a top and a parallel bottom wall interconnected by parallel side walls which are substantially perpendicular to the top and bottom walls. There is an internal generally horizontal wall between the enclosing side walls. Above that internal horizontal wall and limited by the top and side walls is formed a closed rectangular box-like conduit when viewed from an end. In that rectangular space, it is easy to install a band of fiberglass mat to improve thermal insulation of the concrete slab, if desired. Below that internal horizontal wall and connecting it with the bottom and side walls, there is a web of three shorter longitudinal internal walls. One of them is a longitudinal vertical wall extending from the center of the horizontal internal wall (at a central intersection) to the center of the bottom wall. In one embodiment, the other two web walls are symmetrical, sloped down and outward from the center intersection. The side wings taper from a relatively thick area adjacent the side wall to the narrowest area at the end where there is a finger or groove. The sloped walls, side wall bottom wall, and bottom left and right intersections between the bottom wall and side walls are thickened in the area where the wings join the side walls thereby forming an area better able to absorb bending stress which reduces consequent deformation from the side wings when wet concrete is poured above them.
In a second embodiment, the two sloped walls extend symmetrically, are sloped down and outward from a first set of two symmetrical points very close to the center intersection of the horizontal internal wall, through the side walls, and rest at points on the wings near the left and right intersections between the bottom wall and the side walls. Because the sloped walls rest on the wings, they act as tensors and increase the stiffness of each wing sufficient to counter deformation caused by vertical forces acting downward on the top of the wings. In this embodiment, there is no need to taper the thickness of all members connected at the bottom right and left intersections as there is when using the embodiment described above.
There are wing-like webs extending outwardly from each side of each member, having a lower surface, which is substantially on the same plane with the outside lower surface of the bottom wall. The outermost end of one wing has an upwardly extending finger or tongue; and the outermost end of the second wing has a groove like an inverted U, arranged upwardly with the opening facing down. The finger and groove serve as an alignment means. The groove-ending wing fits easily above the tongue-ending wing in a lapping relationship between adjacent members when such members are laid up in a series prepared to receive wet concrete. Since each member has always both wing ending types, for proper lap matching, all members for a formwork deck shall be laid with the tongue wing ending on the same side; that side corresponding with the direction in which the installation proceeds.
The construction technique of the present invention facilitates hung ceiling installations to form a plenum through which heating and air conditioning pipes or ducts are passed.
Further, the construction facilitates the accurate arrangement of steel reinforcing bars because of the unique construction of parts. The invention permits the construction of ribbed reinforced concrete slabs with about one-half the weight of concrete, which might otherwise be required, which slabs are both resistant and stiff.
OBJECTS OF THE INVENTION
It is an object of the invention to provide lightweight, thermoplastic structural formwork members constructed and arranged to be interconnected in a series to serve as formwork for ribbed concrete slabs.
Another object of the invention is to provide lightweight, inexpensive, and easy to install structural members for use in constructing ribbed concrete slabs.
Another object of the invention is to provide formwork for ribbed concrete slabs that forms a continuous impervious structure, eliminating the needs for exterior waterproofing membranes when used in roof construction.
It is another object of the invention to provide formwork which has the longitudinal and transverse flexural strength and stiffness sufficient to resist the weight of the wet and vertical and lateral construction loads, yet needing few transverse intermediate temporary supports while the concrete cures.
It is another object of the invention to provide ribbed concrete formwork having a pleasant appearing exposed surface capable of being used as a finished ceiling with regular longitudinal features or embossing which can be formed during the extrusion process at no extra cost.
Another object of the invention is to facilitate hung ceiling installation in commercial and institutional buildings where it is necessary to have a plenum for heating and air-conditioning pipes and duct work above the ceiling. The formwork provides outward indicia or other markings indicative of areas in which hanger means for the ducts and pipes may be located with assurance of sufficient holding strength of easily penetrated material, for example, to screw in hangers for the hung ceiling, ducts, and pipes.
Another object of the invention is to facilitate installation of thermal insulation for the ribbed slab.
It is yet another object of the invention to facilitate the accurate and easy installation of steel reinforcing bars and/or splice bars in association with the formwork before pouring of the concrete.
Yet another object of the invention is to provide for construction of ribbed reinforced concrete slabs using about one-half the normal weight and volume of concrete as compared to conventional forming techniques.
These and other objects, features, and advantages of the present invention will be more clearly understood and appreciated by review of the following detailed description of the disclosed embodiments and by reference to the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-section of one embodiment of a structural member according to this invention;
FIG. 2 is an alternate preferred structural member according to this invention in cross-section;
FIG. 3A is a partial cross-section of a portion of two adjacent members of the type shown in FIG. 1, having a reinforcement chair with one reinforcement bar;
FIG. 3B is a partial side view of the arrangement of the reinforcement chair of FIG. 3A;
FIG. 4A is a partial cross-section of a portion of two adjacent members of the type shown in FIG. 2, having a reinforcement chair with a plurality of reinforcement bars (or, alternatively, a reinforcement bar and a splice bar);
FIG. 4B is a partial side view of the arrangement of the reinforcement chair of FIG. 4A;
FIG. 5 is a transversal cross-section of a series of the tubular members 9 in a ribbed concrete slab 60 ;
FIG. 5A is a detail of FIG. 5 showing a reinforcing bar 53 in the concrete slab 60 above the longitudinal alignment means of an adjacent pair of the tubular members;
FIG. 5B is a perspective view of a ribbed concrete slab according to this invention;
FIG. 6 is a schematic side elevation of an arrangement of slabs of the type shown in FIG. 5, supported on vertical walls.
FIGS. 7-A, 7 -B and 7 -C are schematic illustrations of the elastic deformation of the cantilever and the maximum deflection at the tip when subject to uniform load w, and attached to an elastic element.
FIG. 8A is a cross sectional view of markings on a ceiling when using the tubular construction members according to this invention (the markings are exaggerated in this view).
FIG. 8B is a cross sectional view of the bottom walls and wings showing only the marks when using tubular construction members according to this invention.
FIG. 9 is a partial cross section of two adjacent members aligned via an alignment means having a longitudinal lobe.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 there is shown a tubular structural member 9 according to this invention. It can be generally described as shaped like a top hat in cross-section with an upright central crown and a flat brim about its bottom. It consists of a bottom surface, a top wall 10 , interconnected by a pair of substantially parallel sidewalls 12 and 13 . Protuberances 24 and 25 provide a mechanical anchorage to the tubular member after the concrete cures, to prevent any separation of the member from the concrete in the event that loads are hung at the bottom of the side walls (e.g. to avoid sliding of the member).
There is a horizontal wall 18 substantially centrally of the member 9 , parallel to the top 10 and the bottom wall or floor 11 . There is a vertical wall 19 interconnected between the bottom wall 11 and the horizontal wall 18 at a central intersection 26 . There are sloped walls 20 and 21 which extend downwardly and outwardly at the same angle to the left and right of the central intersection of the horizontal wall 18 and the vertical wall 19 , with respective opposite ends thereof intersecting the corners formed by the intersection of bottom 11 and side walls 12 or 13 , respectively. Areas 22 and 23 are referred to as the bottom left and right intersections.
There is a wing extending outwardly from each side of the member 9 , forming the brim of the top-hat cross-section. The right-hand wing 16 terminates in an upwardly extending finger or tongue 17 . The left-hand wing 14 terminates in a receiving member 15 having an opening to receive the finger 17 . In a series of members 9 , as shown, for example, in FIG. 3, the finger 17 or 17 ′ is encompassed within a receiving member 15 having an opening or groove to fit the finger 17 . Finger 17 and the receiving member 15 act as an alignment means that serves only to align a series of adjacent members according to this invention. The alignment means does not transmit between the adjacent members any structural load. Rather, each one of the matching wings is able to support independently the load directly above each wing.
The walls (sloped walls, side walls, bottom walls) and wings connecting at the bottom left and right intersections are tapered in thickness thereby providing bending stiffness against rotation of these corners. The tapering of the wings increases the stiffness of the wings which serves to absorb bending stress and reduce consequent deformation caused by the vertical construction loads of the wet concrete forces.
Each of the interior walls 20 and 21 tapers from bottom left and right intersections 22 or 23 , respectively, to the central intersection 26 . The drawings are substantially to scale and in the illustrated preferred embodiment, the taper of walls 22 and 23 is from about four millimeters at the area 22 or 23 to about two millimeters at the area adjacent to 26 . The vertical wall 19 is about two millimeters thick in the preferred embodiment. The horizontal wall 18 is about 1.5 millimeters. The top wall 10 is about 3.2 millimeters.
The bottom wall 11 likewise tapers from the center where it is about two millimeters to a thickness of about four millimeters just before the bottom left and right intersections 22 or 23 . The wings 14 and 16 taper from about four millimeters adjacent to a wall 12 or 13 to about 2.5 millimeters just before the alignment means 15 or 17 . In this embodiment, the receiving member 15 of the alignment means is about 2.5 millimeters in thickness. The receiving member 15 is curved and in the shape of an upside down “U.” The outer surface of the curved section of the receiving member 15 has a diameter of about 7.7 millimeters. The height is about 9.5 millimeters from the bottom surface of the wing 14 to the top of the curve of the receiving member 15 . The curved portion ends 2.5 millimeters from the bottom of the wall to allow insertion of a finger 17 . Finger 17 is about 2.6 millimeters thick and the opening or groove of the receiving member is about 3.0 millimeters wide.
The sidewalls 12 and 13 are about 2.5 millimeters thick from the top wall 10 to the area where the horizontal wall 18 extends across the interior of the member 9 . From there, the side walls 12 and 13 taper from about 2.5 millimeters to approximately 4.0 millimeters at the bottom left and right intersections 22 and 23 , respectively, in order to increase the stiffness of the bottom left and right intersections. The wing 16 is about 37.1 millimeters from a sidewall to the outer surface of the upwardly extending finger 17 . The finger extends upwardly about 9.3 millimeters. The wing 14 is approximately 32 millimeters from the wall 12 to the outside surface of the receiving member 15 .
In FIG. 2, there is shown a preferred embodiment of a tubular structural member according to this invention. The design of this alternative embodiment eliminates the need to taper the walls of any member connected at the bottom right and left intersections 221 , 222 (side wall, bottom wall or wing) to control within acceptable limits the deformation of the wings caused by the weight of the wet concrete.
FIG. 2 shows an embodiment that has a top 201 , a bottom wall 202 , and opposed parallel sidewalls 203 and 204 . There is a horizontal wall 205 centrally located of the member 200 , parallel to the top 201 and the bottom wall 202 . There is a vertical wall 206 interconnected between the bottom wall 202 and the horizontal wall 205 extending from the horizontal wall at a central intersection 220 . A first and second sloped wall 207 and 208 extend downwardly and outwardly at the same angle from a first set of right 209 and left 210 points proximate to the central intersection 220 . The sloped walls 207 , 208 extend through the side walls 203 , 204 , with opposite ends thereof joined at the wings 215 , 216 at a second set of right and left points 211 , 212 proximate to the bottom right and left intersections 221 , 222 formed by the bottom wall and sidewalls. In other words, the opposite ends of the sloped walls 207 , 208 rest on the wings 215 , 216 at a point proximate to the intersection 221 , 222 of the sidewalls 203 , 204 and bottom wall 202 .
In the embodiment of FIG. 2, the tensors, 207 , 208 intersect the wings at points 211 , 212 , respectively, which should be proximate to the bottom left and right intersections 221 , 222 . The tensors cover a portion of the wings between the bottom left and right intersections 221 , 222 and points 211 , 212 and form a triangle that is void of concrete. The portions of the side walls (below the intersection of the tensors with the sidewalls) and the portion of the wings between 211 , 212 and 221 , 222 respectively, are kept small to make these portions very rigid. As a result, the points from which the wings cantilever is from points 211 , 212 to the free ends of the wings. The result is that the bending moment at the attached end of the cantilever (points 211 , 212 ) and the deflection at the tip of the free end of the wings is greatly reduced. Therefore, there is no need to taper any wall or wing as there is in the first embodiment.
To further increase rigidity of the section of the member below the horizontal wall, the side walls from the right and left intersections 221 , 222 to the horizontal wall 205 may be thicker ( 203 b and 204 b ), about 3.2 millimeters thick, than the sidewalls that extend from the horizontal wall 205 to the top walls 201 ( 203 a and 204 a ), which are about 2.5 millimeters thick.
The top wall is longer to extend slightly beyond the side walls to form small protuberances 240 , 241 which provide a mechanical anchorage to the tubular member after the concrete cures, to prevent any separation of the member from the concrete in the event that loads are hung at the bottom of the side walls. Protuberances 240 and 241 are approximately 4 millimeters thick and project outward about 3 millimeters.
The sloped walls 207 , 208 are thinner, about 1.5 millimeters in thickness because they are not intended to provide any bending stiffness, but act as a tensor. The horizontal wall and vertical wall are each about 2.0 millimeters thick and the top wall is about 3.2 millimeters thick. The bottom wall or floor is about 3.0 millimeters thick. The wings are about 3.0 millimeters thick. Overall, the thickness of each wall and wing has a thickness of 3.2 millimeters.
Points 211 , 212 are about 8.0 millimeters from the bottom left and right intersections 221 , 222 of sidewalls 203 , 204 with bottom wall 202 . The distance from the bottom and right intersections to the finger 17 is about 33.6 millimeters. The distance from point 211 to the finger is about 25.6 millimeters. The distance from the bottom left intersection 222 to the receiving member is about 36.2 millimeters. The distance from point 212 to the receiving member is about 20.5 millimeters.
In the construction of the embodiments shown in FIGS. 1, and 2 , all corners, both inside and outside, should be rounded to aid in the extrusion process.
In FIG. 3A, which is a partial cross-section of some adjacent parts of an adjacent pair of structural members 9 , there is shown a wing 14 having a receiving member 15 with an opening which has received within it an upwardly extending finger or tongue 17 ′ on a wing 16 ′ of an adjacent member 9 for alignment and water-proofing purposes. The fitting relationship is such that mortar will not flow through the alignment means, thus making the deck impermeable in nature. The alignment means includes a wing 14 that has a receiving member 15 about 0.4 millimeters wider than the thickness of finger 17 to allow easy assembly, and the end of the receiving member 15 rests on top of wing 16 ′ and that contact is made tighter with the weight of the concrete. No fastening device or securing device is necessary to secure the alignment of adjacent members. This arrangement is constructed and arranged to provide a simple way to align the members while preventing passage of mortar, thereby creating an impermeable formwork,
It is not necessary to align the members of the present invention via the aligning means to form a deck. Each member could simply be laid with the finger-ending wing at the same side, right or left. Therefore, the wings with the receiving ends each will always face and lap the finger of the adjacent member. Installation proceeds in the same direction of the finger edge side, toward right or left, chosen for the finger side. Because the wing having the receiving member is longer and laps over the finger, it is subject to a slight increased deflection when receiving wet concrete than that of the wing having the finger. This difference in deflection of the wing having the receiving member causes the receiving member to press down contacting the adjacent wing (see FIG. 9 showing point of contact as 401 ). The purpose of the alignment means is to create an impermeable deck.
The present invention also includes a reinforcement chair 50 to support reinforcement bars. The chair 50 is removably mountable on the receiving member 15 of the alignment means. FIG. 3A shows a reinforcement chair 50 made also of extruded plastic, having an upward opening 51 to receive a reinforcement bar 53 and a downward opening 52 to mount the receiving member 15 of the alignment means. In this embodiment, the downward and upward openings are curved in nature to cooperate with the curved alignment means. The downward opening 52 is of sufficient size to engage in a close-fitting but loose relationship with the outer surface of revolution of the opening of the receiving member 15 . The downwardly opening 52 closely conforms to the outer surface of revolution of receiving member 15 and has legs that extend to the top of wings 14 and 16 . The upper opening 51 is sized to accept a reinforcing bar 53 in a close-fitting snap-on relationship. The legs are long enough to prevent the reinforcement chair 50 from falling to either side.
In FIG. 3B there is shown a side elevation of a portion of the parts of FIG. 3A, indicating the relationship of the reinforcing bar 53 , the reinforcement chair 50 , and the plane in which the upper surface of the wing 14 exists. The chairs are spaced about four feet apart. The chairs are about one-half to three-quarter inches long, measuring along the axis of a reinforcing bar or “rebar” as they are sometimes called.
In FIG. 4A there is a shown a second embodiment of the reinforcement chair of this invention. The shape of the reinforcement chair 80 is rectangular in nature and would, for example, serve to cooperate with the alignment means shown in FIG. 2 . No embodiment is limited to cooperate with a particular reinforcement chair and thus, may be interchangeable as long as the alignment means are of the same shape for cooperation with the reinforcement chair.
FIG. 4A shows a reinforcement chair 80 that is elevated with legs 81 , 82 above the receiving member 15 of the alignment means. The chair includes a downward opening formed by the two bottom legs, 81 and 82 , and an upward opening formed by two upper legs 83 , 84 to receive a plurality of reinforcement bars 90 (or a reinforcement bar and a splice bar). A horizontal bar 86 extends almost the length between the sidewalls of two adjacent members and serves to divide the upper legs 83 , 84 from the bottom legs 81 , 82 , and also to support the plurality of reinforcement bars. Because of the elevated nature of the reinforcement chair 80 , it is necessary to have a horizontal bar 86 that nearly extends the length between two sidewalls of two members in order to prevent the chair from falling to one side once the wet concrete is poured. Moreover, this embodiment serves to comply with fire codes and other regulations normally imposed in school buildings and other like buildings.
The upper legs, lower legs and horizontal bar are about 2.0 millimeters thick. The length of the horizontal bar is about 63 millimeters. The distance between the adjacent members in FIG. 4A is about 64.7 millimeters. The opening between the two upper legs is about 13 millimeters wide and the opening between the two lower legs is about 8 millimeters wide. The length of the chair is about 15 millimeters.
FIG. 4B shows a side view of the reinforcement chair shown in FIG. 4 A. The reinforcement bar 90 a is directly on top of another reinforcement bar 90 b due to the upper legs 83 , 84 . Ordinarily, reinforcement bars are placed right next to each other in the same horizontal plane and tied together manually for purposes of keeping such bars together in place. This embodiment avoids any manual securing of the reinforcement bars. A laborer need only drop in place the reinforcement bars or reinforcement bar and splice bar in the chair.
In FIG. 5 there is shown a plurality of the members 9 in a ribbed concrete slab 60 . There is shown a wire mesh reinforcement sheet 61 laid on the top surface of the series of the plastic members 9 . A series of parallel reinforcing bars 62 are tied to the wire mesh 61 arranged parallel to the reinforcing bars 53 , which reinforcing bars 53 are supported by a series of reinforcement chairs 50 (not shown). As can be seen, there is formed a series of hollow enclosed valleys. At the bottom of each valley, the mating alignment of adjacent members are engaged in mortar impervious contiguous relation.
Looking for the moment at FIG. 5A, which is a detail of a portion of FIG. 5, parts are enlarged to better show the relationship of reinforcing bar 53 in the concrete slab 60 .
In FIG. 5B, there is shown a perspective view of a portion of a slab construction, shown in FIG. 5 in which the hollow tubular nature of the member 9 can be better appreciated. This view emphasizes the lightweight nature of a ribbed slab using a series of hollow thermoplastic members according to this invention.
In FIG. 6, there is shown a ribbed concrete slab as it might be supported in a building. Element 63 is an outside wall and element 64 is an intermediate wall or beam support. Thermoplastic members 9 and 9 ′ are shown in an appropriate fashion supported by the walls 63 and 64 . Top rebar 62 is placed exactly above the intermediate supports as shown in FIG. 6 . The exposed nature of the ceiling is likewise schematically demonstrated. In FIG. 6, we have shown concrete poured about the ends of the slabs on top of the walls. There are simple means, like tape, provided to prevent uncured concrete from entering the plastic members 9 and 9 ′. The top rebar 62 serves to resist the reverse bending force that occurs above the intermediate support and also to avoid cracking through the joint between 9 and 9 ′. A series of such top rebars is similarly positioned across all such interior joints over the length and width of the structure.
Now turning to FIGS. 7A-7C, as stated above, the wings project outward from the bottom left/right intersections (Tube) in the same plane of the bottom, as if extensions of the bottom wall formed a ceiling. The concrete ribs of the slab are formed between the side walls of the parallel adjacent members and have the wings of those members forming the bottom of each rib and matching their edges to prevent leakage of the mortar from the wet concrete above them. In the first and second embodiment, the match of the wings is at the center of rib bottom form. Each wing carrying structurally and independently the wet concrete above it, being in cantilever from the side wall in one embodiment and mostly in cantilever (from the points 211 , 212 outward in FIG. 2) in the second embodiment.
FIGS. 7A-7C illustrate the elastic deformation of the cantilever and the maximum deflection at the tip when subject to uniform load w, and attached to an elastic element.
FIG. 7A shows the deformation assuming the cantilever element is elastic but the attachment (rest of the member) of it is absolutely rigid. The tip deformation will be called Δ 1 .
FIG. 7B shows the deformation assuming the cantilever is absolutely rigid, but the attaching element (rest of the member) is deformable when subject to the bending moment caused by the cantilever element. The elastic deformation of the attaching element will be a rotation of the attaching plane, represented by the angle ø. The tip of the cantilever will move downward a distance Δ 2 =ø×S.
FIG. 7C represents the actual condition, applying the principle of superposition to the above assumptions made for FIGS. 7A and 7B. The actual deflection of the tip of the cantilever being Δ=Δ 1 +Δ 2 . The analysis shows the importance and the need to control the rotation of the point of attachment of the wing to reduce Δ by reducing Δ 2 .
As a result, there is a need to provide substantial stiffness both to the wings in cantilever and to the tube at the two bottom corners where these wings are attached, to avoid unpleasant deflection of the wings. In the first embodiment shown in FIG. 1, this is done by providing the bottom left and right intersections formed by the sidewalls and bottom wall (including sloped walls) with bending stiffness against rotation of these corners. The tapered thickness of these walls, thicker at the bottom left and right intersection and thinner at the other ends, is an effective form to obtain the needed rigidity. In the second embodiment, a thin tensor extends out to the top of each wing, reducing the cantilever portion of the wing and the forces that cause rotation of the bottom right and left intersections. With these conditions, the uniform thickness is rigid enough and easy to extrude.
It can also be appreciated that the structure of this invention, including the plastic members 9 facilitate hung ceiling installation in commercial and industrial buildings where it is necessary to have plenums to pass heating and air-conditioning ducts and pipes. In the embodiment shown in FIGS. 8A and 8B, longitudinal markings 300 at the intersection of the side walls 203 , 204 with the bottom wall 202 serve to delineate the boundaries of the side walls 203 , 204 so that a threaded screw or other like material can be placed in the middle 301 of the bottom of the side walls 203 , 204 . As shown in FIG. 8B, after installation of a slab construction according to this invention, these marked areas 300 will be detectable on the exposed ceiling surface (the variation in thickness of the wings and bottom walls in FIG. 8A and 8B are exaggerated for exemplary purposes). Threaded screws easily penetrate the plastic material from which members 9 are made of and are much less expensive and easier to install than power-driven nails and the like, which normally are used with concrete slabs. The variation in the visible texture at the bottom-exposed surface is about 0.5 millimeters high.
The hollow interior of the structural members 9 and 40 facilitate the installation of thermal insulation, for example, by filling the longitudinal tubular portions with fiberglass, either blown or by inserting pieces of insulation mats.
Another embodiment for the alignment means is shown in FIG. 9 which includes an alignment means having a finger with a longitudinal lobe 400 . The lobe 400 is a means of separation that serves to ensure that the finger 17 does not come in direct contact with the left inner side of the receiving member 15 , to avoid capillary action to raise water between them. As shown in FIG. 9, the receiving member comes in contact with the wing having the finger at point 401 .
Use of the members according to this invention facilitates the accurate and precise arrangement of steel reinforcing bars, not only because of the novel seat construction, but because it can be accomplished without the cost of the labor involved in tying reinforcing wires which is the usual practice.
Construction according to this invention provides for reinforced concrete slabs of about one-half the weight and concrete volume for slabs with the same strength and stiffness requirements. Approximately 80 millimeters or 3.25 inches average thickness of concrete (from top of slab to top of wings buried in concrete) can be used to build a roof slab span of about six meters or 20 feet. In residential intermediate size floor slabs, they can be up to about five meters or 16 feet at the same concrete thickness. Conventionally, the latter would require 150 millimeters or six inches in normal reinforced concrete slab.
The time and labor required to build a ribbed concrete slab, according to the invention, is substantially reduced for many reasons. For example, the task of placing the formwork is much simpler because the present invention is a single component that can be installed easily and efficiently without heavy equipment or special craftsmanship; afterward the component is not removed, but stays permanently integrated in the concrete floor or roof. Additionally, the amount of time to install slab reinforcement is drastically reduced because there is no need to wire the reinforcing bars in place. Since about one-half the volume of concrete is required, additional time and labor are saved. No formwork stripping is needed. Ceiling plastering, painting and the like can be eliminated.
In the above description, exemplary dimensions have been given in describing the operation of structural members when incorporated in a ribbed concrete slab forming process. It should be understood by those skilled in the art that other dimensions can be calculated, using conventional techniques, to determine appropriate dimensions for installations other than exemplary ones described herein.
For performance verification we have used properties of available thermoplastic material. It should be likewise understood that plastic materials other than the exemplary one described above which will provide the properties described to a member made therefrom are considered the functional equivalent of those described herein and can thus likewise be used.
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A very lightweight tubular building element for the construction of reinforced concrete floors and roofs; providing the formwork for the casting in place of the structural concrete and a high quality finished ceiling at the same time. It is a single component that can be installed easily and efficiently without heavy equipment or special craftsmanship; afterward the component is not removed, but stays permanently integrated in the concrete floor or roof. It forms a deck that is impervious, eliminating cumbersome cleaning during construction and leakage afterward, saving the common need of a costly waterproofing membrane over the slab. The formwork deck, composed of a plurality of the invention component, weighs less than four (4) pounds per square foot; and a single component for a common 15 feet span weighs less than 30 pounds, which can be easily handled by only one laborer. Furthermore, in forming the concrete, the plurality of this component creates hidden closed air spaces in the slab that saves concrete, reduces the overall weight of the building and provides better thermal insulation in comparison with a conventional solid concrete slab of same span, thickness and strength.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a division of application of U.S. Ser. No. 09/976,537, filed Oct. 12, 2001 now U.S. Pat. No. 6,852,654.
TECHNICAL FIELD
The invention disclosed herein is directed to a hydroentangled nonwoven fabric and the making thereof, whereby the outer surface fibers of a single fibrous batt are highly hydroentangled and the inner fibers of the single fibrous batt are lightly entangled, the resulting fabric thus exhibits a low linting, lofty structure, and favorable tactile and ductile softness while obtaining sufficient physical strength.
BACKGROUND OF THE INVENTION
The use of natural fiber materials in medical and industrial applications has been found to be highly advantageous in situations where a non-linting, absorbent pad or wiper is required. A material that has been employed in such applications is found in the Webril material from the Kendall Company of Massachusetts. The Webril material is a compressed, mercerized cotton fibrous batt. The mercerization process involves the swelling of the natural cotton's ribbon like profile into an approximately round profile of larger diameter. Typically, caustic washes are utilized while the cotton batt is under tension to induce the swelling of the cotton fiber. Because of the use of a caustic solution, it is necessary to subsequently treat the cotton material with an acidic solution so as to neutralize the material and render it useable. A number of complicated steps are required to successfully perform the process, with a significant amount of environmentally harmful effluent being produced.
In the interest of forming natural fiber nonwoven pads or wipers without the by-products of mercerization, the application of a resin binder in conjunction with hydroentanglement was explored as evidenced by U.S. Pat. No. 2,862,251, No. 3,033,721, No. 3,769,659, and No. 3,931,436 to Kalwaites et al., and U.S. Pat. No. 3,081,515 and No. 3,025,585 to Griswold et al, the disclosures of which are herein incorporated by reference. The application of resin binder was found to have a deleterious effect on the softness of the corresponding nonwoven fabric.
The findings by Evans, U.S. Pat. No. 3,485,706, the disclosure of which is herein incorporated by reference, suggested that the impedance of energetic water streams on a fibrous batt could produce a nonwoven fabric by the entanglement of those fibers with one another through the depth of the fibrous batt, thus obviating the need for a resin binder. However, the action of the water streams upon the fibrous batt and the action of entangling the fibers result in a fabric having significantly decreased bulk, and correspondingly decreased tactile and ductile softness.
Various attempts have been made in order to obtain a durable natural fiber nonwoven fabric while maintaining sufficient strength and softness. In U.S. Pat. No. 5,849,647 to Neveu, herein incorporated by reference, a hydrophilic cotton stratified structure is formed by interceding an air-randomized core in between two previously formed, highly fiber oriented carded layers. The stratified layers are subsequently treated with a soda liquor which is then boiled off to render an integrated structure. While a cotton structure performed by the manner described can render an ultimate material that is low linting, the material must undergo substantial processing in the forming of separate and distinct layers and the juxtaposition of those layers during the caustic integration step. U.S. Pat. No. 4,647,490 to Bailey et al., the disclosure of which is herein incorporated by reference, formed an apertured, cotton fiber nonwoven material by hydroentanglement induced by oscillating water streams. In the Bailey process, the fibers of the fibrous batt are washed down and through the fibrous batt in order to entangle the fibers and form apertures in the fabric. U.S. Pat. No. 4,426,417 to Meitner et al., the disclosure of which is herein incorporated by reference, incorporated the use of thermoplastic meltblown during the formation of a fibrous batt as a means for attaining the loft for absorbency and maintain sufficient physical strength by bonding the fibers together. As the nature of the Meitner process is based upon the total and effective binding of the fibers to the thermoplastic meltblown there are potential issues with unbound or loosely bound fibers being disengaged from the meltblown.
Given the prior art attempt to form a non-linting, soft and yet strong absorbent materials, there remains a need for a nonwoven fabric exhibiting these characteristics and yet is formed in an expeditious and uncomplicated manner.
A method for forming a suitable nonwoven fabric meeting the aforementioned requirements has been identified in the application of fluidic energy such that a single fibrous batt is imparted with a highly entangled surface of outer fibers while retaining the loft and absorbency of a lightly entangled central layer of core fibers.
SUMMARY OF THE INVENTION
The present invention is directed to a method of forming a nonwoven fabric, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired.
In accordance with the present invention, a method of making a nonwoven fabric embodying the present invention includes the steps of providing a fibrous batt comprising a fibrous matrix. While use of natural fibers is common, the fibrous matrix may comprise synthetic fibers or blends of natural and synthetic fibers. The synthetic fibers are chosen from the group consisting of polyacrylates, polyolefins, polyamides, and polyesters and combinations thereof. Further, the synthetic fibers may comprise homogeneous, bicomponent, and/or multi-component profiles and the blends thereof.
In a particularly preferred form, the fibrous batt is carded and cross-lapped to form a fibrous batt. The fibrous batt is then continuously indexed through a station composed of a rotary foraminous surface and a fluidic manifold. Fluid streams from the fluidic manifold impinge upon the fibrous batt at a controlled energy level so as to integrate a portion of the overall fibrous content. The energy level is controlled such that the energy is sufficient to induce high levels of entanglement in the surface fibers, but has insufficient transmitted energy to induce high levels of entanglement of the inner fibers. A plurality of such stations can be employed whereby fluid streams are at the same or differing energy levels, impinging one or alternately both surfaces of the fibrous batt. The resulting differentially entangled nonwoven web exhibits a highly entangled fibrous outer surface and a lightly entangled fibrous core.
Subsequent to hydroentanglement, the present method further contemplates the provision of a three-dimensional image transfer device having a movable imaging surface. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, the disclosure of which is hereby incorporated by reference. In a typical configuration, the image transfer device may comprise a drum-like apparatus that is rotatable with respect to one or more hydroentangling manifolds.
It is within the purview of this invention that tension control means can be employed to further enhance the physical performance of the resulting lofty material.
A further aspect of the present invention is directed to a method of forming a nonwoven fabric which exhibits a sufficient degree of softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications. The fabric exhibits a high degree of loft and absorbency, thus permitting its use in those applications in which the fabric is applied as a cleaning wipe. Further, the material exhibits pleasant aesthetics, thus lending itself to application in medical applications.
A method of making the present durable nonwoven fabric comprises the steps of providing a fibrous matrix or batt, which is subjected to controlled levels of hydraulic energy. A homogeneous cotton fibrous batt has been found to desirably yield a fabric with soft hand and good absorbency. The fibrous batt is formed into a differentially entangled nonwoven fabric by the application of sufficient energy to entangle only the outer layers of the fibrous batt. Subsequently, the fabric can be passed over an image transfer device defined by three-dimensional elements against which the differentially entangled nonwoven fabric is forced during further application of further energy, whereby the fibrous constituents of the web are imaged and patterned by movement into regions between the three-dimensional elements of the transfer device.
It is within the purview of the present invention that physical property altering chemistries can be incorporated into the resulting differentially entangled fabric. Such chemistries include for example antimicrobial and anti-static agents which can be durably applied to the constituent fibers of the fibrous batt, to the fibrous batt during manufacture, and/or to the resulting fabric.
Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of an apparatus for manufacturing a differentially entangled nonwoven fabric, embodying the principles of the present invention; and
FIG. 2 is a diagrammatic view of five consecutive entangling sections and an image transfer station.
FIG. 3 is a cross-sectional view of a differentially entangled nonwoven fabric of the present invention, magnified at 20×; and
FIG. 4 is a cross-sectional view of the differentially entangled nonwoven fabric shown in FIG. 2 , magnified at 40×; and
FIG. 5 is a cross-sectional view of the differentially entangled nonwoven fabric shown in FIG. 3 , magnified at 10×, the upper and lower highly entangled surfaces having been pulled away from the lightly entangled central fibrous layer.
DETAILED DESCRIPTION
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
The present invention is directed to a method of forming nonwoven fabrics by hydroentanglement, wherein the outer surface of the fabric is substantially more entangled than the core layer. Hydroentanglement by this method is controlled by the application of fluidic energy such that the energy imparted into fibers of the fabric is sufficient to highly entangle only the outer fibers. The inner fibers are lightly entangled such that the overall structure is resistant to separation of the layers, yet retain much of the loftiness or bulk of the fibrous core layer that is responsible for tactile and ductile softness as well as absorbency. By advancing the fibrous batt with a relatively low tension through one or more entanglement stations, differential fiber entanglement is achieved, with the physical properties, both aesthetic and mechanical, of the resultant fabric being desirably achieved.
In accordance with a further aspect of the present invention, a nonwoven fabric can be produced which can be employed in medical applications such as undercast padding, with the fabric exhibiting sufficient strength, softness, drapeability, extensibility, and cushioning qualities. The level of entanglement of the nonwoven fabrics for this application may be controlled such that the level of entanglement of the surfaces is reduced so that the fibrous inner layer can retain further loft. In the alternative, the surface entanglement can be increased while retaining a somewhat reduced loftiness of the fibrous inner layer so that the surface layers are extremely resistant to linting. A material of this nature is found to have use in the graphic arts and lithography as it can be employed as a non-abrasive, absorbent wiper. It is within the scope of the present invention to control the level of entanglement in the resulting fabric to obtain materials with varying degrees of loft and linting performance.
Nonwoven fabrics are frequently produced using staple length fibers, the fabric typically has a degree of exposed surface fibers that will lint if not sufficiently retained into the structure of the fabric. The present invention provides a finished fabric that can be cut, processed or treated, and packaged for retail sale. The cost associated with forming and finishing steps can be desirably reduced.
With reference to FIG. 2 , therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous batt that typically comprises natural fibers, but may comprise synthetic staple fibers and natural/synthetic fiber blends. The fibrous batt is preferably carded and cross-lapped to form a fibrous batt, designated P. In a current embodiment, the fibrous batt comprises 100% cross-lap fibers, that is, all of the fibers of the web have been formed by cross-lapping a carded web so that the fibers are oriented at an angle relative to the machine direction of the resultant web. In this current embodiment, the fibrous batt has a draft ratio of approximately 2.5 to 1. U.S. Pat. No. 5,475,903, the disclosure of which is hereby incorporated by reference, illustrates a web drafting apparatus.
FIG. 2 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous forming surface in the form of belt 02 upon which the fibrous batt P is positioned for pre-entangling by entangling manifold 01 into a wetted, lightly entangled fibrous web P′. Pre-entangling of the fibrous web is subsequently effected by movement of the web P′ sequentially over a drum 10 having a foraminous forming surface, with entangling manifold 12 effecting entanglement of the web. Further entanglement of the web may be effected on the foraminous forming surface of a drum 20 by entanglement manifold 22 , with the web subsequently passed over successive foraminous drums 30 , 40 and 50 , for successive entangling treatment by entangling manifolds 32 , 42 and 51 . The total, optimal energy input to the fibrous batt to give the desired level of surface entanglement is in the range of about 0.027 to 0.046 hp-hr/lb.
The entangling apparatus of FIG. 2 may further include an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 61 , 62 , 63 and 64 , which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed. The total energy applied to the fibrous batt of the imaging manifolds is adjusted to maintain the energy input in the range of about 0.027 to 0.046 hp-hr/lb.
The present invention contemplates that the fibrous web P′ be advanced onto the moveable imaging surface of the image transfer device at a rate which is substantially equal to the rate of movement of the imaging surface. A J-box or scray can be employed for supporting the precursor web P′ as it is advanced onto the image transfer device to thereby minimize tension within the fibrous web. By controlling the rate of advancement of the fibrous batt P and the web P′ through the process so as to minimize, or substantially eliminate, tension within the web, differential hydroentanglement of the fibrous web is desirably effected.
FIG. 3 and FIG. 4 show a cross-section of a material produced by the present invention at 20× and 40× magnification, respectively. It should be noted that the “upper” and “lower” layers correspond to the highly entangled outer fibers of the fibrous batt.
FIG. 5 show a cross-section of the same material as depicted in FIG. 3 and FIG. 4 , whereby the outer highly entangled layers have been pulled apart from the lightly entangled central core fibers.
Manufacture of a durable nonwoven fabric embodying the principles of the present invention is initiated by providing the precursor nonwoven web preferably in the form of a natural and/or synthetic fibers, most preferably a cotton or cotton blend, which desirably provides good tactile and ductile softness and absorbency. During development, it was ascertained that fabric weights on the order of about 1 to 8 ounces per square yard, with the range of 2 to 5 ounces per square yard being most preferred, provided the best combination of softness, drapeability, absorbency, and durability.
EXAMPLES
Example 1
Using a forming apparatus as illustrated in FIG. 1 , a nonwoven fabric was made in accordance with the present invention by providing a fibrous batt comprising 100 weight percent cotton fiber. The fibrous batt had a basis weight of 3.3 ounces per square yard (plus or minus 7%). The fibrous web was 100% carded and cross-lapped, with a draft ratio of 2.5 to 1.
The fabric comprised 100 weight percent cotton as available from Barnhardt Manufacturing Company under code number RMC#2811. The fibrous batt was entangled by a series of entangling manifold stations such as diagrammatically illustrated in FIG. 1 and in greater detail in FIG. 2 . FIG. 2 illustrates disposition of fibrous batt P on a foraminous forming surface in the form of belt 02 , with the batt acted upon by a pre-entangling manifold 01 operating at 40 bar to form a wetted and lightly entangled fibrous web P′. Pre-entangling of the fibrous web is subsequently effected by movement of the web P′ sequentially over a drum 10 having a foraminous forming surface, with entangling manifold 12 , operating at 40 bar, effecting entanglement of the web. The web then passes through a series of entangling stations comprising drums having foraminous forming surfaces, for entangling by entangling manifolds, with the web thereafter directed about the foraminous forming surface of a drum 20 for entangling by entanglement manifold 22 . The web is thereafter passed over successive foraminous drums 30 , 40 and 50 , with successive entangling treatment by entangling manifolds 32 , 42 and 51 . In the present examples, each of the entangling manifolds included 120 micron orifices spaced at 42.3 per inch, with manifolds 22 , 32 , 42 and 51 successively operated at 0, 50, 0, and 0 bar, with a line speed of 20 meters per minute. The total energy input into the fibrous batt is calculated to be 0.034 hp-hr/lb. A web having a trimmed width of 120 inches was employed.
Comparative Example
The comparative example is selected from a commercially available product in the form of Webril 100% Cotton Undercast Padding as available from the Kendall Company. This product is formed by compression forming cotton fiber during a mercerization process.
The accompanying Table 1 sets forth comparative test data for a fabric made by the present invention compared against a commercially available mercerized cotton fabric. Testing was done in accordance with the following test methods.
Test
Method
Basis weight (ounces/yd 2
ASTM D3776
Bulk (inches)
ASTM D5729
Tensiles MD and CD Grabs (lb/in)
ASTM D5034
Elongation MD and CD Grabs (%)
ASTM D5034
Tensiles MD and CD Strips (lb/in)
ASTM D5035
Elongation MD and CD Strips (%)
ASTM D5035
Absorbent capacity (%)
EDANA 10.3
Airborne particle shedding (Helmke drum)
IEST-RP-CC003.2*
*IEST-RP: Institute of Environmental Sciences and Technology Recommended Practice. The materials were cut in to samples measuring nominally 6 inches by 9 inches, and the unfinished edges were not sewn under before testing.
The physical test data for Example 1 and the Comparative Example are given in Table 1. The data in Table 1 show that the nonwoven fabric manufactured by the present invention has more uniform performance versus the comparative example when comparing the machine direction to the cross direction tensile and elongation properties. The materials were also tested for particle shedding. The material manufactured by the present invention exhibited a lower average number of particles shed for each of the particle sizes examined. For particle sizes less than or equal to 1 micron, the material manufactured by the current invention shed 2 to 3 times fewer particles.
From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
TABLE 1
Comparative
Physical Property
Units
Example 1
Example
Basis Weight
osy
3.3
3.1
Bulk
in
0.04
0.03
Strip Tensile - MD
lb./in.
1.1
1.5
Strip Tensile - CD
lb./in.
0.7
0.2
Combined Strip Tensile/Basis Weight
0.5
0.5
Strip Elongation - MD
%
30.0
25.0
Strip Elongation - CD
%
73.8
80.6
Combined Strip Elongation/Basis
31.1
33.7
Weight
Grab Tensile - MD
lb./in.
4.4
2.5
Grab Tensile - CD
lb./in.
3.7
0.9
Combined Grab Tensile/Basis Weight
2.4
1.1
Grab Elongation - MD
%
45.0
34.0
Grab Elongation - CD
%
43.5
108.1
Combined Grab Elongation/Basis
26.5
42.5
Weight
Absorbent capacity
%
2000
1300
TABLE 2
Particles (×10 3 )/min/m 2
Parti-
Parti-
Parti-
Parti-
cles
cles
cles
cles
Particles
Particles
≧0.5
≧0.7
≧1.0
≧2.0
≧3.0
≧5.0
Sample
μm
μm
μm
μm
μm
μm
Example 1
37.9
32.5
26.3
16.1
9.9
5.4
(3.5)*
(2.6)
(2.3)
(1.6)
(1.2)
(0.9)
Comparative
99.9
76.1
52.0
24.2
13.2
6.8
Example
(28.8)
(22.3)
(15.7)
(8.1)
(4.6)
(2.6)
*Numbers in parentheses represent the standard deviation.
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The invention is directed to a hydroentangled nonwoven fabric, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired. Fabrics formed in accordance with the present invention exhibit a sufficient degree of softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications such as cast padding or orthopedic wraps.
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This application is a continuation of Ser. No. 08/668,593, filed Jun. 19, 1996, now U.S. Pat. No. 5,799,821. Ser. No. 08/668,593 is a continuation of Ser. No. 08/282,950, filed Jul. 29, 1994, now U.S. Pat. No. 5,562,231.
FIELD OF THE INVENTION
This invention relates to a substantially circular tablet dispenser component system which may be adapted for a variable day start of a prescribed periodic tablet regimen. Also provided are a tablet dispenser kit, a tablet package adopted for filling the tablet dispenser system, methods of filling the tablet dispenser of the invention and methods of administering a prescribed regimen of medication using the tablet dispenser system of the invention.
BACKGROUND OF THE INVENTION
Medicaments and other pharmaceutical preparations are often prescribed for patients on a time related or scheduled dispensing basis. Examples of tablets or pills that are prescribed in a set periodic regimen include tablets or pills adapted for oral ingestion that are used for birth control, for regulating blood pressure, for regulating blood lipids, as antibiotics and for treating a variety of other ailments such as diabetes. Such extended time periodic regimens are particularly adaptable to preventative medicine (e.g. regulating blood pressure or birth control) or for treatment of chronic ailments which all require a relatively long course of therapy.
The amount of drug provided in a solid form pharmaceutical preparation such as a tablet or pill is inherently controlled so that each tablet contains a fixed amount of dosage so that there is little or no confusion as to the amount which should be taken. Variability in pharmaceutical administration is often, if not invariably, attributable to patient uncertainty, forgetfulness and/or confusion as to whether or not a tablet has been taken at the prescribed rate and time. This problem can be compounded when the dosage is to be repeated a number of times daily or when multiple medicaments are prescribed or when medicaments are to be taken over a long course of therapy which may extend from weeks to years. This problem may be applicable to most every type of patient including the elderly, the chronically ill (who may be in a weakened state), and the active person engaged in a long term course of treatment such as contraception or hormone replacement therapy.
As a result of problems of confusion, uncertainty or forgetfulness a patient may in reality take more or less than the prescribed rate of dosage that is indicated, thereby, inadvertently altering the prescribed course of treatment. To assure maximum effectiveness of medication prescribed it is desirable to provide a dispenser that will aid the patient in adhering to the prescribed time schedule for dosing whether that be once daily, multiple daily doses or less frequent doses.
Tablet dispensers and devices for dispensing solid form pharmaceutical preparations such as tablets or pills over a time related sequence are known. Examples of such a tablet dispenser is disclosed in U.S. Pat. No. 4,165,709 which provides for a dispenser which allows a user to take a tablet on a prescribed basis, e.g. a daily basis, by providing an indicator that denotes the days of the week. The disclosure of this patent is hereby incorporated herein by reference. No provision is available in this device for enabling one to preset a specific day of the week in which the first designated pill in a differing series of pills is to be taken in a fashion that is simple and efficient. For example, if an indicator mechanism is not adjustable and is preset to require that the first pill of a regimen made up of different pills is to be taken on a particular day of the week, such as Sunday, and a user is prescribed the medication on a Monday, the user will be at risk for a period of time from Monday to the following Sunday. Producing seven different dispensers that will cover the start of each day of the week is a possible, albeit an impractical, solution to this problem.
Other patents such as U.S. Pat. Nos. 4,915,256, 4,646,936 and 4,667,845 describe various pill dispensers which provide for a daily indicator which may designate the period when particular pills are to be taken and can be preset to start the regimen on any day selected by the user. While such pill dispensers accomplish a desirable end of providing for any day start of a prescribed regimen with means for pills to be dispensed on a given day, such are not entirely practical for various reasons. These devices may be either complicated to use or difficult to refill. For example, a counter clockwise rotation of a circular pill dispenser may be difficult to understand and unnatural for a user; a design requiring multiple steps which may be erroneously taken out of sequence could lead to patient confusion or frustration and/or a noncompliant package, whereby a designated initial pill is not provided in the desired initial position in the dispenser.
It is therefore an object of the present invention to provide a unique design for dispensing tablets which is simple and intuitive to use, readily refillable by the patient/consumer and relatively foolproof, i.e. assures compliance and avoids inadvertent mistakes. Further, the present invention is intended to provide a dispensing system which can provide a prescribed regimen of pills in a consistent manner with a high degree of confidence while also providing an any day start feature. Additional objects and advantages of the invention will be set forth, in part in the description which follows and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention are realized and obtained by means of the devices, combinations, and methods particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
To achieve the objects and purposes of the invention, as embodied and fully described herein, the present invention provides a tablet dispenser component system comprising as a first component a rotatable substantially circular unidirectional knob having indicators of periodicity thereon. The rotatable knob is encircled with a notched skirt comprising a plurality of notches spaced substantially equally apart.
A second component comprises a substantially flat support having a single tablet dispensing aperture and a rising wall portion protruding therefrom to form an interior cup portion. A third component comprises a center axis means which is engaged and fixed onto the flat support. A first engagement means is provided whereby the rotatable knob is rotatably joined to the flat support. A second engagement means is provided comprising unidirectional ratchet means to form a functional system with the rotatable knob for unidirectionally rotating the rotatable knob in a circular fashion about the center axis means.
The rotatable knob and either the flat support or central axis means have unidirectional ratchet means comprising a plurality of ratchet stops corresponding to a single space or notch on the notched skirt. In preferred embodiments the ratchet means comprises a ratchet track and spring pawls for positive engagement into the track to provide for each ratchet stop. The track and pawls may be located on the rotatable knob and fixed center axis or flat support. For example, the track may be located on the rotatable knob and the spring pawls located below the rotatable knob on the flat support or the track may be located on the center axis means and the spring pawls located on the rotatable knob.
The fourth component of the system comprises a separate and removable tablet package adapted to fit over the rotatable knob with means to positively engage the notched skirt such that the two components rotate in unison. The tablet package comprises a plurality of collapsible tablet pockets each containing a tablet arranged substantially circularly about the package. The spacing of the tablet pockets corresponds to each stop of the ratchet means whereby a new tablet is placed over the tablet dispensing aperture upon the positive engagement of each stop on the ratcheted rotatable knob. The tablet pockets are lidded with a frangible membrane which is interposed between the pockets and the single tablet dispensing aperture of the support. A tablet is dispensed from the package by collapsing the pocket which is in registry with the aperture thereby urging the tablet to fracture the membrane and pass through the aperture. The collapsible tablet pockets are formed to accommodate tablets of substantially circular, non-circular or caplet-like shape. In preferred embodiments the tablet package is fixed to a substantially rigid or stiff platform piece comprising a plurality of tablet apertures which correspond to the tablet pockets and one or more, preferably two, sprocket lugs on the interior thereof to positively fit in and engage the notched skirt.
In preferred embodiments of the tablet dispenser of the invention the substantially flat support and interior cup portion, formed by wall portions rising from the flat support base is provided with means for retaining the tablet package and for interlocking the tablet package in place upon engagement of a first stop of the unidirectional ratcheted and rotatable knob. The tablet package is removable from the support means upon completion of a full rotation of the ratcheted and rotatable knob. In a particularly preferred embodiment, the rotatable knob comprises a calendared ring which is unidirectionally rotatable about the fixed center axis in a clockwise direction wherein the notched skirt is attached to the rotatable ring portion thereof. The fixed center axis preferably has an indicator mark thereon aligned with the single tablet dispensing aperture of the flat support component.
In other preferred embodiments of the invention the tablet package has at least two complementary projections to positively engage at least two notches in the notched skirt when fitted over the rotatable knob. In preferred embodiments, the collapsible tablet pockets are formed to accommodate tablets of substantially circular, noncircular or caplet-like shape.
In a particularly preferred embodiment of the invention the substantially flat support is adapted with means for receiving, orienting and interlocking the tablet package by the provision of at least two, preferably three, inward extending ledges protruding from the rising wall portion therefrom. The shape and orientation of the ledges correspond to at least two, preferably three, complementary recesses on the tablet package, thus permitting reception of the tablet package onto the flat support in a single initial position of tablet orientation about the flat support. A designated tablet is positioned above the tablet dispensing aperture at the initial tablet position and the tablet package is interlocked onto the base upon dispensing of the initial tablet followed by a single advance of the calendared rotatable knob whereby the tablet package underlaps the ledges and is held in place thereby. The tablet package is therefore not disengageable or removable until a complete rotation of the knob returns the tablet package to the initial tablet position.
In particularly preferred embodiments the inward extending ledges are spatially arrayed, preferably asymmetrically, to inhibit the receipt of the package on the substantially flat support and the disengagement, discharge or removal of the tablet package from the substantially flat support at any position other than the initial tablet position. Further, the inward extending ledges are preferably, arrayed, shaped or sized to receive or disengage with the complementary notched tablet package only at the initial tablet position.
In preferred embodiments of the system of the invention the rotatable knob is marked with at least one set of the seven days of the week whereby each of the markings is oriented to a single tablet position in the tablet package corresponding to an indicated day of the week when engaged in the flat support portion. A single tablet corresponding to an indicated day of the week is fed over the single tablet dispensing aperture of the flat support portion upon each advance of the positively engaging stop of the calendared rotatable knob to the subsequent day of the week. The calendared rotatable knob is preferably provided with days of the week in at least three sets of seven images on the rotatable knob. Any setting of the calendared knob in relation to the indicator mark(s), thus, may constitute a predisposed start day setting for the package.
In preferred embodiments the tablet dispenser system comprises a lid or cover portion which fits over the support base to provide an enclosed compact package. Preferably, the lid and support include interlocking means for engaging the compact package in a closed position when not is use.
In other embodiments the invention is provided with medicament or a tablet dispenser kit for the administration of a particular medicinal regimen comprising a tablet dispenser which is filled with the prescribed medicament in a preset prescribed orientation which complies with the periodic regimen of administration indicated. In particularly preferred embodiments, the medicament is an oral contraceptive or hormone replacement therapy medicament provided in a prescribed regimen. In another kit embodiment, the tablet package is presented as a separate component from the dispensing container thereby calling attention to the refillability features of the system.
The present invention also provides for a method of administering a prescribed regimen of tablet medication comprising utilizing a tablet dispenser system of the invention whereby the tablets deployed therein and the orientation of the days of the week to each tablet position is adapted to a prescribed regimen. Preferably, the prescribed regimen is for providing oral contraceptive or hormone replacement therapy.
The present invention also provides for a tablet package adapted for receipt and use in the tablet dispenser system of the invention which may be provided for refilling the tablet dispenser system.
Further, a method of filling or refilling the tablet dispenser system of the invention is provided which comprises the step of aligning at least two complementary recesses on the tablet package with at least two inward extending ledges protruding from the rising wall portion of the substantially flat support of the tablet dispenser; and placing a tablet package onto the substantially flat support.
In other embodiments a method of filling the tablet dispenser system of the invention is provided comprising the steps of rotating the rotatable knob marked with the days of the week to align the desired start day of the week with the initial tablet position; aligning at least two complimentary recesses on the tablet package with at least two inward extending ledges protruding from the rising wall portion of the substantially flat support; and placing the tablet package onto the substantially flat support.
In other embodiments, subsequent steps are provided for dispensing the initial tablet located at the initial tablet position and rotating the rotatable knob one stop to the next day to positively engage the tablet package in the tablet dispenser thereby inhibiting disengagement of the package until a full rotation of the rotatable knob has been completed. In another embodiment, the tablet package is anchored in the load position by a movable holding lug on the flat support of the tablet dispenser system.
In yet another embodiment, the tablet housing is bonded to the stiff platform by a plurality of posts attached to the platform, threaded through holes in the housing, and headed over in rivet fashion. The platform is designed to come apart upon removal of the tablet housing rendering it nonfunctional for reuse and separable for recycling.
In another embodiment of the invention a tablet dispenser component system is provided comprising:
a circular tablet package comprising a plurality of sequentially arranged collapsible tablet pockets each containing a tablet arranged substantially circularly about the package wherein the tablet package comprises at least two asymmetrically spaced notches about the outer periphery of the ringed circular package;
a base support comprising a single tablet dispenser aperture therein and at least two ledges which are shaped, sized, and oriented to receive the tablet package in only one position of positive engagement thereon whereby a designated tablet of the tablet package is provided over the single tablet dispensing aperture;
a means for rotating the circular tablet package about the base support around a center axis portion situated on the base support to orient tablets in the sequentially arranged tablet pockets of the tablet package over the tablet dispensing aperture; and
a means for positively engaging the tablet package onto the base support upon the initial dispensing of a tablet from the tablet package and rotation of the tablet package to move the next sequentially arranged tablet pocket over the tablet dispensing aperture.
In another embodiment of the invention a tablet dispenser system for dispensing a regimen of tablets in a designated sequence is provided comprising:
as a first element, a flat support having a single tablet dispensing aperture therein and an encircling wall portion erected thereto defining a cup-like interior;
as a second element, a pivot connected to the center of the flat support defining an axis;
as a third element, a rotatable knob having a top surface with indicators of periodicity marked thereon in correspondence with the tablets, a means for gripping thereby to apply rotary force, and a central bore sized for encircling the pivot;
as a fourth element, a first connecting means for rotatably connecting the rotatable knob coaxially to the flat support;
as a fifth element, a means for intermittent unidirectional advancement of the knob about the axis with registry corresponding to the aperture and the indicators of periodicity;
as a sixth element, a circular tablet package comprising a housing containing the tablets in a plurality of frangibly lidded collapsible tablet pockets arranged circularly about the package at a radial distance corresponding to the distance of the aperture from the axis and having a central bore sized for encircling the rotatable knob;
as a seventh element, a means for orienting the tablet package to the flat support, whereby the first tablet is located over the aperture and misorientation of the tablet package to the flat support is inhibited; and
as an eight element, a second connecting means for connecting the tablet package to the rotatable knob upon loading onto the flat support for any initial setting of the knob such that rotary force applied to the knob is translated to the tablet package providing the manner in which the tablet package is advanced thereby causing each tablet of the regimen to be presented in the designated order, accompanied with the corresponding indicator of periodicity and registered by the intermittent unidirectional advancement means, to the aperture for the purpose of dispensing a single tablet at a time from the tablet dispenser by collapsing the collapsible tablet pocket positioned thereto and urging the tablet through the frangible lidding into and through the aperture.
The invention also provides a tablet package adapted for placement into the tablet dispenser system of the invention. In preferred embodiments the tablet package comprises a hole in its center and notches in its outer periphery which are shaped, sized or oriented to be placed upon a base support for the tablet package which support comprises a center knob and protruding ledges which are complementary to the hole and notches of the tablet package, respectively. Whereby, the tablet package is received onto the base support in only a single desired orientation providing a designated tablet of the tablet package over a single tablet dispensing aperture in the base support of the tablet dispenser system.
The invention also provides an intuitive tablet dispenser component kit for dispensing a regimen of solid dosage preparations in a designated sequence, comprising:
as a first element, a container;
as a second element, a refill carrier housing the solid dosage preparations in a circular array loaded into the container, the refill carrier presented separately upon introduction to emphasize a refillable feature;
as a third element, a means for individually dispensing the solid dosage preparations from the refill carrier; and
as a fourth element, a set of timing indicators, appropriate for the course of therapy and in correspondence with the solid dosage preparations in count and layout, affixed to, and in registry with, the refill carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-5 and 6-13 illustrate two distinct embodiments of the present invention.
FIG. 1 is a perspective view of a tablet dispenser incorporating the present invention with the notched skirt and tablet platform provided in a cut away view;
FIG. 2 is a side view of the tablet dispenser in a closed position;
FIG. 3 is a plan view of the cup like support portion of the dispenser with the tablet package provided in a cut away view;
FIG. 4 is a cross-sectional view of FIG. 4 with the tablet dispenser shown in a closed position;
FIG. 5 is an exploded cross-sectional view of FIG. 4 with a tablet dispenser provided as if in a closed position;
FIG. 6 is a perspective view of a tablet dispenser incorporating the present invention in a closed position;
FIG. 7 is a perspective view of the tablet dispenser in an open position with a tablet package (refill unit) positioned for loading;
FIG. 8 is an exploded perspective view of the tablet dispenser and tablet package (refill unit);
FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 6 with the tablet dispenser shown in a closed position;
FIGS. 10 and 11 show details of the ratchet mechanism of the tablet dispenser;
FIG. 12 is a perspective view of the tablet package (refill unit) which is adapted for insertion into the pill dispenser of the invention with a cut away view of the blister ring to show the tablet package platform;
FIG. 13 is a perspective view of a tablet package platform upon which a blister ring containing tablets may be mounted; and
FIG. 14 is a top plan view of the tablet package platform.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to preferred embodiments of the invention. Examples of two preferred embodiments are illustrated in the accompanying figures and described in detail below with reference to such figures and the numbers provided therein.
Referring now to FIGS. 1-6, a first preferred embodiment of the invention will be described in further detail. FIG. 1 is a perspective view of a tablet dispenser 1 incorporating the tablet dispenser system of the present invention. The tablet dispenser 1 comprises as a first component, a substantially circular unidirectional rotatable knob 3 which is encircled with a notched skirt 9 comprising a plurality of notches 11 spaced substantially equally apart. The rotatable knob 3 comprises a flat surface 2 and a cylindrical wall 4. A portion of the cylindrical wall 4 may be provided with ridges 94 in a knurling pattern for enhancing hand gripping of the rotatable knob 3. The rotatable knob 3 is mounted onto a second component, which is base 5 comprising a substantially flat support 6, having a single tablet dispensing aperture 13, and a rising wall 8 extending from the periphery of the flat support 6.
The rotatable knob 3 is attached to the flat support by engagement means around a third component which is a fixed center axis means 7 about which said rotatable knob 3 may be rotated in a circular fashion. The fixed center axis means 7 has a flat top 14 and includes an optimal pointer shaped indicator 15 which aligns with an angular ledge 17, a current or initial tablet position 97 and a corresponding day of administration 12 imprinted on the flat surface 2 of the rotatable knob 3.
The tablet dispenser shown in FIG. 1 comprises a fourth component which is a separate and removable tablet package 19 which is adapted to fit over the rotatable knob 3 with means to positively engage the notched skirt 9 thereof such that the two components rotate in unison. The separate and removable tablet package 19 comprises a rigid platform 24 and an essentially flexible blister ring 26 upon which tablets 99 are provided in collapsible tablet pockets 21. The tablet package 19 comprises a plurality of collapsible tablet pockets 21 each containing a tablet 99 arranged substantially circularly about the package whereby the spacing of the tablet pockets 21 correspond to each stop of the ratchet means, whereby a new tablet 99 is placed over the tablet dispenser aperture 13 upon the positive engagement of each stop on the ratcheted rotatable knob 3. The tablet pockets 21 are lidded with a frangible membrane 22 (best seen in FIG. 4) which is sealed to the blister ring 26 and interposed between the tablets 99 in the tablet pockets 21 and a single tablet dispensing aperture 13. A substantially rigid or stiff platform 24 comprises a plurality of tablet apertures 23 which are substantially aligned with each tablet pocket 21. A tablet 99 is dispensed from the tablet dispenser 1 by collapsing the tablet pocket 21 which is in registry with the single tablet dispensing aperture 13 thereby forcing the tablet to fracture a frangible membrane 22 and pass through the apertures 23 and 13 (as seen in FIG. 4). The rigid platform 24 and the flexible blister ring 26 are held together by bonding means (e.g. glue, ultrasonic welding or staking).
The base 5 has a rising wall 8 extending from the flat support 6 to form a cup like interior space in which the rotatable knob 3 and tablet package 19 are housed. The base 5 comprises at least two inwardly extending ledges 16 protruding from the rising wall portion 8 toward the center axis means 7. The shape and the orientation of the ledges 16 correspond to at least two complementary recesses 18 on the tablet package 19 permitting reception of the tablet package 19 onto the flat support 6, whereby a designated first tablet 97 is positioned above the tablet dispensing aperture 13 at the initial or current tablet position 98 which is indicated by an angular ledge 17. The angular ledge 17 may be cooperative with ledges 16 by corresponding to complementary recesses 20 and 18 of the tablet package 19 to provide reception of the tablet package 19 onto the flat support 6. The tablet package 19 is interlocked onto the base 5 upon a single advance of the calendared rotatable knob 3 whereby a portion of the rigid platform 24 underlaps the inwardly extending ledges 16 and 17. The tablet package is not disengageable or removable until a complete rotation of the knob 3 returns the tablet package 19 to the initial tablet position 98. A finger lever 32 is provided, diametrically opposite the angular ledge 17, as is more fully discussed below in the description of FIG. 3.
The tablet package further comprises a cover 101 which together with the base 5 protects the dispenser contents from impact damage and light degradation particularly where the base and cover material is of such density and opacity as to filter out degradative wavelengths of light and to protect the dispenser's contents from physical damage attendant to normal use. A latch strut 103 extends toward the base 5 from the cover 101. The latch strut 103 comprises an inward hook 131 and an outward lever 132. When the cover 101 is closed onto the base 5, the latch strut 103 passes through a latch seat aperture 133 into a cavity beneath latch seat 105 thereby snapping the inward hook 131 beneath the bottom surface of the latch seat 105 and abutting the outward lever 132 to the top surface of the latch seat. The latch seat 105 is connected to the base 5 by torsion arms 134 such that latch lever 135 overhangs the base. To open the dispenser, the latch lever 135 is urged upward thereby lifting the outward lever 132 while rotating the seat aperture 133 into disengagement from the inward hook 131 resulting in the cover springing ajar.
FIG. 2 is a side view of a tablet dispenser 1 in a closed position upon which the cover 101 is closed upon the base 5 over the flat support 6.
FIG. 3 is a plan view of the cup like support portion of the dispenser base 5 with the blister ring 26 provided in a cut away view showing many of the components described for FIG. 1 above. A notch 20 in the tablet package 19 at the current dispensing tablet position 97 permits the tablet package to be placed over the angular indicating ledge 17. The top of the rotatable knob 3 is marked with the seven days of the week repeated for four weeks or 28 days of administration 12. Ratchet spring pawls 10 are shown by ghost lines on the edges of the rotatable knob 3. An optional day indicator 15 is positioned on top of fixed center axis 7 and points to the current day 12 at the current dispensing pill position 97 and aligns with the angular indicator 17.
The rotatable knob 3 has a notched skirt 9 and a flat top surface 2 connected by a cylindrical wall 4. The flat top surface 2 is imprinted with days of administration 12 of a number corresponding to the number of tablet pockets 21 and in such a way that the days align both with the tablets 99 disposed in the tablet pockets 21 and the ratchet positions (not shown). The tablet pockets 21 and tablets 99 disposed therein are sequenced such that they advance clockwise continuously without interruption. The notched skirt 9 is edged with notches 11 of a number corresponding to the pill positions and similarly coaligned with the ratchet system and the tablets 99. Sprocket lugs 110 of the tablet package 19 are shown in engagement with notches 11 of the notched skirt 9. This engagement of sprocket lugs 110 causes the tablet package 19 to interlock and rotate in unison with the notched skirt 9 of the rotatable knob 3.
A holding lug 31 is appended to the rising wall portion 8 of the flat support 6 and overhangs the tablet package 19 when the tablet package is inserted onto the tablet dispenser 1 thereby adding a safety feature for the load position where ledges 16 and recesses 18 are in bypass alignment. The rising wall portion 8 of the flat support 6 is provided with slots 34 to allow articulation of the holding lug 31 when the tablet package 19 is pressed into location. The finger lever 32 is provided to ease the removal of the tablet package.
FIG. 4 is a cut away view taken along line 4--4 of FIG. 3 with a pill package shown in a closed position. A first pair of hinge struts 140 depend from the cover and interleave with a second pair of hinge struts 140 attached to the rising wall portion 8 to form a hinge between the cover and base when pin 109 is threaded into four aligned holes 108 of the two pairs of hinge struts. The cover 101 performs the function, together with base 5, of protecting the dispenser contents from impact damage and light degradation, and each is shaped in a manner to cup roughly one-half of the enclosed volume. The latching means comprising strut 103 and seat 105 are in an engaged and locked position.
FIG. 5 is an exploded cut away view taken along line 4--4 of FIG. 3 with a tablet dispenser provided as if in a closed position. A base insert 5b, which includes center axis portion 7, is snap fitted into base unit 5a by friction jackets 51 of the base unit 5a and friction posts 53 of the base insert unit 5b. The interior portions of the notches 11 of the notched skirt 9 engage two or more protruding lugs 110 of the tablet package 19, upon such engagement the tablet package 19 moves as the rotatable knob 3 moves thus rotating the tablet package 19 and the tablets 99 contained therein along their circular pathway around the dispenser and sequentially deploys an individual tablet 99 over the tablet dispensing aperture 13 upon each ratchet stop of the ratcheted rotatable knob 3. The base insert 5b also contains ratchet spring-pawls 10 circularly positioned and symmetrically arrayed around the axis of symmetry and tangentially inclining upward from the plane of the floor, rising in a clockwise direction. An elevated structure centered on the axis of symmetry provides a fixed center axis means 7 for rotatably connecting the rotatable knob 3 by three flexible retainer struts 87 which overhang a retaining ledge 88 on the inner diameter of the rotatable knob 3. The retainer struts 87 and ledges 88 allow bypass of the rotatable knob 3 during assembly and thereafter form a rotatable assemblage.
The bottom of the notched skirt 9 contains a circular ratchet track 81 with clockwise tending vertical ramps 83 of a number corresponding to the number of tablet pockets 21, aligned with the days 12, the tablets 99, and the base aperture 13. The clockwise tending vertical ramps 83 ride over, depress and engage the ratchet spring-pawls of the base providing discrete positioning of the tablets 99 over the base aperture 13 and in alignment with sequential days 12 while preventing counterclockwise backoff.
The tablet dispenser of the invention may be operated as follows, referring to FIGS. 1 and 3: To fill the tablet dispenser 1 with the tablet package 19, the user rotates the rotatable knob 3 to align the current or desired start or initial day of the week 112 with angular ledge 17 and pointer shaped indicator 15. The user then places the tablet package 19 onto the base 5 by aligning the complementary recesses 18 of the tablet package 19 with the extending ledges 16 of the base 5 and the angular ledge 17 with the complementary recess 20 and fitting the tablet package 19 over the base 5 and the holding lug 31. The tablet package 19 is pressed over the holding lug 31 and into the base 5 to insert the tablet package 19. The sprocket lugs 110 of the tablet package 19 are thereby oriented for engagement with the notched skirt 9 for rotatable operation. After dispensing the first tablet 99, the user rotates the rotatable knob 3 so that the specific mark 12, indicating the second day on which a tablet is to be taken, is in alignment with pointer 17 (this also aligns the tablet, corresponding with that particular day, in registry with the aperture 13 in flat support 6). When it is time to take the next tablet 99, the user presses downwardly on collapsible pocket 21 thereby urging the tablet 99 to fracture frangible membrane 22 and pass through its corresponding tablet aperture 23 in the platform 24 and then through aperture 13 in the flat support 6 for collection thereafter. The ratchet track 81 in cooperation with the pawls 10, unseen to the user, controls the rotation so that each tablet passes incrementally over and in registration with the aperture. This procedure continues until the supply of tablets is exhausted, whereupon the user merely lifts out the empty tablet package and replaces it with a new tablet package containing a full supply of tablets thus refilling the tablet dispenser.
Referring now to the FIGS. 6--13, a second preferred embodiment of the invention will be described in detail.
FIG. 6 shows the table dispenser 200 in a closed position whereby a cover 202 sits atop a flat support 201.
FIG. 7 shows the tablet dispenser system comprising a tablet dispenser 200 and circular tablet package 205. The tablet dispenser comprises a flat support 201, a cover 202, and a rotatable knob 203 rotatably fixed onto the flat support by pivot 204 thereby providing an axis of rotation for the rotatable knob. The cover and base are connected at hinge 206. The recitation of the hinge structure is similar to that previously described. The circular tablet package 205 contains a regimen or kit of tablets or pills 207 illustrated in a count of 28 (partially shown). Upon loading, the circular tablet package connects to the rotatable knob such that torque applied to the knob rotates each tablet 207 of the circular tablet package in turn over a tablet dispensing aperture 208 located in the flat support 201 thereby providing means for a selected tablet to be expressed from the tablet dispenser.
In the exploded view of FIG. 8, the flat support 201 is bounded by an encircling wall portion 209 erected thereon. Attached to the flat support at the center is a cylindrical wall portion 210. The pivot 204 comprises a flat surface 211 mounted onto and overlapping a cylindrical stalk 212 which provides a support means. The overlap defines a bottom surface 223, best illustrated in FIG. 10, which forms the base for a circular ratchet track 224. The outside diameter of the stalk 212 is of such dimension as to cause a friction fit with the interior surface 247 of the cylindrical wall portion 210 when assembled thereto. An orientation means for the pivot is provided by four radial vanes 213 extending inward from the cylindrical wall portion 210 which nest within four complementary slots 214 in the base of the stalk 212 when assembled. The slots are provided by with lead-in chamfers 215 to guide the slots into position when assembling. A fastening means is provided by circumscribing corrugations 216 on the stalk 212 and complementarily-placed inscribing corrugations 217 on the interior surface 247, the sets of opposing corrugations interlocking when the pivot 204 is pressed into the cylindrical wall portion 210 causing the sets to bypass.
The flat support encircling wall portion 209 supports two rounded ledges 225 and a pointed ledge 226, all of which extend inwardly with clearance underneath. The pointed ledge, positioned adjacent to the aperture 208, provides a means for indicating the position of the aperture during and after the loading of the circular tablet package 205. The encircling wall portion 209 also supports a holding lug 227 attached to a slotted portion (not shown) of the wall which snaps over the tablet package 205 during loading in order to retain it thereafter. The holding lug 227 has a ledge portion 228, best shown in FIG. 9, serving the function of holding the tablet package in place on the flat support, and an inclined plane portion (not shown) providing a means for levering the structure aside during loading. The outside surface of the encircling wall portion 209 contains a latch recess 229, positioned at a point diametrically opposite the hinge 206, which works in cooperation with a latch lug 230 in the cover, best shown in FIG. 9, to provide a latching means when the tablet dispenser is closed.
The rotatable knob 203 has a top surface 248 supported by an exterior cylindrical wall 249 and has a central bore 218. The central bore is of sufficient dimension to surround the pivot stalk 212 when the pivot flat top surface 211 is nested within recess 246 which is bounded by an interior cylindrical wall 219 extending downward from the inside diameter of the top surface 216. Extending inward from the bottom edge of the interior cylindrical wall, defining the floor of the recess 246, are four spring pawls 220. The spring pawls comprise four accurately-arrayed spring arms 221 which terminate in four ratchet pawls 222 which, in turn, provide a cantilevered upward bias by the spring arms from base points lying on a common circle corresponding to the ratchet tract 224 (see FIG. 10). When the pivot 204 is seated in the cylindrical wall portion 210 of the flat support 201 passing through the central bore 218 of the rotatable knob 203, thereby providing connecting means with the flat support, the ratchet pawls 222 close with the ratchet track 224, thereby forming a means for intermittent unidirectional advancement of the rotatable knob. The pawls and track have a rest position, as best shown in FIG. 11, defining a ratchet stop. The sliding face 232 of the pawl provides for clockwise advancement of the rotatable knob 203 and the abutting face 223 limits counterclockwise motion. The number of ratchet stops corresponds to the number of tablets 207 in the regimen. The ratchet stops are in fixed alignment with the flat support 201 and, in particular, with the dispensing aperture 208, by means of the radial vanes 213. The interposition of componentry is best shown in the cut-away view of FIG. 9.
A notched skirt 231 extends outward from the bottom edge of the exterior cylindrical wall 249. The notches also correspond to the number of tablets 207 of the tablet package 205 and are in registry, linked by the spring pawls 220, with the stops on the ratchet track 224 (FIG. 10) and, associatively, with the dispensing aperture 208. Indicators of periodicity 251, such as days of the week, are printed or engraved onto the top of the flat surface 248 of the rotatable knob 203, also in registry with the ratchet track stops. An indicator mark 233 is similarly printed or engraved onto the flat surface 211 of the pivot 204 in fixed registry with the dispensing aperture 208, providing, in cooperation with the indicators of periodicity, a means for indicating by name (e.g. day of week) the ratchet position corresponding to the aperture. Knurls 234 are formed into the top outside edge of the rotatable knob 203 thereby providing a means for gripping when torque is applied to the knob by hand.
The circular tablet package 205 comprises a tablet housing 235 and a rigid skeletal structure 236. The tablet housing contains the tablets 207 between a layer of flexible material having collapsible tablet pockets 237, such as thermoformed PVC film, and a frangible lidding, such as aluminum foil, sealed underneath. The tablet housing 235 is shaped like a donut and is perforated with two pilot holes 238 adjacent the inside diameter. During assembly, the pilot holes are threaded over posts 239 attached to lugs 240 on the rigid skeletal structure 236. The posts are then headed over in rivet fashion thereby unitizing the rigid skeletal structure with the tablet housing 235 to form the complete tablet package 205. After use, the spent tablet housing can be stripped from the rigid skeletal structure for the purpose of recycling materials by pulling the tablet housing away from the rigid skeletal structure thus rupturing the connecting structure of the lugs 240 at the fragile necks 241, which are otherwise robust when remaining combined with the tablet housing 235. The rigid skeletal structure 236 has apertures 242 of a number corresponding to the number of tablets, and arrayed so as to fall beneath each of the collapsible tablet pockets 237 of the tablet housing 235 when oriented thereto by the pilot holes 238. A tablet 207 is dispensed by applying finger pressure to a collapsible tablet pocket thereby urging the tablet 207 through the frangible film and the supporting aperture.
The circular tablet package 205 is provided with two rounded cut-aways 243 and a pointed cut-away 244 complementary in size, shape, and layout, respectively, to the rounded ledges 225 and the pointed ledge 226 appended to the flat support 201. The pointed cut-away 244 corresponds to a designated first tablet of the regimen. The cut-aways 243 and 244, in cooperation with the ledges 225 and 226, permit loading of the circular tablet package 205 into the tablet dispenser 200 in only one initial orientation thereby furnishing a designated first tablet at the dispensing aperture 208 for initial dispensing. A connecting means is provided by the lugs 240 of the rigid skeletal structure 236 which are complementarily shaped to interlock with the notched skirt 231 of the rotatable knob 203. Upon advancement of the next tablet to the aperture 208 by rotation of the rotatable knob, the periphery rail 245 of the rigid skeletal structure 236 underpasses the ledges 225 and 226 by traversing the clearance underneath thereby locking the circular tablet package 205 within the tablet dispenser 200. Because the layout or geometry of the cut-aways and ledges permits a match at only the loading position, the locking arrangement is maintained until the advancement completes a circle back to the initial position. The circular tablet package 205 can then be removed, and the tablet dispenser 200 can be refilled with a fresh tablet load via a new tablet package.
FIG. 12 is a perspective view of the tablet package (refill unit) which is adapted for insertion into the pill dispenser of the invention with a cut away view of the blister ring to show the tablet package platform.
FIGS. 13 and 14 are perspective views of a tablet package platform upon which a blister ring containing tablets may be mounted. The substantially circular platform comprises a rigid skeletal structure 236 having posts 239 on the inside diameter which are attached to lugs 240. The lugs 240 are connected to the rigid skeletal structure 236 by means of fragile necks 241. The rigid skeletal structure 236 has apertures 242 for passage of tablets and cutaways or notches 243 and 244 which are adapted to correspond to ledges in the tablet dispenser for positive and correct placement of the tablet package into the tablet dispenser system.
While the material for the elements of the tablet dispenser are generally left to choice and compatibility with the functions of the dispenser, the rotatable knob, the center axis means, the support base, rigid platform and cover are preferably made of plastic. Plastic materials such as general purpose polystyrene are conveniently injection molded into the desired configurations, while providing sufficient rigidity and durability for continual, frequent and repeated use of the dispenser. The cover, base, and calendar components may be injection molded in high impact polystyrene (HIPS). The days of the week are imprinted onto the top calendar surface, and the indicator mark 15 is similarly highlighted by imprinting. The method of imprinting is either by hot stamping or by pad printing. These three components may be preassembled and supplied as a unit. As alluded to briefly above, the tablet package blister pack 19 has collapsible pockets made from plastic, and inasmuch as they contain the tablets, it is preferable that the dispenser be sufficiently compact to fit in the palm of the user's hand. Typically, the diameter of the circular platform which has twenty-eight (28) openings therein is about 3.0 inches (7.6 cm.), while the support is slightly larger.
The refill composite consists of a platform injection-molded in medium impact polystyrene (MIPS) and a blister unit containing the pills. The platform and blister are bonded together in a fixed orientation. The blister may comprise polyvinyl chloride (PVC) film which is thermoformed into cavities to receive the tablets or pills before laminating the aluminum foil lidding, and subsequently die-cutting the laminate from the web, according to well-known manufacturing processes.
Thus there has been provided a tablet dispenser for dispensing tablets or similar solid-form pharmaceutical preparations according to a time related regimen whereby the user thereof is plainly informed when the tablet should be taken thereby eliminating the uncertainty and confusion which may often accompany the taking of such pharmaceutical preparations and following of prescribed dosage regimens.
The scope of the present invention is not limited by the description, examples and suggested uses herein and modifications can be made without departing from the intended scope and spirit of the invention. For example, other components may be added to the dispenser including additional locking mechanisms for making the package more child or tamper resistant or additional aesthetic features including embossing or coloring of the package. The dispenser may also be easily adapted to different languages or days of periodicity of dosage by application of an adhesive label over the calendared knob. The dispenser may be further adopted for twice daily pharmaceutical regimens by providing a.m. or p.m. markings in addition to the days of the week. Further, the ledges on the tablet dispenser base and notches on the tablet package may be interchanged by providing an extended cavity in the base to accept a notched tablet package therein. The present invention may also be used to provide a dispenser for vitamins, minerals or other nutrients.
As illustrated above, application of the dispenser of the present invention for medical and pharmaceutical uses can be accomplished by any clinical, medical and pharmaceutical methods and techniques as are presently and prospectively known to those skilled in the art. Thus it is intended that the present invention cover the modifications and variations of this invention provided that they come within the scope of the appended claims and their equivalents.
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This invention relates to a substantially circular tablet dispenser component system which may be adapted for a variable day start of a prescribed periodic tablet regimen. Also provided are a tablet dispenser kit, a tablet packge adapted for filling the tablet dispenser system, methods of filling the tablet dispenser of the invention and methods of administering a prescribed regimen of medication using the tablet dispenser system of the invention.
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BACKGROUND INFORMATION
[0001] The present exemplary embodiment relates generally to the field of automation control systems, such as those used in industrial and commercial settings. It finds particular application in conjunction with techniques for providing, accessing, configuring, operating, or interfacing with input/output (I/O) devices that are configured for coupling and interaction with an automation controller, and will be described with particular reference thereto. However, it is to be appreciated that the present exemplary embodiment is also amenable to other like applications.
[0002] Automation controllers are special purpose computers used for controlling industrial automation and the like. Under the direction of stored programs, a processor of the automation controller examines a series of inputs (e.g., electrical input signals to the automation controller) reflecting the status of a controlled process and changes outputs (e.g., electrical output signals from the automation controller) based on analysis and logic for affecting control of the controlled process. The stored control programs may be continuously executed in a series of execution cycles, executed periodically, or executed based on events. The inputs received by the automation controller from the controlled process and the outputs transmitted by the automation controller to the controlled process are normally passed through one or more I/O devices, which are components of an automation control system that serve as an electrical interface between the automation controller and the controlled process.
[0003] Traditional I/O devices typically include a base configured to couple the I/O device with a bus bar or the like, a terminal block for communicatively coupling the I/O device with field devices, and an I/O module that includes circuitry for performing communication functions and/or logic operations. In operation, a traditional I/O device typically communicatively couples with field devices (e.g., sensors and actuators) via terminals of the terminal block such that the I/O device can receive input signals from the field devices and provide output signals to the field devices.
[0004] In many applications, a large number of bases are arranged in close proximity to each other along a bus bar mounted on a wall or other surface. Each base supports both a terminal block and an I/O module. This type of configuration is sometimes referred to as a slice I/O because each set of bases, modules, and terminal blocks appear to be a “slice” of a larger structure.
[0005] Traditional automation control systems receive power from a power source (e.g., an electrical grid or battery) through field power distribution (FPB) modules, which are specialized modules for providing power to components of the automation control system. Depending on the size and nature of a particular automation control system, different numbers and types of field power distribution modules may be required. Indeed, as modules (e.g., I/O modules) are connected with a power bus of a modular automation controller system, the type or amount of power may need to be changed or augmented. For example, in traditional systems, a particular type of FPB module may be required for powering analog I/O, and a different type of FPB module may be required for powering discrete I/O. Additionally, a single FPB module can only support a limited number of automation control system modules or devices.
[0006] FPB modules break the field power distribution to downstream components. An FPB essentially comprises a terminal block and I/O module that is configured to break field power while passing on control power. A new field power source can be supplied via the terminal block such that downstream field power can be different than upstream field power. As such, an FPB module essentially bridges the control power between adjacent I/O modules, while shunting the field power and offering an input connection to a different field power source.
BRIEF DESCRIPTION
[0007] In accordance with an aspect of the present disclosure, an input/output (I/O) device for an automation control system comprises a device housing containing control circuitry, the device housing being mountable to a support, a control power input for receiving control power from a first adjacent I/O device when connected thereto, the control power input configured to supply control power to the control circuitry, a control power output for outputting control power to a second associated adjacent I/O device, a field power input for receiving field power from the first associated adjacent I/O device when connected thereto, and a field power output for transmitting field power to the second associated I/O device. The field power input is selectively removable to prevent field power from being received by the I/O device from the first associated adjacent I/O device when connected thereto.
[0008] The field power input can include a pair of blade connectors protruding from the housing via at least one opening, the pair of blade connectors configured to mate with corresponding connectors of a field power output of the first adjacent I/O device, the blade connectors being selectively removable from the device housing of the I/O device. The field power input can further comprise an input housing including a connector body therein, the connector body including at least one pair of cantilevered arms between which a blade connector is received, the connector body further comprising a threaded bore in which a removable fastener is received, the removable fastener being engaged with the blade to restrict removal of the blade from the input housing. The removable fastener can include a screw having a terminal end thereof engaged in a slot of the blade, whereby the terminal end of the screw restricts withdrawal of the blade from the connector body.
[0009] The input/output device can further include a cover for covering the opening in the device housing when the blade terminals are removed therefrom. The cover can extend around at least a portion of two adjacent side of the device housing. The device housing can have a relatively wide side and a relatively narrow side, and the cover can extend around at least a portion of both the relatively narrow side and the relatively wide side.
[0010] The input/output (I/O) device can also include a terminal block having an input for receiving a second source of field power, whereby the second source of field power is delivered to the field power output when the field power input is removed.
[0011] In accordance with another aspect, an automation control system comprising a plurality of I/O devices mounted to a support and connected in series, at least one of the I/O devices being a field power break (FPB) I/O device as described herein.
[0012] In accordance with another aspect, a method for selectively breaking field power distribution in an automation control system comprises providing at least one I/O device including a device housing mountable to a support, a control power input for receiving control power from a first adjacent associated I/O device, the control power input configured to supply control power to the control circuitry, a control power output for outputting control power to a second adjacent associated I/O device located opposite the first adjacent associated I/O device, a field power input for receiving field power from the first adjacent associated I/O device, and a field power output for transmitting field power to the second adjacent associated I/O device, wherein the field power input is selectively removable to prevent field power from being received by the I/O device from the first associated I/O device, and selectively removing the field power input from the I/O device to break field power distribution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a diagrammatical representation of an exemplary control and monitoring system;
[0014] FIG. 2 is a perspective view of an I/O device in accordance with the present disclosure;
[0015] FIG. 3 is a perspective view of a pair of exemplary I/O modules in accordance with the present disclosure;
[0016] FIG. 4 is perspective view of the I/O modules of FIG. 3 illustrated in coupled state;
[0017] FIGS. 5( a )-5( d ) are perspective views of an exemplary I/O module in various states during removal of the blade contacts and installation of the bus cap;
[0018] FIG. 6 is a perspective view of a field power break I/O module and an I/O module;
[0019] FIG. 7 is a perspective view of a pair of I/O modules with their housings removed to show the selectively removable contact assemblies thereof;
[0020] FIG. 8 is a perspective view of a pair of selectively removable contact assembly in a connected state;
[0021] FIG. 9 is a perspective view of a pair of selectively removable contact assemblies wherein one of the assemblies has its contacts removed;
[0022] FIG. 10 is a perspective view of a power connector main body with a blade contact installed; and
[0023] FIG. 11 is a perspective view of the power connector main body of FIG. 10 with the blade contact removed.
DETAILED DESCRIPTION
[0024] FIG. 1 is a diagrammatical representation of an exemplary control and monitoring system adapted to interface with networked components and configuration equipment in accordance with embodiments of the present techniques. The control and monitoring system is generally indicated by reference numeral 10 . Specifically, the control and monitoring system 10 is illustrated as including a human machine interface (HMI) 12 and an automation controller or control/monitoring device 14 adapted to interface with components of a process 16 .
[0025] The process 16 may take many forms and include devices for accomplishing many different and varied purposes. For example, the process 16 may comprise a compressor station, an oil refinery, a batch operation for making food items, a mechanized assembly line, and so forth. Accordingly, the process 16 may comprise a variety of operational components, such as electric motors, valves, actuators, temperature elements, pressure sensors, or a myriad of manufacturing, processing, material handling, and other applications. Further, the process 16 may comprise control and monitoring equipment for regulating process variables through automation and/or observation.
[0026] For example, the illustrated process 16 comprises sensors 18 and actuators 20 . The sensors 18 may comprise any number of devices adapted to provide information regarding process conditions. The actuators 20 may include any number of devices adapted to perform a mechanical action in response to a signal from a controller (e.g., an automation controller). The sensors 18 and actuators 20 may be utilized to operate process equipment. Indeed, they may be utilized within process loops that are monitored and controlled by the control/monitoring device 14 and/or the HMI 12 . Such a process loop may be activated based on process inputs (e.g., input from a sensor 18 ) or direct operator input received through the HMI 12 .
[0027] As illustrated, the sensors 18 and actuators 20 are in communication with the control/monitoring device 14 and may be assigned a particular address in the control/monitoring device 14 that is accessible by the HMI 12 . As illustrated, the sensors 18 and actuators 20 may communicate with the control/monitoring device 14 via one or more I/O devices 22 coupled to the control/monitoring device 14 . The I/O devices 22 may transfer input and output signals between the control/monitoring device 14 and the controlled process 16 . The I/O devices 22 may be integrated with the control/monitoring device 14 , or may be added or removed via expansion slots, bays or other suitable mechanisms. For example, additional I/O devices 22 may be added to add functionality to the control/monitoring device 14 . Indeed, if new sensors 18 or actuators 20 are added to control the process 16 , additional I/O devices 22 may be added to accommodate and incorporate the new features functionally with the control/monitoring device 14 . The I/O devices 22 serve as an electrical interface to the control/monitoring device 14 and may be located proximate or remote from the control/monitoring device 14 , including remote network interfaces to associated systems.
[0028] The I/O devices 22 may include input modules that receive signals from input devices such as photo-sensors and proximity switches, output modules that use output signals to energize relays or to start motors, and bidirectional I/O modules, such as motion control modules which can direct motion devices and receive position or speed feedback. In some embodiments, the I/O devices 22 may convert between AC and DC analog signals used by devices on a controlled machine or process and DC logic signals used by the control/monitoring device 14 . Additionally, some of the I/O devices 22 may provide digital signals to digital I/O devices and receive digital signals from digital I/O devices. Further, in some embodiments, the I/O devices 22 that are used to control machine devices or process control devices may include local microcomputing capability on an I/O module of the I/O devices 22 .
[0029] In some embodiments, the I/O devices 22 may be located in close proximity to a portion of the control equipment, and away from the remainder of the control/monitoring device 14 . In such embodiments, data may be communicated with remote modules over a common communication link, or network, wherein modules on the network communicate via a standard communications protocol. Many industrial controllers can communicate via network technologies such as Ethernet (e.g., IEEE802.3, TCP/IP, UDP, EtherNet/IP, and so forth), ControlNet, DeviceNet or other network protocols (Foundation Fieldbus (H1 and Fast Ethernet) Modbus TCP, Profibus) and also communicate to higher level computing systems.
[0030] FIG. 2 is a perspective view of a plurality of I/O devices 22 connected to an I/O adapter 24 in accordance with embodiments of the present disclosure. Although only two I/O devices 22 are illustrated, it will be appreciated that any number of I/O devices can be used in accordance with the present disclosure. The I/O adapter 24 is configured to provide system power to the I/O devices 22 , as well as to enable conversion between the communications protocols of the I/O devices 22 and the control/monitoring device 14 . As illustrated, the I/O adapter 24 and the plurality of I/O devices 22 are mounted to a DIN rail 26 , which is an industry standard support rail for mounting control equipment in racks and cabinets. The plurality of I/O devices 22 are electrically coupled in series along the DIN rail 26 such that field power and system information and power may be communicated between the I/O devices 22 , and back through the I/O adapter 24 to the control/monitoring device 14 . In other embodiments, the DIN rail 26 may be replaced with a different type of mounting structure. It will be appreciated that the I/O devices can be used in a wide variety of configurations, and the arrangement illustrated in FIG. 2 is merely exemplary in nature.
[0031] Each of the I/O devices 22 includes an I/O module 27 having a base portion 28 for physically and communicatively connecting the I/O device 22 to the DIN rail 26 , the I/O adapter 24 and/or adjacent I/O devices 22 . In addition, the base portion 28 of the I/O device 22 is configured to physically and communicatively connect the I/O device 22 with other I/O devices 22 via the DIN rail 26 , field and system electrical contacts as described in greater detail below, base connection features as described in greater detail below, and so forth. In addition, each of the I/O devices 22 includes a terminal block 30 (which, in certain embodiments, may be removable from the base 28 ) for electrically connecting the I/O device 22 to field devices, such as the sensors 18 and actuators 20 illustrated in FIG. 1 . As described in greater detail below, in certain embodiments, each terminal block 30 may include status indicators that are directly aligned with (e.g., adjacent to or directly integrated with) terminals of the terminal block 30 . It will be appreciated that the I/O modules 27 include I/O control circuitry and/or logic. In general, the I/O modules 27 receive input signals from the field devices, deliver output signals to the field devices, perform general and/or specific local functionality on the inputs and/or outputs, communicate the inputs and/or outputs to the control/monitoring device 14 and/or the other I/O devices 22 , and so forth.
[0032] As shown in FIGS. 3 and 4 , adjacent I/O modules 27 are coupled together and/or to the DIN rail 26 (not shown in remaining figures) by sliding or otherwise bringing the components together in alignment. Respective pairs of blade terminals 44 and 46 mate with corresponding fork connectors (not shown in FIGS. 3 and 4 , but described in more detail below) to electrically couple the downstream I/O module 27 (right I/O module in FIG. 4 ) with the upstream I/O module 27 (left I/O module in FIG. 4 ). Blade contacts 44 carry field power while blade contacts 46 carry control power.
[0033] As described above, in the past a FPB module would be interposed between the I/O device 22 when it was necessary to break the field power distribution therebetween.
[0034] Turning to FIGS. 5-11 , and initially to FIG. 5 , it will be appreciated that the I/O modules 27 of the present disclosure obviate the need for a FPB module to break field power distribution to downstream components by facilitating a break through a selectively removable contact system. The selectively removable contact system allows a system designer to selectively remove the contacts of an I/O module to isolate a downstream I/O module from its adjacent upstream counterpart. By providing an I/O module with selectively removable contacts, the present disclosure allows systems to be constructed without FPB modules thereby decreasing costs and simplifying the process.
[0035] FIG. 5 illustrates an exemplary I/O module 27 in various states (a)-(d) as it is transformed from the state shown in FIG. 5( a ) to the state shown in FIG. 5( d ) , which will be referred to herein as a field power break (FPB) I/O module, and designated with a new reference numeral 50 . For clarity, the DIN rail and other components are not shown in the remaining figures. As will become apparent, the FPB field module 50 is outwardly identical to I/O module 27 except that the blade contacts 44 have been removed such that the field power is not passed to FPB I/O module 50 from an upstream I/O module 27 . As will also be described, an optional bus cap 52 can be installed to provide a physical barrier between adjacent I/O modules, and to provide a visual indication that a given I/O module is an FPB module 50 .
[0036] FIG. 5( a ) illustrates an exemplary I/O device 22 including an I/O module 27 in accordance with the present disclosure. The I/O device 22 includes a terminal block mounted to the I/O module 27 . Blade contacts 44 in the base portion 28 of the I/O module 27 are provided for connecting the I/O module 27 to an adjacent upstream I/O module in the manner described above.
[0037] In FIG. 5( b ) , the blade contacts 44 are illustrated separated from the base portion 28 of the I/O module 27 . In this embodiment, screws 54 are used to retain the blade contacts 44 in the I/O module 27 . As will be appreciated, other fasteners and/or retention mechanisms can be used to secure the blade contacts 44 .
[0038] Once the blade contacts 44 are removed, a bus cap 52 can be installed over the opening in the base portion 28 from which the blade contacts 44 previously protruded. This is illustrated in FIGS. 5( c ) and 5( d ) . The bus cap 52 will generally be made from an insulator material, such as plastic or the like. The bus cap 52 not only provides a barrier between the internal components of the I/O adaptor 24 , but extends to a front edge of the I/O device 22 to serve as a visual indicator the I/O module is a FPB I/O module 50 . This allows a system designer or technician to readily identify the FPB modules 50 by simply locating those I/O modules with a bus cap 52 installed. The bus cap 52 , or portion thereof that is visible when installed, can be colored with a specific color to assist in identification. In the illustrated embodiment, the bus cap 52 includes a tab 53 that cooperates with a slot on the I/O adapter 24 to retain the bus cap 52 thereto.
[0039] In FIG. 6 , it will be appreciated that the FPB I/O module 50 can be installed adjacent I/O module 27 in an otherwise typical fashion. However, due to the removal of the blade contacts 44 and installation of the bus cap 52 , no field power connection will be made between the modules.
[0040] Turning to FIGS. 7-11 , an exemplary selectively removable contact assembly will be described. The selectively removable contact assembly generally comprises a power connector housing 72 that is configured to mate with a PCB 74 and includes the blade and fork contacts for making the field power connection between adjacent I/O modules as described above. In FIG. 7 , two such circuit boards 74 and power connector housings 72 are illustrated in a connected fashion with the housings of each I/O module removed for clarity. In the remaining figures, the PCB 74 associated with each power connector housing is not shown for clarity.
[0041] Turning to FIGS. 8 and 9 , partial cutaway views illustrate a pair of power connector housings 72 in a physically coupled fashion. In FIG. 8 , the power connector housings 72 are each associated with an I/O module 27 and thus field power connection is made between the I/O modules. In FIG. 9 , the power connector housing on the right is associated with an FPB I/O module and thus no field power connection is made between the I/O modules.
[0042] In FIG. 8 , each power connector housing 72 supports power connector main body 75 which includes a PCB connector 76 for electrically coupling with PCB 74 . The PCB connector 76 in the illustrated embodiment includes cantilevered arms 78 for gripping and connecting with contacts of the PCB 74 . The power connector main body 75 also includes a pair of blade and fork connectors 44 and 82 for coupling to the field power terminals of an adjacent I/O module. It will be appreciated that, in this embodiment, the blade connectors 44 are selectively removable and, as noted above, FIG. 9 illustrates a pair of power connector housings wherein the blade contacts 44 have been removed from the power connector housing 72 on the right, and a bus cap 52 has been installed between the power connector housings 72 .
[0043] With reference to FIGS. 10 and 11 , the power connector main body 75 and contacts are shown in isolation. The power connector main body 75 generally comprises a base portion 86 that is generally made of a conductive material such as a metal or metal alloy. Extending upwardly from the base portion is PCB connector 76 which, as noted, generally comprises a pair of cantilevered arms for compressive engaging a PCB. At one end of the base portion 86 are a pair of cantilevered arms comprising the fork connector 82 , and at the opposite end is blade connector 44 . A portion of blade connector 44 is supported between a pair of cantilevered arms 88 of the base portion 86 that define therebetween a slot. As best shown in FIG. 11 , a screw 90 or other fastener is threaded or otherwise engaged with the base portion 86 to secure the blade 44 in the base portion 86 . A leading end of the screw is configured to engage in a slot 92 of the blade connector 44 to restrict withdrawal of the blade connector 44 when installed.
[0044] It will be appreciated that in one embodiment, the power connector main body 75 can be formed as an integral piece such as by suitable stamping operations or the like, with only the blade connector 44 and the screw 90 being separate, selectively removable components. In addition, the blade connector 44 can be secured to the base portion 86 in other manners such as snapfit connections and the like.
[0045] This description uses examples to disclose the invention and also to enable any person skilled in the art to practice the invention, including making and using devices or systems and performing any incorporated methods. The patentable scope of the invention 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 language of the claims.
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An input/output (I/O) device for an automation control system includes a device housing containing control circuitry, the device housing being mountable to a support, a control power input for receiving control power from a first adjacent I/O device when connected thereto, the control power input configured to supply control power to the control circuitry, a control power output for outputting control power to a second associated adjacent I/O device, a field power input for receiving field power from the first associated adjacent I/O device when connected thereto, and a field power output for transmitting field power to the second associated I/O device. The field power input is selectively removable to prevent field power from being received by the I/O device from the first associated adjacent I/O device when connected thereto.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/122,097 (now U.S. Pat. No. 7,835,269), filed on May 16, 2008, which claims the benefit of U.S. Provisional Application No. 60/938,334 filed May 16, 2007. The disclosures of the applications referenced above are incorporated by reference herein.
BACKGROUND
The present invention relates generally to data communications. More particularly, the present invention relates to faster link down for data communications.
Current Gigabit Ethernet (1000BASE-T) physical-layer devices (PHYs) require a significant amount of time, on the order of hundreds of milliseconds (ms) to indicate a link down condition. FIG. 1 shows a prior art Gigabit Ethernet PHY 100 in accordance with IEEE standard 802.3. Referring to FIG. 1 , PHY 100 includes a physical layer controller 102 , a physical layer monitor 104 , and a maxwait_timer 106 . In operation, PHY 100 is connected to a physical link 108 . Physical link 108 includes a receive physical link 112 and a transmit physical link 114 .
Physical layer controller 102 implements a PHY control state machine 200 specified by FIG. 40-15 of IEEE standard 802.3, reproduced here as FIG. 2 . Referring to FIG. 2 , PHY control state machine 200 starts maxwait_timer 106 when entering the SLAVE SILENT state. The maxwait_timer 106 is used by physical layer monitor 104 to indicate a link down condition.
Physical layer monitor 104 implements a physical link monitor state machine 300 specified by FIG. 40-16 of IEEE standard 802.3, reproduced here as FIG. 3 . Referring to FIG. 3 , when receive physical link 112 fails (loc_rcvr_status=NOT_OK) in the LINK UP state, physical link monitor state machine 300 will not move to the LINK DOWN state, and indicate that physical link 108 has failed (link_status=FAIL) until maxwait_timer 106 expires (maxwait_timer_done=TRUE).
According to the IEEE 802.3 standard, maxwait_timer is nominally initialized to 350±5 ms when PHY 100 is configured as a SLAVE for physical link 108 , and 750±5 ms when PHY 100 is configured as a MASTER. In contrast, fault-tolerant networks are generally required to detect a faulty link, and shift data transmission from the faulty link to a non-faulty link, in 50 ms or less. Clearly, the delay imposed by maxwait_timer upon the transition of physical link monitor state machine 300 from the LINK UP state to the LINK DOWN state is too long.
One possible solution is to simply initialize maxwait_timer to a lower value. However there is a danger that the loc_rcvr_status will bounce between OK and NOT_OK during initial training, resulting in a premature entry into the LINK DOWN state of FIG. 2 , which will cause the link_status variable to transition from OK to FAIL. This transition will cause the auto-negotiation arbitration state machine (FIG. 28-16 of IEEE 802.3) to restart. When the arbitration state machine restarts, the link_control variable is set to DISABLE, which resets the IEEE 802.3 state machines shown in FIGS. 1 and 2 .
SUMMARY
In general, in one aspect, an embodiment features an apparatus comprising: a physical layer controller adapted to start a first timer for a physical link comprising a receive physical link; and a physical link monitor comprising a monitor module adapted to determine a local receiver status for the receive physical link, and a controller adapted to indicate a link status is OK for the physical link when the local receiver status is OK, wherein the controller comprises a speed up mode circuit to indicate the link status is FAIL for the physical link when the local receiver status is not OK and a speed up mode is enabled, regardless of the status of the first timer.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 shows a prior art Gigabit Ethernet PHY in accordance with IEEE standard 802.3.
FIG. 2 shows the PHY control state machine specified by FIG. 40-15 of IEEE standard 802.3.
FIG. 3 shows the link monitor state machine specified by FIG. 40-16 of IEEE standard 802.3.
FIG. 4 shows a Gigabit Ethernet PHY according to an embodiment of the present invention.
FIG. 5 shows a physical link monitor state machine for the Gigabit Ethernet PHY of FIG. 4 according to an embodiment of the present invention.
FIG. 6 shows a Gigabit Ethernet PHY that does not employ a link_up_timer according to an embodiment of the present invention.
FIG. 7 shows a physical link monitor state machine for the Gigabit Ethernet PHY of FIG. 6 according to an embodiment of the present invention.
FIG. 8 shows a Gigabit Ethernet PHY that employs neither a link_up_timer nor a loss_lock_timer according to an embodiment of the present invention.
FIG. 9 shows a physical link monitor state machine for the Gigabit Ethernet PHY of FIG. 8 according to an embodiment of the present invention.
The leading digit(s) of each reference numeral used in this specification indicates the number of the drawing in which the reference numeral first appears.
DETAILED DESCRIPTION
Embodiments of the present invention provide fast link down detection and indication for network devices such as Gigabit Ethernet devices. However, while embodiments of the present invention are described in terms of Gigabit Ethernet devices, embodiments of the present invention apply to other sorts of network devices as well, as will be apparent from the disclosure and teachings provided herein. Some embodiments of the present invention are otherwise compliant with all or part of IEEE standard 802.3, the disclosure thereof incorporated by reference herein in its entirety.
FIG. 4 shows a Gigabit Ethernet PHY 400 according to an embodiment of the present invention. Although in the described embodiments, the elements of Gigabit Ethernet PHY 400 are presented in one arrangement, other embodiments may feature other arrangements, as will be apparent to one skilled in the relevant arts based on the disclosure and teachings provided herein. For example, the elements of Gigabit Ethernet PHY 400 can be implemented in hardware, software, or combinations thereof. Gigabit Ethernet PHY 400 can be implemented as a network device such as a switch, router, network bridge, network interface controller (NIC), and the like.
Referring to FIG. 4 , PHY 400 includes a physical layer controller 402 , a physical layer monitor 404 , and a maxwait_timer 406 . In operation, PHY 400 is connected to a physical link 408 . Physical link 408 includes a receive physical link 412 and a transmit physical link 414 .
Physical layer controller 402 implements a PHY control state machine such as that specified by FIG. 40-15 of IEEE standard 802.3, reproduced here as FIG. 2 . Referring to FIG. 2 , PHI control state machine 200 starts maxwait_timer 406 when entering the SLAVE SILENT state. The maxwait_timer 406 is used by physical layer monitor 404 to indicate a link down condition.
Physical layer monitor 404 includes a monitor module 416 adapted to determine a local receiver status (loc_rcvr_status) for receive physical link 412 , and a controller 420 adapted to indicate a link status (link_status) for physical link 408 in accordance with a speed up mode signal (speed_up_mode), a loss_lock_timer (loss_lock_timer) 426 , and a link up timer (link_up_timer) 428 . Controller 420 includes a normal mode circuit 422 and a speed up mode circuit 424 . Normal mode circuit 422 is adapted to indicate the link status is FAIL for physical link 408 when the local receiver status is not OK, maxwait_timer 406 expires, and speed up mode is disabled (loc_rcvr_status=NOT_OK*maxwait_timer_done*speed_up=disabled). Speed up mode circuit 424 is adapted to indicate the link status is FAIL for physical link 408 when the local receiver status is not OK and the speed up mode is enabled (loc_rcvr_status=NOT_OK*speed_up=disabled). Note that in speed up mode, maxwait_timer 406 is not used to delay indication of the failure of physical link 408 .
Controller 420 implements a physical link monitor state machine 500 according to an embodiment of the present invention, as shown in FIG. 5 . Referring to FIG. 5 , state machine 500 enters a LINK DOWN state when pma_reset=ON+link_control≠ENABLE, as specified by IEEE standard 802.3. When state machine 500 enters the LINK DOWN state, controller 420 asserts link_status=FAIL.
However, when monitor module 416 determines the local receiver status is OK (loc_rcvr_status=OK), state machine 500 moves to a HYSTERESIS state. When state machine 500 enters the HYSTERESIS state, controller 420 starts a stabilize timer (start stabilize_timer). If during the HYSTERESIS state, monitor module 416 determines the local receiver status is not OK (loc_rcvr_status=NOT_OK), state machine 500 returns to the LINK DOWN state. But if, when the stabilize timer expires, the local receiver status is OK (stabilize_timer_done*loc_rcvr_status=OK), state machine 500 moves to a LINK UP state.
When state machine 500 enters the LINK UP state, controller 420 asserts link_status=OK, and starts link up timer 428 (start link_up_timer). For example, link up timer 428 can be initialized to one second or more to ensure that the local receiver status (loc_rcvr_status) has stabilized. Exit from the LINK UP state depends on the speed up mode signal (speed_up_mode).
If during the LINK UP state, speed up mode is disabled, monitor module 416 determines the local receiver status is not OK, and maxwait_timer 406 expires (loc_rcvr_status=NOT_OK*maxwait_timer_done=TRUE*speed_up=disabled), then state machine 500 returns to the LINK DOWN state. But if during the LINK UP state, speed up mode is enabled and link_up_timer 428 expires (link_up_timer_done*speed_up=enabled), state machine 500 moves to a LINK UP 2 state.
When state machine 500 enters the LINK UP 2 state, controller 420 starts a loss_lock_timer 426 (start loss_lock_timer). For example, loss_lock_timer 426 can be initialized to less than 50 ms (or even to 0 ms) to ensure a rapid transition to the LINK DOWN state when the local receiver status is not OK (loc_rcvr_status=NOT_OK). Exit from the LINK UP 2 state also depends on the speed up mode signal (speed_up_mode).
If during the LINK UP 2 state, speed up mode is disabled (speed_up=disabled), then state machine 500 returns to the LINK UP state. And if during the LINK UP 2 state, speed up mode is enabled and the local receiver status is OK when loss_lock_timer 426 expires (loc_rcvr_status=OK*loss_lock_timer_done*speed_up=enabled), state machine 500 returns to the LINK UP 2 state. But if during the LINK UP 2 state, speed up mode is enabled and the local receiver status is not OK when loss_lock_timer 426 expires (loc_rcvr_status=NOT_OK*loss_lock_timer_done*speed_up=enabled), state machine 500 returns to the LINK DOWN state regardless of the status of maxwait_timer 406 . Note that this transition is governed by loss_lock_timer 426 rather than maxwait_timer 406 . Therefore Gigabit Ethernet PHY 400 achieves fast link down detection and indication.
In some embodiments, link_up_timer 428 is not used. FIG. 6 shows a Gigabit Ethernet PHY 600 according to such an embodiment of the present invention. Although in the described embodiments, the elements of Gigabit Ethernet PHY 600 are presented in one arrangement, other embodiments may feature other arrangements, as will be apparent to one skilled in the relevant arts based on the disclosure and teachings provided herein. For example, the elements of Gigabit Ethernet PHY 600 can be implemented in hardware, software, or combinations thereof. Gigabit Ethernet PHY 600 can be implemented as a network device such as a switch, router, network bridge, network interface controller (NIC), and the like.
Referring to FIG. 6 , PITY 600 includes a physical layer controller 602 , a physical layer monitor 604 , and a maxwait_timer 606 . In operation, PHY 600 is connected to a physical link 608 . Physical link 608 includes a receive physical link 612 and a transmit physical link 614 .
Physical layer controller 602 implements a PHY control state machine such as that specified by FIG. 40-15 of IEEE standard 802.3, reproduced here as FIG. 2 . Referring to FIG. 2 , PHY control state machine 200 starts maxwait_timer 606 when entering the SLAVE SILENT state. The maxwait_timer 606 is used by physical layer monitor 604 to indicate a link down condition.
Physical layer monitor 604 includes a monitor module 616 adapted to determine a local receiver status (loc_rcvr_status) for receive physical link 612 , and a controller 620 adapted to indicate a link status (link_status) for physical link 608 in accordance with a speed up mode signal (speed_up_mode), and a loss_lock_timer (loss_lock_timer) 626 . Controller 620 includes a normal mode circuit 622 and a speed up mode circuit 624 . Normal mode circuit 622 is adapted to indicate the link status is FAIL for physical link 608 when the local receiver status is not OK, maxwait_timer 606 expires, and speed up mode is disabled (loc_rcvr_status=NOT_OK*maxwait_timer_done*speed_up=disabled). Speed up mode circuit 624 is adapted to indicate the link status is FAIL for physical link 608 when the local receiver status is not OK and the speed up mode is enabled (loc_rcvr_status=NOT_OK*speed_up=disabled). Note that in speed up mode, maxwait_timer 606 is not used to delay indication of the failure of physical link 608 .
Controller 620 implements a physical link monitor state machine 700 according to an embodiment of the present invention, as shown in FIG. 7 . Referring to FIG. 7 , state machine 700 enters a LINK DOWN state when pma_reset=ON+link_control≠ENABLE, as specified by IEEE standard 802.3. When state machine 700 enters the LINK DOWN state, controller 620 asserts link_status=FAIL.
However, when monitor module 616 determines the local receiver status is OK (loc_rcvr_status=OK), state machine 700 moves to a HYSTERESIS state. When state machine 700 enters the HYSTERESIS state, controller 620 starts a stabilize timer (start stabilize_timer). If during the HYSTERESIS state, monitor module 616 determines the local receiver status is not OK (loc_rcvr_status=NOT_OK), state machine 700 returns to the LINK DOWN state. But if when the stabilize timer expires, the local receiver status is OK (stabilize_timer_done*loc_rcvr_status=OK), state machine 700 moves to a LINK UP state.
When state machine 700 enters the LINK UP state, controller 620 asserts link_status=OK, and starts loss_lock_timer 626 (start loss_lock_timer). For example, loss_lock_timer 626 can be initialized to less than 50 ms (or even to 0 ms) to ensure a rapid transition to the LINK DOWN state when the local receiver status is not OK (loc_rcvr_status=NOT_OK). Exit from the LINK UP state also depends on the speed up mode signal (speed_up_mode).
If during the LINK UP state, speed up mode is disabled, monitor module 616 determines the local receiver status is not OK, and maxwait_timer 606 expires (loc_rcvr_status=NOT_OK*maxwait_timer_done=TRUE*speed_up=disabled), then state machine 700 returns to the LINK DOWN state. But if during the LINK UP state, speed up mode is enabled and the local receiver status is not OK when loss_lock_timer 626 expires (loc_rcvr_status=NOT_OK*loss_lock_timer_done*speed_up=enabled), state machine 700 returns to the LINK DOWN state regardless of the status of maxwait_timer 606 . Note that this transition is governed by loss_lock_timer 626 rather than maxwait_timer 606 . Therefore Gigabit Ethernet PHY 600 achieves fast link down detection and indication.
In some embodiments, neither link_up_timer 428 nor loss_lock_timer 426 are used. FIG. 8 shows a Gigabit Ethernet PHY 800 according to such an embodiment of the present invention. Although in the described embodiments, the elements of Gigabit Ethernet PHY 800 are presented in one arrangement, other embodiments may feature other arrangements, as will be apparent to one skilled in the relevant arts based on the disclosure and teachings provided herein. For example, the elements of Gigabit Ethernet PHY 800 can be implemented in hardware, software, or combinations thereof. Gigabit Ethernet PHY 800 can be implemented as a network device such as a switch, router, network bridge, network interface controller (NIC), and the like.
Referring to FIG. 8 , PHY 800 includes a physical layer controller 802 , a physical layer monitor 804 , and a maxwait_timer 806 . In operation, PHY 800 is connected to a physical link 808 . Physical link 808 includes a receive physical link 812 and a transmit physical link 814 .
Physical layer controller 802 implements a PHY control state machine such as that specified by FIG. 40-15 of IEEE standard 802.3, reproduced here as FIG. 2 . Referring to FIG. 2 , PHY control state machine 200 starts maxwait_timer 806 when entering the SLAVE SILENT state. The maxwait_timer 806 is used by physical layer monitor 804 to indicate a link down condition.
Physical layer monitor 804 includes a monitor module 816 adapted to determine a local receiver status (loc_rcvr_status) for receive physical link 812 , and a controller 820 adapted to indicate a link status (link_status) for physical link 808 in accordance with a speed up mode signal (speed_up_mode). Controller 820 includes a normal mode circuit 822 and a speed up mode circuit 824 . Normal mode circuit 822 is adapted to indicate the link status is FAIL for physical link 808 when the local receiver status is not OK, maxwait_timer 806 expires, and speed up mode is disabled (loc_rcvr_status=NOT_OK*maxwait_timer_done*speed_up=disabled). Speed up mode circuit 824 is adapted to indicate the link status is FAIL for physical link 808 when the local receiver status is not OK and the speed up mode is enabled (loc_rcvr_status=NOT_OK*speed_up=disabled). Note that in speed up mode, maxwait_timer 806 is not used to delay indication of the failure of physical link 808 .
Controller 820 implements a physical link monitor state machine 900 according to an embodiment of the present invention, as shown in FIG. 9 . Referring to FIG. 9 , state machine 900 enters a LINK DOWN state when pma_reset=ON+link_control≠ENABLE, as specified by IEEE standard 802:3. When state machine 900 enters the LINK DOWN state, controller 820 asserts link_status=FAIL.
However, when monitor module 816 determines the local receiver status is OK (loc_rcvr_status=OK), state machine 900 moves to a HYSTERESIS state. When state machine 900 enters the HYSTERESIS state, controller 820 starts a stabilize timer (start stabilize_timer). If during the HYSTERESIS state, monitor module 816 determines the local receiver status is not OK (loc_rcvr_status=NOT_OK), state machine 900 returns to the LINK DOWN state. But if, when the stabilize timer expires, the local receiver status is OK (stabilize_timer_done*loc_rcvr_status=OK), state machine 900 moves to a LINK UP state.
When state machine 900 enters the LINK UP state, controller 820 asserts link_status=OK. Exit from the LINK UP state also depends on the speed up mode signal (speed_up_mode).
If during the LINK UP state, speed up mode is disabled, monitor module 816 determines the local receiver status is not OK, and maxwait_timer 806 expires (loc_rcvr_status=NOT_OK*maxwait_timer_done=TRUE*speed_up=disabled), then state machine 900 returns to the LINK DOWN state. But if during the LINK UP state, speed up mode is enabled and the local receiver status is not OK (loc_rcvr_status=NOT_OK*speed_up=enabled), state machine 900 returns to the LINK DOWN state regardless of the status of maxwait_timer 706 . Note that this transition is not governed by maxwait_timer 806 . Therefore Gigabit Ethernet PHY 800 achieves fast link down detection and indication.
Embodiments of the invention can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention can be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention can be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program can be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language can be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory. Generally, a computer will include one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits).
A number of implementations of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other implementations are within the scope of the following claims.
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An apparatus including a monitoring module, a first timer, and a first circuit. The monitoring module is configured to (i) monitor a link when the link is up and (ii) detect when the link fails. The first timer is configured to expire in a predetermined time after the link fails. The first circuit is configured to generate an indication that the link is down. The first circuit is configured to generate the indication (i) in response to the monitoring module detecting that the link has failed and (ii) before the first timer expires.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/500,402 covering an invention entitled “Staged Full-Image Decompressing and Half-Toning By Less than Full-Image Data-File Stages”, filed Sep. 5, 2003. The inventorship is the same in that provisional application as it is in this application, and the entirety of that provisional patent application is hereby incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to a unique system and methodology for decompressing and half-toning an image data file utilizing an approach in which decompressing and half-toning activities take place in stages, each of which involves image processing in “units” defined generally by being less than the whole of the relevant, full-image data file.
[0003] According to practice of this invention, an image data file, such as a compressed image data file, is treated in stages which involve less than the full content of the file, such as on a line-by-line basis, or a several-line by several-line basis. In each of these stages, the invention (a) first performs, with respect to yet un-decompressed image data, a decompression function, (b) next performs any image-line (or row) resizing which may be necessary, (c) next performs a half-toning function regarding what has just been decompressed, and (d) then performs a buffer-storage function relative to the completed, just decompressed and half-toned partial result, until all of the subject data in an image file has been handled.
[0004] The various features and advantages of the invention will become more fully apparent as the description which now follows is read in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a simplified block/schematic diagram illustrating the structure and methodology of the present invention.
[0006] FIG. 2 is a more detailed block/schematic diagram further illustrating the structure and methodology of what is shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0007] Turning now to the drawings, and referring first of all to FIG. 1 , indicated generally at 10 herein are the structure and methodology, in their preferred and best-mode forms, of the present invention effectively engaged in an illustrative practice of the invention. At 12 in FIG. 1 is a document which is to be “handled”, including an image, shown in dash-dot lines at 14 , which can be described as being made up of plural lines of pixels, such as the four lines shown at 14 a , 14 b , 14 c , 14 d . Line 14 a is illustrated isolated from other lines in image 14 . Lines 14 b , 14 c , 14 d are illustrated as vertically next-adjacent lines in image 14 .
[0008] By any suitable technique, and utilizing any appropriate compression algorithm, image 14 has been compressed into a compressed image file which is represented by block 16 in FIG. 1 . Shown at 18 is a “Decompress and Halftone” block, a block 20 which is labeled “Increment Output Row and Store”, and an “Output”, or “Exit”, block 22 . It is essentially within blocks 18 , 20 that the structure, and the implementation, of, the present invention exist and take place, respectively. Block 20 is also referred to herein as storing structure.
[0009] As will be more fully elaborated, block 18 processes the compressed image file represented by block 16 by dealing with less that the entirety of the image file in different successive stages of processing. A preferred manner of practicing the invention involves addressing, within file 16 , “staged” portions of that file that preferably take the form either of single lines (rows), or of several vertically contiguous lines (rows) of pixels.
[0010] With regard to a single line, or row, such as row 14 , block 18 processes this, in accordance with the invention, as a row singularity. With regard to vertically contiguous rows, or lines, such as those indicated at 14 b , 14 c , 14 d , block 18 effectively deals with these as a unit. Such a “unit” might typically take the form of vertically contiguous rows wherein vertically next-adjacent pixels are alike. Under no circumstance, however, does block 18 deal with the entirety of the image file, such as that represented by block 16 .
[0011] Within block 18 decompression and half-toning, and if desired any resizing, etc., are performed, and in each stage of processing, or rather at the conclusion of each such stage, the decompressed, resized (if applicable), and half-toned partial result is stored in a buffer which can be viewed as being within block 20 in FIG. 1 . When the entirety of image file 16 has been processed by staged decompression of portions of this image file, followed by staged half-toning of those decompressed portions, a final decompressed and half-toned output image is made available via block 22 .
[0012] FIG. 2 in the drawings elaborates the process of the invention which has just been generally described with respect to FIG. 1 . Thus, what can be seen in FIG. 2 is that included within block 18 in FIG. 1 are a “Compute Input Row Index” block 24 , and a Yes/No “New Row?” inquiry block 26 . Blocks 24 , 26 are referred to herein collectively as selecting structure. The respective Yes and No output answers from block 26 are presented, respectively, either to a block 28 labeled “Decompress Next Row”, or to a block 30 labeled “Copy Previous Row”. Block 28 is also referred to herein as decompressing structure. An output from block 28 is fed to a block 32 which is labeled “Resize Row”, and which is also referred to herein as resizing structure, wherein any row (or line) resizing which may be required is appropriately performed. Associated with each of blocks 28 , 32 is a conventional data-row buffer (not specifically shown) wherein a row of data processed by the particular block may be temporarily stored. Output from block 32 is supplied to a block 34 which is labeled “Halftone Row”. Block 34 is also referred to herein as half-toning structure. Output from block 34 is fed to previously mentioned block 20 . With respect to information dealt with by block 20 , there is provided another Yes/No inquiry block 36 which is labeled “More Rows?”.
[0013] In the practice of this invention, block 24 performs a computation indexing with respect to an input row, or plural input rows, that are to be processed. If, as determined by block 26 , there is a new, single row (or plural rows) to process, decompression of that row, or rows, takes place in block 28 utilizing any appropriate decompression algorithm. The output from block 28 is then subjected to any called-for resizing, etc., in block 32 , and the output from block 32 is then half-toned in block 34 , with the resulting partial result then stored within the buffer mentioned earlier within block 20 . If there are more rows to process, as determined by block 36 , the process just described essentially repeats itself. Had the answer to the question posed by block 26 been No, then control would have been handed to block 30 whose functionality is clearly described by its labeling in FIG. 2 . More specifically, block 30 looks to the data row which is then temporarily stored in the data-row buffer associated with block 32 , and sends this row to block 34 for half-toning.
[0014] The architecture of an algorithm which may successfully be employed in this just-described process is as follows:
while (Number of Scan lines >= 0) if (Source Line == Previous Source Line) Re-halftone previous line; else read jpeg scan lines; Resize Line; Convert to Printer K; Halftone Line; Previous Source Line = Source Line; end if Target Index += Target Stride; Source Line += └Source Height / Target Height┘ E += modulo[Source Height / Target Height]; if (E >= Target Height) E −= Target Height; Source Line += Source Stride; end if end while
[0015] In this manner, an entire image, such as image 14 , is processed on the basis of less than whole-file units selected from the related compressed image file. Processing takes place in stages, with such selected data units being first decompressed, resized if necessary, and then half-toned and stored in a buffer, until the entire image has been dealt with. The process thus followed by practice of the invention is both speedy and efficient.
[0016] Accordingly, while a preferred embodiment and certain manners of practicing the invention have been described herein, it is appreciated that other variations and modifications may be made without departing from the spirit of the invention.
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Offered by the present invention is an image decompression and half-toning system and methodology which operate in stages to select portions, but not the entirety, of the relevant image data file that is to be processed. With respect to each handled portion, practice of the invention involves performing first an appropriate decompression function, next, a half-toning function, and then, a buffer-storing function.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of European Patent Application No: 07405131.9, filed on May 1, 2007, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a sheet feeder for supplying a conveying device with folded signatures, comprising a gripper drum with at least one gripper for removing the signatures individually from a stack. In such a device, a peripherally arranged stopping device on the gripper drum includes a stop element against which the signatures can be aligned, respectively, with the fold forward. An opening mechanism opens the individual signatures aligned against the stopping device and deposits the signatures on the conveying device while also reversing their direction.
[0003] Sheet feeders of this type have long been used, for example in gathering and wire-stitching machines. These sheet feeders use a gripper drum to pull folded signatures individually from a stack, to open the signatures and deposit them, for example on a gathering chain. Sheet feeders of this type must meet the requirement of ensuring a trouble-free deposit of the signatures, even if different formats and different types of paper are used.
[0004] One essential parameter which limits the production speed is the speed at which the signature impacts the stop element. The impact causes a compressing and buckling of the signatures, especially with thin signatures, or causes the signatures to rebound from the stop element, which causes problems when the signatures are opened with the aid of the opening drums. This problem has long been known and several solutions have already been proposed.
[0005] German patent document DE-A-30 35 497 discloses a sheet feeder of the aforementioned type, which is embodied with a movable stop element. The stop element respectively takes over the signatures with a synchronous movement and then slows the signatures down, which is designed to prevent a compressing of the signatures that arrive at high speed at the stop element.
[0006] German patent document DE-A-197 38 920 discloses a sheet feeder having a belt arranged upstream of the stop element, which forms a wedge-shaped intake opening for the signatures. The goal is to achieve a stabilization of the signatures during the impact with the end stop by using the friction between the signatures and the belt.
[0007] European patent document EP-A-0 716 995 discloses a sheet feeder, for which a guide arrangement that is connected to a stop element for signatures is automatically adjusted and displaced by the supplied signature and for which the stop element itself is made of rubber or a rubber mixture that dampens the impact of the signature.
[0008] Especially with heavy signatures, it is difficult even with the aforementioned, proposed devices to sufficiently reduce the kinetic energy at high speeds when the signatures impact with the stop elements, to prevent excessive deformations that would interfere with the further processing.
SUMMARY
[0009] The above and other objects are accomplished according to one aspect of the invention wherein there is provided a sheet feeder for supplying a conveying device with folded signatures from a stack of folded signatures, the sheet feeder comprising gripper drum including at least one gripper to individually remove respective signatures from the stack; a stopping device including a stop element peripherally positioned on the gripper drum to stop the signatures and to align the signatures with the fold of the signatures in a forward direction; an opening device to open the individual signatures, to deposit the signatures on the conveying device, and to reverse the forward direction of the signatures; a delay element moving in the same direction as the gripper drum and at a conveying speed less than a speed of the gripper drum; and a press-on device arranged upstream of the stop element to press the signatures released by the gripper against the delay element and to slow down the individual signatures upstream of the stop element to an approximate speed of the delay element prior to the signatures hitting the stop element.
[0010] With the sheet feeder according to the invention, the speed of the signatures is therefore reduced gradually through the transfer to a delay element with substantially lower speed. As a result, the signatures can be slowed down, for example to half the peripheral speed of the gripper drum. Upon impact with the stop element, the signatures in that case move at only half the speed and can be controlled more securely. In particular thin signatures can thus be processed at high capacity without the signatures being compressed noticeably at the stop element. Thick and heavy signatures, which have correspondingly high kinetic energy, can be controlled easier.
[0011] A press-on device according to one modified embodiment of the invention is arranged on the stopping device itself, thus providing a simple and yet stable support for these press-on devices. The press-on devices simultaneously stabilize the signatures in the area of the stopping device.
[0012] The press-on device may comprise at least one press wheel which fits against one outside of the delay element. This press wheel presses the individual signatures against the outside of the delay element, just prior to the impact, thereby considerably reducing the conveying speed of the signatures. Two press wheels, arranged at a distance to each other, may be provided to allow for a broad and secure support and stabilization of the signatures when these impact with the stop element.
[0013] The press-on device according to a different modification of the invention may be arranged on one arm of the stopping device and pressed with tension against the delay element, wherein the tension may be adjustable. The signatures can thus be slowed down securely to the lower conveying speed.
[0014] The delay element according to a different modification of the invention is driven by the gripper drum, which can be realized particularly easily from a structural point of view by using a friction wheel that moves along with the gripper drum, at a distance to the axis of rotation. The friction wheel in this case can be driven with the aid of a toothed belt, which is engaged in a locally fixed belt pulley.
[0015] According to a different modification of the invention, the delay element is provided with at least one ring positioned along the periphery of the gripper drum, wherein the individual signatures are pressed against an outside surface of this ring before reaching the stop element. A particularly secure and stable slowing down of the signatures is ensured if two rings of this type are provided, which respectively have one outside surface. The radius of the outside surfaces is equal to or smaller than the radius on which the grippers transport the signatures to the stopping device.
[0016] The signatures may be gripped simultaneously by two grippers, which are respectively arranged directly adjacent to the aforementioned outside surfaces of the rings. The spacing between the outside surfaces is thus the same or insignificantly smaller than the spacing between the grippers, which are respectively arranged in pairs.
[0017] According to another modification of the invention, the delay element is provided with at least one endlessly circulating belt, which is arranged at the very least in the region of the stopping device and is driven with a speed that is considerably lower than the conveying speed of the aforementioned grippers.
[0018] According to yet another modified embodiment of the invention, the signatures can be slowed down to an especially low conveying speed if the delay element is provided with two or more than two members that operate at different conveying speeds. The signatures can thus be slowed over the course of two or more stages to an especially low speed. As a result, the speed at which the signatures impact with the stop element can be reduced even further and thus also the danger of damage to the signatures.
[0019] The sheet feeder is particularly suitable as a feeder for a gathering chain, but other conveying devices can also be equipped with a sheet feeder of this type.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present invention will be more readily understood from the following detailed description when read in conjunction with the accompanying drawings, in which:
[0021] FIG. 1 A view from the side of a sheet feeder according to the invention, wherein one side wall of the housing is omitted for drawing reasons;
[0022] FIG. 2 A section through the sheet feeder, along the line II-II in FIG. 1 ;
[0023] FIG. 3 A section through the sheet feeder, along the line III-III;
[0024] FIG. 4 A three-dimensional view of a part of the sheet feeder according to the invention;
[0025] FIG. 5 A partial view of the sheet feeder according to the invention; and
[0026] FIG. 6 A partial view of a signature stop element according to a modified embodiment;
[0027] FIG. 7 A partial view of a signature stop element according to a another modified embodiment;
[0028] FIG. 8 A diagram, which explains the changes in the speed of the signature while it is conveyed on the gripper drum.
DETAILED DESCRIPTION
[0029] The sheet feeder 1 shown in FIG. 1 comprises a housing 5 , provided with side plates 5 a arranged at a distance to each other, of which only one is shown in FIG. 1 . A so-called A-shaft 2 is positioned inside the housing 5 , which for the present embodiment is driven in the direction of arrow 9 and thus clockwise around an axis of rotation 11 with the aid of a drive that is not shown herein. With the A-shaft 2 , a separate folded signature 7 is respectively pulled from a stack 8 , which can also be arranged inside the housing 5 , and is conveyed with the fold 7 a facing forward in the direction of arrow 9 toward a stopping device 32 . The stopping device 32 is adjusted to the format of a signature 7 and, together with a stop element 10 , forms an end stop for the individual folded signatures 7 . The signatures 7 , which rest with the fold 7 a against the stop element 10 , are gripped by a B-shaft 3 and a C-shaft 4 and are opened in a manner known per se and deposited onto a conveying device, for example a gathering chain 15 . The signatures 7 , which are deposited saddle-shaped on the gathering chain 15 , are conveyed parallel to the axis of rotation 11 and are supplied to other devices, not shown herein, for further processing. The B-shaft 3 and the C-shaft 4 can be embodied in a manner known per se and will therefore not be explained further herein. These shafts can furthermore be replaced by a different, suitable device for opening the signatures 7 and depositing these on a conveying device.
[0030] According to FIG. 2 , a gripper drum 13 (See FIGS. 1 and 4 ) is provided with two wheels 13 a and 13 b , arranged at a distance to each other, which are fixedly connected to a shaft 19 . This shaft 19 is positioned in the housing 5 and is driven with the aid of a toothed belt 37 . Three grippers 6 , each consisting of a gripper arm 6 a and a gripper support 6 b , are positioned uniformly spaced apart along the periphery of each of the two wheels 13 a and 13 b . The grippers 6 are arranged in pairs, for example on the outside, meaning they are at a greater distance in the direction of the axis of rotation 11 than the two wheels 13 a and 13 b . However, it is also conceivable to arrange the grippers 6 of at least one of the wheels 13 a and/or 13 b between the wheels 13 a and 13 b . The gripper arms 6 a are respectively attached to a control shaft 31 , which is connected to control cams arranged inside a housing 33 (See FIG. 4 ), and can be pivoted with the aid of this control shaft for gripping respectively one signature 7 in a manner known per se.
[0031] Two opened grippers 6 are shown at the top of FIG. 4 while the remaining grippers 6 are closed. As shown in FIG. 1 , a signature 7 is gripped and held along the fold 7 a by respectively two gripper arms 6 a and two gripper supports 6 b in the closed state. Three signatures 7 per rotation can be transported with the gripper drum 13 . The gripper drum 13 can also be embodied such that it can transport only one signature 7 per rotation or more than three signatures 7 per rotation. The arrangement of grippers 6 shown herein only represents one embodiment of the gripping means.
[0032] Each wheel 13 a and 13 b is provided with respectively one ring 14 , driven with the aid of a drive 34 (See FIG. 2 ). The two rings 14 are driven with a peripheral speed that is considerably less than the speed of the gripper drum 13 . The peripheral speed of the two rings 14 , for example, is half the peripheral speed of the gripper drum 13 . FIG. 3 shows that the outside diameter of the rings 14 is selected to be the same or smaller than the diameter for the rotation of the grippers 6 gripping the signatures 7 when these rotate around the axis of rotation 11 .
[0033] The drive 34 comprises a belt pulley 18 , which is positioned on the shaft 19 and is fixedly connected to the housing 5 with the aid of a bracket 38 . The belt pulley 18 is therefore immovable, relative to the housing 5 . Arranged at a distance to the shaft 19 is a different belt pulley 21 that is connected non-rotating to a shaft 16 , wherein this shaft is mounted with the aid of a holder 17 on the gripper drum 13 , parallel and at a distance to the shaft 19 . A toothed belt 20 moving in a direction represented by the arrow 23 is fitted around the belt pulleys 18 and 21 , which can be tensioned with a belt tensioning device 22 . If the gripper drum 13 rotates on the shaft 19 around the axis 11 , then the shaft 16 moves along a circular orbit around the axis 11 , in a manner similar to a planet. As a result of the engagement of the toothed belt 20 , the shaft 16 simultaneously rotates around its axis. For driving the two rings 14 , two friction wheels 24 are mounted at a distance to each other on the shaft 16 , wherein FIG. 2 shows that the friction wheels are respectively pressed against an inside surface 25 of the rings 14 .
[0034] The peripheral speed and the rotational direction of the rings 14 can be influenced by correspondingly selecting the transmission ratio of the pulleys 18 and 21 , as well as the diameter of the friction wheels 24 and the inside diameter of the inside surface 25 of the rings 14 . For example, the transmission ratio is preferably selected such that the peripheral speed of the two rings 14 amounts to approximately 20 to 40% of the peripheral speed of the gripper drum 13 . In place of the frictional transfer of the rotational movement from the wheels 24 to the rings 14 , a different method of transfer can also be used, for example using a toothing. Furthermore conceivable is an embodiment where the rings 14 are driven separately, for example with a suitable motor.
[0035] The individual signatures 7 that are pulled from the stack 8 are then transported preferably with a uniform conveying speed v 1 to the stopping device 32 . Shortly before a fold 7 a ( FIG. 1 ) of the signature 7 impacts with the stop element 10 , the respective two grippers 6 release the signature 7 . Essentially at the same time as the respective grippers 6 open up, the signature 7 is pressed with two press wheels 12 against respectively one outside surface 30 of the two rings 14 , as shown in FIGS. 2 and 3 respectively. As a result of the frictional contact with the outside surfaces 30 , the signature 7 is slowed down to the peripheral speed v 2 of the two rings 14 and, in the process, loses kinetic energy. The contact pressure of the two press wheels 12 can be adjusted with an adjustment device 35 ( FIG. 1 ) of the stopping device 32 . This contact pressure can be changed, for example with the aid of a piston that is admitted with adjustable compressed air. Furthermore conceivable is a design where a spring is used to generate the desired contact pressure. The friction between the signature 7 and the outside surfaces 30 and thus also the negative acceleration of the signature 7 can be adjusted by changing the contact pressure.
[0036] The signature 7 is then conveyed further with correspondingly reduced speed, until the fold 7 a comes to rest against the stop element 10 and the signature 7 is aligned accordingly. The stop element 10 preferably consists of a resilient material, which for the most part prevents the printed product from bouncing back. The exposed edges of the signature 7 , which extend parallel to the fold 7 a , are then gripped by the B-shaft 3 and the C-shaft 4 and the signature 7 is opened, so that it can be deposited on the gathering chain 15 as shown in FIG. 1 . The direction of the signature 7 is reversed while it is pulled from the stopping device 32 .
[0037] Before the signature 7 is gripped by the B-shaft 3 and the C-shaft 4 and is opened, the signature 7 is aligned with the stop element and, as a result of the frictional force, remains aligned with the stop element 10 and the two rings 14 . This frictional force is overcome when the signature 7 is pulled from the stopping device 32 .
[0038] The two rings 14 together with the press wheels 12 form a delay element 36 for conveying the signatures 7 in the same direction as the grippers 6 , but with considerably reduced speed.
[0039] FIG. 6 shows a sheet feeder 1 ′, having basically the same basic design as the sheet feeder 1 , but with a modified delay element 36 ′ according to one variant. In place of the two rings 14 , this embodiment comprises an endlessly rotating belt 26 that is guided over deflection rollers 27 and is driven by a drive roller 28 . The belt 26 is tensioned with a tensioning roller 29 . As can be seen, the belt 26 is guided along a curved path in the region of the deflection rollers 27 and extends upstream and downstream of the stop element 10 . The belt 26 may be driven with a uniform speed v 2 , wherein the speed v 2 corresponds to the speed of the delay element 36 . The speed v 2 does not have to be uniform, but can also be controlled to be variable. For example, the speed v 2 can be controlled to drop in the direction of transport of the signatures 7 to the stop element 10 , so that the speed of the signature 7 is reduced even further when it impacts with the stop element 10 .
[0040] The gripper drum 13 , which is not shown in FIG. 6 , conveys a signature 7 that is pulled from the stack 8 , as described in the above. Before hitting the stop element 10 , the signature 7 is gripped by the pressure wheel 12 and is pressed against the belt 26 . At the same time, the gripper 6 which has been conveying the signature 7 opens up and the signature 7 is thus transferred to the belt 26 for further conveying. In the same way as the sheet feeder 1 , the conveying speed of the signature 7 is reduced as a result of the lower conveying speed of the belt 26 . A gradual delay over several stages is also possible with the sheet feeder 1 ′, wherein several belts 26 and press wheels 12 would then be provided. The gripping of the signatures 7 with the B-shaft 3 and the C-shaft 4 as well as the depositing on the gathering chain 15 and/or the conveying device takes place as explained in the above.
[0041] A different suitable press-on element, e.g. an endlessly circulating belt 12 ′ that is guided over deflection rollers 47 as shown in FIG. 7 , can also be provided in place of the press wheel 12 . Also possible is an embodiment with two belts 26 , arranged at a distance to each other, and correspondingly two press wheels 12 . In that case, the signatures 7 are gripped accordingly by two belts 26 and two press wheels 12 and are conveyed to the stop element 10 .
[0042] The course of the speed during the transport of the signature 7 in the region of the stopping device 32 is explained in further detail in the following with the aid of the diagram shown in FIG. 8 and the representation according to FIG. 5 . FIG. 5 shows a first angle position α 1 at which the gripper 6 opens up, which grips the signature 7 . At the angle α 1 the respective signature 7 is pressed against the rings 14 , essentially at the same time as the grippers 6 open up, thus reducing the signature 7 speed v 1 to the speed v 2 , as shown with the example of a curve K 2 in FIG. 8 . While traveling from the angle position α 1 with peripheral speed v 1 , the respective signature 7 is slowed down to the peripheral and/or conveying speed v 2 by the time it reaches a second angle position α 2 . At the angle position α 3 , the signature 7 hits the stop element 10 with the fold 7 a facing forward and is slowed by this element to the peripheral speed v 0 and thus to zero speed.
[0043] The curve K 3 in FIG. 8 represents the speed course for a signature 7 , which is conveyed with the aid of a delay element 36 and/or 36 ′, for which the speed is controlled to be variable with the aid of a cam control or a motor. During the transport of the respective signature 7 , the speed of the delay element 36 and/or 36 ′ from the angle position α 1 to the angle position α 2 is reduced with the aid of the aforementioned control and/or the motor. As a result, it is possible to further reduce the speed at which the signature 7 impacts with the stop element 10 . FIG. 4 shows that the corresponding impact speed is substantially lower than the speed v 2 . As mentioned above, such a speed delay can be achieved over several stages.
[0044] In FIG. 8 , the curve K 1 shows the course of the speed in a sheet feeder according to prior art where the signatures 7 hit the stop element 10 at the angle position α 3 without being delayed. The signatures 7 are thus abruptly stopped with the speed v 1 of the gripper drum 13 when they reach the stop element 10 and/or are slowed to the peripheral speed v 0 .
[0045] It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A sheet feeder for supplying a conveying device with folded signatures from a stack of folded signatures, the sheet feeder including a gripper drum. The gripper drum includes at least one gripper to individually remove respective signatures and a stopping device. The stopping device including a stop element to stop and align the signatures with the fold of the signatures in a forward direction. The sheet feeder includes an opening device to open the individual signatures, to deposit the signatures on the conveying device, and to reverse the forward direction of the signatures. The sheet feeder includes a delay element moving in the same direction as the gripper drum and at a conveying speed less than the gripper drum speed. A press-on device to press the signatures released by the gripper against the delay element and to slow down the individual signatures prior to the signatures hitting the stop element.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional patent application Ser. No. 61/896,934 filed on Oct. 29, 2013, the entire contents of which are incorporated herein by reference.
FIELD
[0002] This invention relates generally to medical monitors and more specifically to a medical monitoring system for patients and infants. More particularly, this invention relates to integrating a passive sensor array into a mattress, a mattress pad, or sheet placed under a patient, child, or infant.
SUMMARY
[0003] The present invention is directed to a medical sensing device. The device comprises a sheet, a set of first sensors spaced apart about the sheet, a set of second sensors spaced apart about the sheet, and a processor for receiving the first characteristic and second characteristic and generating an alert signal when the first characteristic or the second characteristic is outside a fixed parameter. The first sensors detect a first characteristic and the second sensors detect a second characteristic.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 an embodiment sensor sheet with a plurality of sensor arrays.
[0005] FIG. 2 is an embodiment sensor sheet with a plurality of sensor arrays with sensors coupled to a wiring harness.
DETAILED DESCRIPTION
[0006] The present invention is described with reference to the attached figures, wherein like reference numerals are used throughout the figures to designate similar or equivalent elements. The figures are not drawn to scale and they are provided merely to illustrate the invention. Several aspects of the invention are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide an understanding of the invention. One skilled in the relevant art, however, will readily recognize that the invention can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operations are not shown in detail to avoid obscuring the invention. The present invention is not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the present invention.
[0007] Sensors may detect a characteristic, for example, sensors that detect motion, pressure, temperature, pH, moisture, and other conditions are known to those that are skilled in the art.
[0008] One version of these sensors is to connect them to a computer or other such sensor reading device with wires. Another version is for the sensors to send data wirelessly to a sensor reading device via WiFi or Bluetooth.
[0009] The wireless sensors may be powered by an internal battery or may be powered externally by RF when interrogated by the sensor reading device in a manner similar to RFID tags.
[0010] FIG. 1 illustrates and embodiment sheet 100 with an array of attached sensors 102 , 104 , 106 , and 108 . Each sensor 102 , 104 , 106 , and 108 is adapted to detect a characteristic. A first sensor 102 may be a weight sensor to detect the presence and position of a child, infant or patient. A second sensor 104 may be a moisture sensor to detect blood or excretion of fluids. A third sensor 106 may be a pH sensor to differentiate between various body fluids. A fourth sensor 108 may be a temperature sensor. While these are listed, one of ordinary skill can appreciate that the positions of the sensors 102 , 104 , 106 , 108 are not limiting and that other sensors, such as microphones, heartbeat, pulse, O 2 level, and lung monitors, etc. may be utilized.
[0011] Although a sheet 100 with arrays of sensors is illustrated in FIG. 1 , the sheet may be the surface of a mattress, a mattress pad, or a pad under the bed sheet on which the patient, child, or infant is lying.
[0012] The sensors in FIG. 1 may communicate with a sensor reading device wirelessly with WiFi or Bluetooth. The sensors may be self-powered with an internal battery or may be externally powered by RF in a manner similar to RFID tags or powered by POE interne switch.
[0013] FIG. 2 illustrates an embodiment where the various sensors in the sensor arrays are connected by wires 200 to a wire harness 202 which may then be attached to a sensor reading device with a processor such as a computer 204 . As shown the sensors are connected by a wired connection to the computer. One skilled in the art will appreciate that a wireless connection may be made to the computer, and that the computer may be located remotely from the sheet 100 . One skilled in the art will appreciate that the sensors can be utilized to provide alarms for serious conditions, such as SIDS in infants or discrepancies, such as large variations in weight indicative of unauthorized persons in the bed or extended lack of movement. Data collected can be utilized to create reports, analyze historical data, sleep patterns and other medical data meaningful to one skilled in the art.
[0014] One embodiment for using the sheet is in a bed in a hospital. In this embodiment the sensor sheet 100 is connected to a sensor reading device such as a computer. The sensor reading device may be in the same room as the patient or infant or may be in another room or building. The sensor reading device may summarize the sensor data and plot it on graph. The sensor reading device may also send an alert to a nurse or parent if any of the sensor data goes out of a predetermined range. For example a cell phone alert could be sent out if the patient or infant or child gets out of the bed or fails to move for a certain length of time or wets the bed. One skilled in the art will appreciate that data gathered by the sheet 100 may include sleep positions, bodily fluid alerts, biometric statistics such as heart rate, oxygen level, and blood pressure, patterning data from patient history, breathing recognition and monitoring, absence alerts, weight notifications, contact point notification for non-authorized lifting of body parts, sleepwalker notification, changes in temperature, seizure recognition, shock notification for identification of abuse. Indicia such as the above may be used to provide automated alerts to caregivers or responding agencies, and historical data may be stored onsite or in the cloud. In addition, the doctor, nurse, or parent may receive an alert at any time regarding a change in status of the patient, child, or infant. A central interface for multiple sensor sheets 100 may be utilized at, for example, a nurses station in a hospital or medical practice group. Database information may also be utilized for more long-term analysis of data in nursing homes or hospice settings.
[0015] One skilled in the art will appreciate that the sensors in the sensor sheet 100 may communicate wirelessly with the sensor monitoring device. An interface for accessing the data may be provided on a remote computer, cell phone, or tablet computer. Further, the sheet 100 may comprise multiple components, for example, a sheet for detecting moisture and a pad for detecting pressure, temperature, etc.
[0016] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only and not limitation. Numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above described embodiments.
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A medical sensing device contained in a sheet or mattress pad. The sensing device comprises a number of sets of sensors, each equipped for detecting a characteristic of a patient proximate the device. The characteristic is sent to a processor which determines whether the characteristic is within a pre-determined parameter. If not, an alarm is sounded.
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BACKGROUND OF THE INVENTION
For the consumer and professional, there has been a variety of products available throughout the years for the recoloring of footwear. Aerosol, lacquer-type sprays, and brush-on recolor water-based type finishes have been on the market for a considerable time. These products have had inherent deficiencies. The fast-dry lacquer-type aerosols, or sprays, mostly become hard after they are applied, because the nature of the coating is a solvent-type lacquer, which has been manufactured by dissolving a resin into a solvent. The resulting coating, then, has the properties of the resin-solvent blend. If the resulting coating would be too hard, plasticizer is often added as an external agent to soften the resulting coating. What then happens is that the plasticizer migrates out of the coating, making it hard and brittle. Or, while in the coating, the plasticizer may render the surface tacky. That is the nature of plasticizers. Lacquer-type coatings, whether nitrocellulose, vinyl, or acrylic, do not have the requisite inherent flexibility. Therefore, coatings conventionally are mixtures of chemicals. The resulting coating can exhibit different qualities as it ages. There often is a considerable loss of flexibility, wear, abrasion resistance, etc. As a result, known recolor finishes for shoes, whether they be solvent blends or water-based blends, exhibit qualities of serious aging and deterioration because of the nature of how the coating was manufactured. Thus, a shoe recoloring product loses its washability, durability, and flexibility, because the mixed chemicals do not stay in the condition they were, at the time of mixing.
Almost all new sneakers soon get dirty, and show signs of wear and tear after they are used in sports activities. The same is true for most shoes and footwear. It is not uncommon for sneakers and shoes to show considerable signs of use and wear shortly after being purchased.
One popular product on the market now is a water-based color coating for ladies shoes. It has very poor water resistance and does not wear well. It is a color coating which is a mixed-together product. Professionals also have available a lacquer-type aerosol which colors shoes and leather, but exhibits the same poor tendencies of all mixed coatings and finishes.
There are similar problems in protecting luggage and other leather and leather-like goods that, like footwear, are subject to scuffing, flexing and changes in humidity, since the finishes available to recolor and protect them are generally the same as those available for recoloring and protecting the outer surfaces of leather and leather-like portions of footwear.
SUMMARY OF THE INVENTION
An item of footwear which has become scuffed or worn, or which is to be protected against wear, on its leather or leather-like external surfaces, is subjected to a preliminary cleaning. Thereafter, a coating of polyurethane elastomer dissolved in a solvent (preferably half toluene and half isopropyl alcohol), further including a colorant, a thickener and a gloss-lowering agent, is brushed or swabbed onto the surface. The solvent evaporates, leaving a thin, flexible, scuff-resistant coating the color of which covers and hides discoloration and scuffs on the original surface.
DETAILED DESCRIPTION
The surfaces that can be recolored and/or protected using the process and coating material of the present invention are generally the external surfaces, subject to wear and discoloration, of leather and leather-like footwear such as one would ordinarily think to protect using shoe polish, leather protector, vinyl protector and the like.
In addition to leather (tanned animal skin), the following are examples of leather-like materials which can be protected using the method and coating material of the present invention: sneakers, tennis shoes, all types of men's and ladies' footwear, athletic shoes and equipment, belts, briefcases and other leather goods, as well as those made of synthetic or artificial leather, typically polyvinylchloride.
An initial step in practicing the method of the invention is cleaning the surface which is to be coated. The surface may be cleaned by applying a cleaning agent, and then wiping the surface. More than one cleaning agent can be used in succession or mixed together, and any convenient means may be used for applying the cleaning agent then wiping the surface, e.g. spraying, swabbing, dipping, followed by wiping with a cloth, sponge, squeegee or the like.
The preferred cleaning agent is acetone. In addition, the following are examples of cleaning agents which can be used: ethyl acetate, isopropyl alcohol, methyl ethyl ketone and methylisobutyl ketone.
The coating composition used in the present invention includes a reacted polyurethane elastomer, dissolved in a solvent, a pigmented colorant, a thickener and, preferably, a gloss-lowering agent.
The preferred polyurethane elastomer is Spencer Kellogg Products/NL Chemicals Spenlite L89-30S (product code No. 38489) which is believed to be 30% reacted polyurethane elastomer dissolved in 35% toluene and 35% isopropyl alcohol.
The preferred polyurethane elastomer is believed to be a type 5 thermoplastic polyester-type polyurethane elastomer. In addition to the preferred elastomer, the following are examples of polyurethane elastomer which could be used as the polyurethane ingredient of the coating composition of the present invention: QC10 available from K. J. Quinn & Co. of Malden, Mass., and Desmolac 4125, available from Mobay Chemical Corp. of Pittsburgh, Pa.
The preferred solvent for the polyurethane elastomer is a 1:1 mixture of toluene and isopropyl alcohol (which is the same solvent system used by the manufacturer in Spenlite L89-30S). Examples of other solvents which could be used include: methyl ethyl ketone and/or isobutyl ketone mixed with isopropyl alcohol.
Except where the coating is to be used as a clear protective coating on a non-worn surface, the coating composition includes a pigmented colorant. Examples of pigmented colorants which could be used include: thalo blue and titanium dioxide. Pigments must be ground into the resin, not mixed in, as is the case with a typical resin formulation.
(The preference of colorant is dictated by the desired color of the resulting coating.)
By preference, the coating composition further includes a thickener, in order to help keep the pigment evenly dispersed throughout the coating composition. The preferred thickener is Nuodex Nuvis HS, which is believed to consist of acid agents coated with powder which chemically cause a reaction which thickens the coating. Examples of other thickeners which could be used include: lecithin.
By preference, except where the coating is meant to provide the coated surface with a patent leather-like shiny appearance, the coating composition further includes a gloss-reducing agent. A preferred gloss-reducing agent is Syloid, made by The Syloid Company, which is believed to consist of: powdered silica which reduces the gloss levels of paints and coatings. Examples of other gloss-reducing agents which could be used are: other powdered silicas, micron size.
A specific example of a coating composition which is preferred for use in practicing the present invention is as follows:
______________________________________Parts by Weight Ingredient______________________________________1 Spenlite L89-30S1.5 solvent (1:1 toluene and isopropyl alcohol)10 pigment1 Nuvis HS thickener1 Sylox gloss-lowering agent______________________________________
The ingredients may vary in percentage from the point values given above in the specific example of the preferred embodiment. In fact, the ingredients may vary as follows:
______________________________________Range of weight percent Ingredient______________________________________20% to 40% polyurethane elastomer40% to 60% solvent10% to 20% pigment 1% to 3% thickener 1% to 2% gloss-lowering agent______________________________________
The coating composition is preferably applied by using a conventional brush, sponge, swab, wiper or the like to spread on a thin coating, which is preferably allowed to air dry at room temperature.
The coating is preferably applied so thinly that one ounce of the coating composition covers from 10 to 25 square inches of the surface of the leather or leather-like substrate.
The coating composition optionally may include additional ingredients for their respective qualities. Examples of such other possible ingredients, and the range of weight percentages that each may have in the coating composition are: lethicin, 1-3 percent, to improve gloss, slow drying time and increase pigment dispersion; N-methyl perrillidone to slow drying time of the lacquer; other slow solvents such as cellusolve acetate and/or xylene, may be used to slow down drying time.
It should now be apparent that the brush-on finish for footwear and similar articles as described hereinabove, possesses each of the attributes set forth in the specification under the heading "Summary of the Invention" hereinbefore. Because it can be modified to some extent without departing from the principles thereof as they have been outlined and explained in this specification, the present invention should be understood as encompassing all such modifications as are within the spirit and scope of the following claims.
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An item of footwear which has become scuffed or worn, or which is to be protected against wear, on its leather or leather-like external surfaces, is subjected to a preliminary cleaning. Thereafter, a coating of polyurethane elastomer dissolved in a solvent (preferably half toluene and half isopropyl alcohol), further including a colorant, a thickener and a gloss-lowering agent, is brushed or swabbed onto the surface. The solvent evaporates, leaving a thin, flexible, scuff-resistant coating the color of which covers and hides discoloration and scuffs on the original surface.
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BACKGROUND OF THE INVENTION
The mounting of radio antennas on vehicles such as trucks and the tractor members of tractor-trailer combinations has become very popular in view of the use of citizen band radios by which the drivers of such vehicles can be kept in communication with home offices, dispatchers, and other personel as well as other vehicle drivers. Various types of awkward and make shift clamping members for the antennas are used in a number of installations to mount the antennas at various locations upon the cabs, for example, of such vehicles and many of these are ineffective for purposes of securely mounting and supporting the antennas relative to the vehicles and particularly in a manner to insulate the antennas from the metal parts of the vehicle.
It is possible to provide permanently attached brackets to the cabs of vehicles as well as upon other locations upon the vehicle but this requires making holes in the supporting means on the vehicle and this is undesirable, particularly when it is desired to remove the antenna and the bracket, with the result that the holes in the supporting surface are visible.
Certain service vehicles such as police cars, ambulances and the like also are equipped with radio antennas of a substantial type and many of these are mounted either upon the rear bumper of the vehicle or upon one side of a rear fender. The bumper type antenna usually employs a pair of clamping claws which engage upper and lower edges of the bumper, while the brackets attached to one side of a rear fender of the vehicle are of a permanently attached type requiring the making of holes in the fender as referred to above. Other installations also have been made upon such vehicles by mounting the same upon the roof of the cab or body of the vehicle and these also have included the making of holes in the supporting surfaces, all of which is objectionable, especially after the antenna is dismounted for any purpose.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide a simple, strong, durable and effective clamp comprising a pair of similar clamping members having grooves in opposed clamping faces thereof which respectively receive opposite surfaces of an outwardly extending rod-like supporting member such as a bracket arm for rear view mirrors of the type used on the sides of truck cabs and the like which are permanently attached in firm manner to the side of the cab, thereby offering a highly suitable support member, one of said clamping members having a seat in the upper surface thereof which receives an insulating coupling member having a threaded upper end to which the threaded lower end of a vertical, metallic radio antenna is connected in spaced relationship to any metallic portion of the clamping means, whereby a hot wire connector may easily and effectively be clamped between the threaded end of the antenna and the upper end of said insulating coupling member, while a ground wire may be connected to one of the metallic clamping members at a suitable location upon the vehicle.
Another object of the invention is to provide a bore in the upper clamping member to which said insulating coupling member is connected, said bore being threaded to receive a short threaded metallic connector which projects above the seat in said clamping member and is threaded into the lower end of said insulating coupling member to firmly connect the lower end thereof against said seat in said clamping member in a very simple but highly effective manner, the upper end of said threaded connector being spaced from the lower end of the metallic antenna rods so as to be insulated therefrom.
A further object of the invention is to provide the lower end of the radio antenna with a geometrical configuration in cross section, such as hexagonal, to facilitate engagement thereof with a wrench and the threaded extremity of said antenna rod being circular, thereby providing a shoulder at the junction of said threaded end with said geometrical configuration of the rod, said shoulder being employed to effectively clamp said aforementioned apertured metallic connector for a hot wire between said insulating coupling member and said metallic antenna rod in a manner to insulate the hot wire connector from the clamping members.
Details of the foregoing objects and of the invention, as well as other objects thereof, are set forth in the following specification and illustrated in the accompanying drawings comprising a part thereof.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary vertical elevation of an installation illustrating a typical example of antenna mount embodying the principles of the invention and shown as being attached to a horizontal mirror supporting rod of a truck cab which is shown in phantom.
FIG. 2 is a vertical end view of one end of the clamp type mount comprising the present invention, the antenna not being present in said figure.
FIG. 3 is a top plan view of the mount shown in FIG. 2.
FIG. 4 is an enlarged vertical sectional view of the mount illustrated in FIG. 3 as seen on the line 4--4 thereof, the upper end of said figure illustrating a fragmentary lower portion of a typical metallic antenna rod.
FIG. 5 is a vertical sectional view of the upper clamping member of the mount illustrated in FIGS. 2-4, as seen along the line 4--4 of FIG. 3.
FIG. 6 is a fragmentary vertical elevation of the lower end portion of the typical antenna rod shown in FIG. 4 and particularly showing the shoulder formed thereon between the threaded terminal portion and the hexagonal lower portion immediately adjoining said threaded portion.
FIG. 7 is a transverse sectional view of the lower end of the antenna as seen on the line 7--7 of FIG. 6.
DETAILED DESCRIPTION
Referring to FIG. 1, a phantom outline 10 of one side of the cab of a vehicle such as a motor truck is shown, said side supporting a bracket structure 12 having upper and lower parallel arms 14 and 16 by which a rear view mirror 18 is supported at opposite ends. One of said arms provides a very convenient support for an antenna or aerial 20 of the type frequently used on commercial vehicles, for example, for use with citizen band radios that afford either one way or two way communication between the driver of the vehicle and another vehicle, dispatching office, or otherwise. Suitable clamping means for supporting such antenna or aerial 20 upon such vehicle has largerly been left to chance which has resulted in many types of somewhat makeshift clamping devices to support such aerials. The purpose of the present invention however is to provide a simple, but highly effective and structurally strong antenna support 22 which is readily attachable to one of the mirror supporting arms, FIG. 1 illustrating the same being attached to the upper arm 14. Details of said support 22 are as follows.
Support 22 primarily consists of a pair of similar clamping members 24 and 26. For purposes of pleasing appearance as well as providing a smooth exterior surface, said clamping members, in cross section, are semi-circular and the length of said members is preferably substantially equal to the diameter of the members. These members preferably are made from suitable metal such as steel and, for aesthetic purposes, as well as to render them rust proof, the same are finished by applying a coating of chromium or other suitable plating metal thereto or, the same may be made from aluminum and polished to a pleasing surface. Thus, the members 24 and 22 have a curved outer surface and the opposing clamping surfaces 28 and 30 thereof are substantially planar and, in use, preferably are parallel to each other.
For purposes of providing effective engagement of the clamping members with one of the mirror supporting arms, for example, such as arm 14, it will be seen from FIGS. 2 and 4 in particular, that centrally of each clamping surface 28 and 30 and extending for the full length thereof, there is an arm-engaging clamping groove, the groove in clamping member 24 being identified as groove 32, while the groove in clamping member 26 is identified as groove 34. It will be seen that the groove 34 is larger than groove 32 and this difference is purposeful by rendering these grooves more universal than otherwise for purposes of tightly engaging a variety of different types of supporting members such as not only rods which support a rear vision mirror but rods of other types which are employed for various purposes on vehicles of different kinds which have need for supporting a radio antenna. In FIGS. 2 and 4 however, the upper arm 14 shown in FIG. 1 is employed for illustrative purposes to show an exemplary clamping function of the grooves 32 and 34.
The clamping members 24 and 26 are secured in clamping relationship by a plurality of bolts 36 which, for example, may be of the Allen type and the same extend through appropriate holes 38 formed, for example, in triangularly spaced relationship to each other, as shown in FIG. 3 in exemplary manner, within the clamping member 24. Axially aligned holes 47, which are tapped to receive the threads of screws 36, are formed in the other clamping member 26. From FIG. 4 and FIG. 5, it also will be seen that the clamping member 24 is provided with suitable seats 40 which are complementary to the heads of the bolts 36 and permit the heads to be recessed a substantial distance into the interior of the clamping member 24 to minimize projections when the clamping members are secured in operative position. It also will be understood that normally, there is a slight space 42 between the clamping surfaces 28 and 30 of the clamping members in order to insure firm engagement of the clamping grooves 32 and 34 with a supporting member such as arm 14.
The upper clamping member 24 also is provided with an additional seat 44 which is milled into the upper curved surface of said member, diametrically opposite the clamping groove 32 therein and mid-way of the opposite ends of the clamping member 24. Centrally of said seat, there is also a threaded bore 46 which intersects both said seat 44 and clamping groove 32. The bore 46 threadably receives one end of a threaded connector 48 which preferably is metallic such as steel, brass, or otherwise. As shown in FIG. 4, the lower end of connector 48 should not project any substantial distance into the groove 32 and the upper end thereof projects only a limited distance above the seat 44, for purposes to be described.
The present invention also includes an antenna coupling member 50 which is formed from suitable insulating material, such as an appropriate plastic or synthetic resin material of a substantially firm, relatively hard nature in order that the same may be provided with a central bore 52, at least the opposite ends of which are threaded respectively to threadably receive the upper end of the threaded connector 48 which extends into the lower end of bore 52 of coupling member 50 and the upper end of said threaded bore receives a threaded end 54 on what is the lower end of radio antenna 20 when the same is mounted in use. The threaded end 54 of the antenna is only of limited length in order that when the same is fully threaded into the upper end of the bore 52 of coupling member 50, there will be an insulating space 56 provided in the bore 52 between the opposing ends of the threaded end of 54 of antenna 20 and the upper end of threaded connector 48, as clearly shown in FIG. 4.
The exterior surface of coupling member 50 preferably is geometrical in cross section, such as hexagonal, in order that a wrench might be used to firmly thread the same onto the upper end of threaded connector 48 and into tight engagement with the additional seat 44 so as to firmly secure the antenna coupling member 50 to the clamping member 24.
At least the lower end 58 also is geometrical in cross section, such as shown in FIG. 7 in order that a wrench might be employed to tightly thread the lower threaded end 54 of the antenna into the threaded upper end of bore 52 of coupling member 50 and, in so doing, this clamping function is employed for the additional purpose of securing an electrical terminal grommet 60 which is apertured with a hole of a suitable diameter to receive the threaded end 54 of antenna 20 and due to the fact that said threaded end is circular in cross section and is machined into such condition from the hexagonal shape of the lower end 58 of the antenna 20, a shoulder 62 is provided on said lower hexagonal end 58 of the antenna which firmly abuts the upper surface of grommet 60 incident to tightly threading the threaded end 54 of the antenna into the threaded bore of the coupling member 50 and thereby not only tightly secures the grommet to the assembly but establishes electrical connection in a metal-to-metal contact between the antenna 20, which is formed of metal, and the grommet 60 which also is if metal. Due to the fact however that they are both connected to an electrical insulating coupling member 50, a wire 64, which is a "hot" wire that is connected from the radio unit to the aerial will not be grounded.
The antenna mount also is provided with electrical grounding means in the form of a convenient screw 66 which is threaded, for example, into one end of one of the clamping members, such as clamping member 24 as shown in FIGS. 2 and 3, said screw also securing another electrical metallic grommet 68 to said metallic clamping member for purposes of securing a ground wire 70 to the antenna mount and thereby provide the necessary rudiments of an electrical circuit to the antenna support 22.
From the foregoing, it will be seen that the present antenna mount comprises a relatively simple structure which may be easily manufactured and assembled with the use of relatively simple tools so that no professional assistance is required to attach the same to a supporting member of a vehicle, whether automotive or otherwise, in order that a radio antenna 20 may be supported thereby in firm manner and in electrically insulated manner from the arm or other means to which the mount is clamped.
While the invention has been described and illustrated in its several preferred embodiments, it should be understood that the invention is not to be limited to the precise details herein illustrated and described since the same may be carried out in other ways falling within the scope of the invention as illustrated and described.
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A clamp-type mount adapted to be clamped to an outwardly extending rod-like member such as a rear view supporting arm projecting from one side of the cab of a truck and including a pair of similar clamping members having opposed grooves in the adjacent faces of the clamping member to receive said rod-like member, and one of said clamping members having a seat formed thereon for the reception of an electrical insulating coupling member which is attached by a short threaded rod member to said one clamping member against said seat therein and the outer end of said coupling member being threaded to receive a threaded end of a metallic antenna rod and clamp a metallic connector against the outer end of the insulating coupling member for connection of a hot wire thereto.
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RELATED APPLICATIONS
The present application is a divisional of U.S. application Ser. No. 12/612,851, filed Nov. 5, 2009, and claims priority from, Japanese Application Number 2009-090490, filed Apr. 2, 2009, the disclosures of which are hereby incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a guided vehicle, specifically to a guided vehicle equipped with rubber tires suspended by means of air springs used as secondary suspensions or a magnetic levitated vehicle, etc.
2. Description of the Related Art
Recent years, a medium capacity transit system, one of so-called new transit systems, in which guided vehicles equipped with rubber tires travel along exclusive guideways, has become widespread, and also development work toward practical use of magnetically-levitated trains is making advances. Full automatic operation of unmanned vehicles is performed in many of these transit systems. In some case the vehicle has guide wheels to guide it along the sidewall of the guideway.
Many of vehicles used in these new transit system or magnetic levitation system adopt pneumatic suspension as secondary suspensions for the sake of improving ride quality as shown in FIG. 7 . In FIG. 7 , reference numeral 100 is a body of a vehicle, 102 are air springs, 104 are tires, and 106 are guide wheels for guiding the vehicle along a guide rail not shown in the drawing. Left and right tires 104 are connected by an axle covered by an axle housing.
However, the air spring 102 must be located between the axle housing and the vehicle body 100 , so each of the left and right air springs 102 is located at a position inner side from the left and right tires 104 respectively when tires 104 are used. The air spring 102 is composed of a bellows (or diaphragm) made of multi-plied rubber and reinforcing fiber layers and it can withstand a pressure of about 2.0 MPa, however, operating pressure is limited generally to 0.59 MPa or lower in consideration of durability of the bellows (or diaphragm).
Further, the bellows (or diaphragm) act as a spring by its expansion and contraction in vertical directions, so it is shaped to be circular in plan view in order to evade occurrence of local stress concentration which tends to occur if it is not circular in plan view. Therefore, when load to be supported by the air spring increases; the outer diameter of the air spring must be increased to increase its effective load area so that inside pressure of the bellows (or diaphragm) does no exceed the limit pressure. With air springs of large outer diameter, distance between the left and right air springs decreases, resulting in decreased rolling stiffness of the vehicle, that is, resistance to rolling of the vehicle decreases and ride quality is deteriorated. Further, in order to manufacture an air spring of large outer diameter unpracticed heretofore, it is needed to make a mold to form constituent parts, which requires fairly large cost.
Furthermore, with decreased distance between the left and right air springs, tilt adjustment of the vehicle body by adjusting the left and right air spring becomes not easy, and more time is needed to perform tilt adjustment of the vehicle body. It may be thinkable to broaden the tread, i.e. distance between the left and right wheel in order to locate the air springs of increased outer diameter increased to comply with increased vehicle load without decreasing center distance of left and right air spring. However, larger cross-section surface of guideways are required with increased tread of the guided vehicle, a lot of money will be required for provision of infrastructure. As to domestic new transit systems, vehicle width is determined in standardization and cannot be increased by preference.
As to an art to improve stiffness and damping of rolling of a vehicle equipped with air springs, a rear suspension device of a bus is disclosed for example in a patent literature 1 (Japanese Laid-Open Patent Application No. 2001-47830).
According to the literature, in a rear suspension device comprising; air springs located just under the straight side members (component members of the chassis frame) at positions front ward and rear ward from the rear axle housing, and shock absorbers located between the rear axle housing and the straight side members to attenuate vibration of the bellows (or diaphragm) of the air springs; the rear shock absorbers are located outer side from the side members, thereby increasing distance between the left and right shock absorbers, and thereby making the distance between the left and right shock absorber of the rear shock absorbers nearly equal to that of the front shock absorbers. By this, stiffness of rolling and damping of the rolling effectuated by the rear shock absorber is improved, and the effects of suppression of rolling by the rear and front shock absorber become nearly balanced.
In a patent literature 2 (Japanese Laid-Open Patent Application No. 2005-96724) is disclosed a method of controlling tilting of a vehicle body. The invention relates to tilt controlling of the body of a vehicle having front and rear bogies on which the vehicle body is supported by means of air springs.
Tilt control is performed by controlling supply and drain of air to four air springs located on the front and rear bogies at left and right positions respectively. According to the invention, when the vehicle runs through a curve section of rail road, two air springs of either of the front or rear bogie are communicated with each other so that the vehicle body is supported by apparent three-point support on the bogies. In this state, tilting of the vehicle body is controlled by supplying or draining air only to or from air springs not communicated with each other. In this way, air consumption for body tilt control can be decreased.
However, the rear suspension device of a bus as disclosed in the patent literature 1 aims to attain low-floor construction of a bus. As rear axle load is two times that of the front axle in the bus, two air springs of the same size are attached at a forward and rearward position from the rear axle housing for each of left and right side of the vehicle. The left and right air springs depart from each other by more than a little distance, and the two air springs are not communicated with each other. Therefore, the rear axle is supported by four separate air springs, and when there is a bias or deviance in distribution of sprung weight among the four rear air springs, height and tilt adjustment of the vehicle by controlling each separate air spring becomes difficult. That is not problematic in the case of trucks and buses, however, in the case of guided vehicles, it is necessary to severely control difference between the platform surface and floor surface of the vehicle to be in a range of ±few millimeters, so that becomes problematic.
The method and device of controlling tilting of the vehicle body aims only to decrease consumption of air required to tilt the vehicle body when the vehicle runs through a curve section of the rail road by communicating the left and right air spring of either of the front or rear bogie, and can not resolve such a problem that occurs when air springs of increased outer diameter are used in order to comply with increased axle load, i.e. decrease in rolling stiffness due to decreased distance between the left and right air spring.
SUMMARY OF THE INVENTION
Therefore, the object of the invention is to provide a guided vehicle of air spring suspension, with which decreasing center distance of the left and right air spring in order to mount air springs of increased diameter and increased load carrying capacity, which decreasing of center distance of the left and right air springs induces decrease in rolling stiffness of the vehicle resulting in deteriorated ride quality and also induces difficulty in adjusting vehicle height resulting in spending long time in height adjusting operation, will not be required even when load carrying capacity of air springs is required to be increased in order to comply with increased vehicle load.
To attain the object, the present invention proposes a guided vehicle for traveling exclusive guideways having air springs to support the vehicle body on axles thereof, wherein the air spring is composed of a plurality of air spring elements connected to one another so that their inside rooms are communicated to one another.
By connecting a plurality of air spring elements to one another so that their inside rooms are communicated to one another, the outer diameter of each air spring can be decreased, and mounting distance between the left and right air springs can be widened by just that much, so rolling stiffness of the vehicle is increased and the vehicle does not rolls easily and ride quality is improved. Further, by communicating the inside rooms, inside pressure of a plurality of the air springs is always equal, so it does not happen that only one air spring supports the load, and as a plurality of the air springs can be located so that virtual center line thereof coincides with the center line of the axle, superfluous back-and-forth bending force does not exerts on the frame.
When manufacturing an air spring of a diameter not commercially available, enormous cost is needed because a mold, or pattern is needed to be made. By using air spring elements of size commercially available as being done in the invention, increase of load of the vehicle can be dealt with at a low cost.
By mounting the air spring such that they are arranged tandem along the longitudinal direction of the vehicle and symmetrically with respect to the center line of the axle of the vehicle, each air spring can be decreased in outer diameter as mentioned before, and by communicating the inside rooms, front and rear air spring elements are always equal in inside air pressure even when the inside pressure fluctuates and the air spring elements work like a single air spring. Therefore, displacements of the left and right air spring elements are always equal and inclination in the anteroposterior direction does not occur, so, vehicle height adjustment is eased as if left and right wheels are suspended respectively by a single air spring. Further, as air spring of smaller diameter are used, it becomes unnecessary to think of widening the width of the vehicle.
By arranging a plurality of air spring elements such that the centers of the spring elements are on a circle, an air spring further increased in load supporting capacity can be obtained.
Spring constant K of an air spring is given by the following equation:
K =γ×( P 0 /V 0 )× A 0 2
where γ is polytropic index of air, P 0 is inside air pressure, V 0 is inside room volume, and A 0 is effective load area of the air spring respectively.
As can be recognized from the above equation, spring constant K reduces with increased inside room volume V.
Therefore, by composing such that a plurality of air spring elements are covered by a common cover-dish, the volume of the common inside room per one element increases, so spring constant can be decreased further, resulting in further improvement of ride quality.
By connecting a plurality of air spring elements via flexible communicating pipes, flatness of installation face to place each of the air spring elements is of no importance, and each air spring elements is allowed to be mounted on each installation face not level with each other as necessary depending on the construction of the vehicle.
As has been mentioned above, the guided vehicle of the invention is provided with a plurality of air spring elements with inside rooms thereof communicated to one another, so the outer diameter of each of them can be decreased. Therefore, the mounting distance between the left and right air spring can be decreased by just that much, rolling stiffness of the vehicle can be increased resulting in improved ride quality, and it becomes unnecessary to think of widening vehicle width, which will result in an increased cost.
Further, by arranging a plurality of air spring elements such that centers of the spring elements are on a circle, an air spring with increased load supporting capacity can be obtained, and further, by composing such that a plurality of air spring elements are covered by a common cover-dish, the volume of the common inside room per one element increases, so spring constant can be decreased, resulting in improvement of ride quality, because spring constant K is inversely proportional to the inside room volume V 0 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view of the first embodiment of an air spring used for the guided vehicle according to the present invention, FIG. 1B is a cross sectional view along line a-a′ in FIG. 1A , and FIG. 1 c is partial cross sectional view along line b-b′ in FIG. 1A .
FIG. 2A is a diagrammatic front or rear view of the guided vehicle equipped with the air springs of the first embodiment, and FIG. 2B is a diagrammatic partial side view of the vehicle to show the state the axle is suspended via the air springs.
FIG. 3 is a diagrammatic plan view of the guided vehicle showing location of tires and air springs.
FIG. 4A is a plan view of the second embodiment of an air springs used for the guided vehicle according to the present invention, FIG. 4B is a cross sectional view along line d-d′ in FIG. 4A , and FIG. 4C is partial cross sectional view along line e-e′ in FIG. 4A .
FIG. 5A is a plan view of the third embodiment of an air spring used for the guided vehicle according to the present invention, and FIG. 5B is a cross sectional view along line g-g′ in FIG. 5A .
FIG. 6A is a plan view of the third embodiment of an air spring used for the guided vehicle according to the present invention, and FIG. 6B is a cross sectional view along line j-j′ in FIG. 6A .
FIG. 7 is a diagrammatic plan view of the conventional guided vehicle showing location of tires and air springs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be detailed with reference to the accompanying drawings. It is intended, however, that unless particularly specified, dimensions, materials, relative positions and so forth of the constituent parts in the embodiments shall be interpreted as illustrative only not as limitative of the scope of the present invention.
The First Embodiment
FIG. 1A is a plan view of the first embodiment of an air spring used for the guided vehicle according to the present invention, FIG. 1B is a cross sectional view along line a-a′ in FIG. 1A , and FIG. 1 c is partial cross sectional view along line b-b′ in FIG. 1A , FIG. 2A is a diagrammatic front or rear view of the guided vehicle equipped with the air spring set of the first embodiment, and FIG. 2B is a diagrammatic partial side view of the vehicle to show the state the axle is suspended via the air springs, and FIG. 3 is a diagrammatic plan view of the guided vehicle showing location of tires and air springs.
In FIG. 3 showing a diagrammatic plan view of the guided vehicle of the invention, air springs 10 are located between a front left and right wheel 30 and between a rear left and right wheel 30 . Reference numeral 32 is a vehicle body, and reference numeral 38 indicates guide wheels. A plurality of air spring elements (two in FIG. 3 ) including an outer cover 12 , an inner case 14 and a rubber diaphragm (bellows) 18 are arranged to compose an air spring 10 (as shown in FIG. 1A ) located across the center line connecting the center of the left and right wheel, and the air spring elements of the air spring 10 are communicated so that inside air pressure thereof are always equal.
By connecting a plurality of air spring elements to one another so that their inside rooms are communicated to one another, the outer diameter of each air spring can be decreased. Therefore, mounting distance between the left and right air springs 10 can be widened by just that much, so rolling stiffness of the vehicle 32 is increased and the vehicle does not rolls easily and ride quality is improved. Further, by communicating the inside rooms, inside pressure of a plurality of the air spring elements is always equal, so it does not happen that only one air spring element supports the load, and as a plurality of the air springs can be located so that virtual center line thereof coincides with the center line of the axle, superfluous back-and-forth bending force does not exerts on the frame.
Referring to FIGS. 2A and 2B showing respectively a diagrammatic front or rear view of the guided vehicle equipped with the air springs 10 of the first embodiment and a diagrammatic partial side view thereof, reference numeral 30 are wheels, 32 is a vehicle body, 34 is an axle housing, and 40 is left and right suspension frames. A carriage is provided to the vehicle shown in the drawing via the air springs 10 on the lower side of the vehicle body 32 . As shown in FIG. 2B , two air spring elements are arranged tandem along the longitudinal direction of the vehicle and symmetrically with respect to the axle housing 34 that contains the axle of the vehicle. Also, the air spring elements of each air spring 10 are connected via a communicating pipe 26 so that inside air pressure thereof is always equal.
As shown in FIG. 2B , an end of each of two parallel links 36 is pivotally fixed to the vertical part of each of the left and right suspension frames 40 . The air springs 10 are located between the basal portion of the suspension frame 40 fixed at the bottom part of the vehicle body and the axle housing 34 fixed to the carriage side.
A first embodiment of the air spring is shown in FIGS. 1A-1C . Each air spring element of the air spring 10 of the first embodiment is comprised of the air spring element including the outer case 12 , the inner case 14 , and the annular rubber diaphragm (bellows) 18 connecting the outer periphery of the inner case 14 and that of the air spring element. The inner periphery of the rubber diaphragm (bellows) 18 is fixed to the outer periphery of the inner case 14 , and the outer periphery of the bellows 18 is clamped to the outer periphery of the air spring element via a circular clamp 28 . Reference numeral 16 is an air inlet, 22 is an outer cover-fixing bolt. The air spring 10 is fixed to the horizontal part of the suspension frame 40 by an outer case-fixing bolt 22 . Reference numeral 20 is a stopper supported by the bottom of the inner case 14 . The stopper 20 restricts vertical movement of the inner dish 14 . Reference numeral 24 is a positioning pin attached to the bottom of the inner case 14 to position of the air spring 10 , and reference numeral 26 is the communication pipe.
Each of the two air spring elements of the air springs 10 of the first embodiment provided with the inner case 14 located concentrically to the air spring element, and the diaphragm 18 composed of rubber bellows, is connected to each other by the communicating pipe 26 so that inside pressure of both the air spring elements is always equal. The communicating pipe 26 may be a metal pipe or flexible rubber hose. The inner diameter of the communicating pipe 26 is preferably 15φ or larger so that inside pressure of both air springs is always equalized.
When the communicating pipe 26 is made of flexible pipe such as a rubber hose, evenness or flatness of the face of a flange for mounting the air springs 10 is not a point to take care of, and it is permissible that each flange face for mounting each air spring 10 of the air spring set is not leveled with each other.
The stopper 20 is to prevent the air spring 10 to be pressed over the shrinkage stroke between the air spring element and the stopper 20 when some weights are added onto the air spring elements. Further, since the diaphragm 18 is actuated from the up and down displacement, the shape of the diaphragm 18 in planar view is circular geometry, and other shapes are not preferred as the deformation of the diaphragm becomes locally uneven causing the durability of the diaphragm decreased.
Therefore, as clear from FIGS. 1B and 1C , the diaphragm 18 is formed in same form around the inner case 14 . The inner pressure of the air spring is controlled by admitting and releasing the compressed air through the air inlet 16 from a compressed air tank (not shown). Moreover, the air spring is fixed by the outer case fixing bolt 22 and the positioning pin 24 .
Although in the embodiment, two air spring elements are arranged tandem along the longitudinal direction of the vehicle body and symmetrically with respect to the axle center line, and connected by a communicating pipe, it is also possible to arrange more than two air spring elements along the longitudinal direction of the vehicle body and symmetrically with respect to the axle center line, and connect them with communication pipes.
The Second Embodiment
A second embodiment of air springs is shown in FIGS. 4A-4C . FIG. 4A is a plan view, FIG. 4B is a section along line d-d′ in FIG. 4A , and FIG. 4C is a partial cross section along line e-e′ in FIG. 4A .
In the embodiment, the inner case and diaphragm are the same as those of the first embodiment shown in FIG. 1 , and an outer case having a common inside air room as versus providing communication pipe in the case of the first embodiment is provided covering air spring elements to constitute an air spring.
In FIGS. 4A-4C , reference numeral 50 is an air spring, and reference numeral 52 is an outer case covering the spring elements each of which includes an inner case 54 , an annular diaphragm 58 , a stopper 60 , and these are the same as those of FIG. 1 as can be recognized from the figures. Reference numeral 62 is an outer case fixing bolt, reference numeral 64 is a inner case positioning pin, and reference numeral 68 is a circular clamp.
By providing the outer case 52 , volume of the closed room (inside volume) formed by the inner case 54 , the diaphragms 58 , and the cover-dish 52 increases as compared with the air spring of FIG. 1 . Therefore, spring constant can be reduced, resulting in improved ride quality. Spring constant K of an air spring is given by the following equation:
K =γ×( P 0 /V 0 )× A 0 2
where γ is polytropic index of air, P 0 is inside air pressure, V 0 is inside air room volume, and A 0 is effective load area of the air spring respectively.
As can be recognized from the above equation, spring constant K is inversely proportional to inside air room volume V 0 , so spring constant of the air spring of FIG. 4 is decreased due to increased inside volume V 0 as compared with the air spring of FIG. 1 , and ride quality is improved.
The Third Embodiment
When minor decrease in center distance of the left and right air spring by using inner case is permissible for example in an auto truck, etc., improvement of ride quality can be achieved by providing an inner case for more than two air spring elements arranged circularly as shown in FIGS. 5 and 6 , resulting from reduced spring constant caused by increased inside air room volume.
FIG. 5 shows an air spring 70 consisting of three air spring elements 82 covered by an outer case 72 so that the closed inside room is common for the three air spring elements. Each of the air spring elements 82 includes an inner case 74 , an annular rubber diaphragm 76 , a stopper 78 , and a positioning pin 80 . The three air spring elements are arranged such that the centers thereof are on a circle.
FIG. 6 shows an air spring 86 consisting of six air spring elements 98 covered by an outer case 88 so that the closed inside room is common for the six air spring elements. Each of the air spring elements 98 includes an inner case 90 , an annular rubber diaphragm 92 , a stopper 94 , and a positioning pin 96 . The six air spring elements are arranged such that the centers thereof are on a circle. By arranging a plurality of air spring elements and covering them with an outer case, the volume of the inside closed air room can be increased as compared with the case in which a plurality of air spring elements are arranged and their inside closed air rooms are communicated, so spring constant can be decreased and ride quantity can be increased. The air spring elements of the invention work as a single air spring because each of the constituent air springs or constituent air spring elements actuate under the same air pressure.
Further, in order to provide an air spring of large effective load area not commercially viable, it is needed to begin from making a mold for forming constituent parts of the air spring, which will result in high manufacturing cost. By utilizing a plurality of air spring elements of commonly used sizes to compose an air spring of large effective load area, an air spring of very large load carrying capacity can be provided at low cost.
According to the invention, a guided vehicle equipped with air springs of large load carrying capacity to comply with increased vehicle load and having increased ride quality can be provided.
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In a guided vehicle of air spring suspension for running along exclusive guideways, decreasing of center distance of the left and right air spring to mount air springs of increased dimension and increased load carrying capacity, which decreasing of the center distance induces decrease in rolling stiffness of the vehicle resulting in deteriorated ride quality and also induces difficulty in adjusting vehicle height resulting in spending long time in height adjusting operation, will not be required even when load carrying capacity of air springs is required to be increased in order to comply with increased vehicle load. A plurality of air spring elements are mounted tandem along the longitudinal direction of the vehicle with the air spring elements connected with each other so that air pressure thereof is always equal.
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This application claims benefit of priority based on prior provisional application No. 61/270,093 filed on Jul. 3, 2009.
This invention was made with U.S. Government support from the National Institute of Mental Health (NIMH) of National Institutes of Health, under the Small Business Innovation Research (SBIR) Phase I Grant No. 1 R43MH084365. In accordance with the Federally Sponsored Research or Development, the U.S. Government has certain rights to this invention.
FIELD OF INVENTION
This invention relates to novel pyridoindolobenzox- and thiazepine derivatives for the treatment of schizophrenia and other central nervous system (CNS) disorders.
PRELIMINARY NOTE
Various prior art references in the specification are indicated by italicized Arabic numerals in brackets. Full citation corresponding to each reference number is listed at the end of the specification, and is herein incorporated by reference in its entirety in order to describe fully and clearly the state of the art to which this invention pertains.
Unless otherwise specified, all technical terms and phrases used herein conform to standard organic and medicinal chemistry nomenclature established by International Union of Pure and Applied Chemistry (IUPAC), American Chemical Society (ACS), and other international professional societies. The rules of nomenclature are described in various publications, including “Nomenclature of Organic Compounds” [1], and “Systematic Nomenclature of Organic Chemistry” [2], which are herein incorporated by reference in their entireties.
BACKGROUND
CNS disorders comprise several major categories as described in the Diagnostic and Statistical Manual of Mental Disorders (DSM IV-TM) [3]. Psychotic disorders include schizophrenia, paranoia, and manic-depressive illness. Motor disorders include Parkinson's disease, epilepsy, and Tourette's syndrome. Mood disorders include depression, mania, and bipolar disorder. Anxiety disorders include generalized anxiety, phobias, panic attacks, and obsessive compulsive disorders. Cognitive disorders include autism, mild cognitive impairment (MCI), Attention Deficit Hyperactivity Disorder (ADHD), and dementia. Substance-related disorders include narcotic addiction and withdrawal; and eating disorders such as Anorexia Nervosa, bulimia, and obesity. Other disorders involving CNS include sleep disorders, endocrine disorders, or pain.
It is well established that a particular CNS disorder may involve complex interactions of multiple neuroreceptors and neurotransmitters, and, conversely, a single neuroreceptor may be implicated in several CNS disorders as exemplified by the serotonin (5-hydroxytryptamine or “5-HT”) and dopamine (3,4-dihydroxyphenyl-ethylamine or “D”) systems outlined in Table 1. Many of the receptors that are distributed in the brain are also found in other areas of the body including gastrointestinal (GI) tract, blood vessels, and muscles, and elicit physiological response upon activation by appropriate ligands.
TABLE 1
Receptor Subtypes, Distribution, and Associated CNS Disorders.
Receptor
Implicated Disorders
Sertotonin
5-HT 1A
Addiction, aggression, anxiety, appetite, memory, mood,
erectile dysfunction, sexual behavior, sleep, sociability.
5-HT 1B
Addiction, aggression, anxiety, learning, memory, mood,
penile erection, sexual behavior.
5-HT 1D
Anxiety, locomotion, vasoconstriction.
5-HT 1E
Unknown.
5-HT 1F
Vasoconstriction.
5-HT 2A
Addiction, anxiety, appetite, cognition, learning, memory,
mood, perception, psychosis, sexual behavior, sleep.
5-HT 2B
Addiction, anxiety, appetite, GI motility, sleep,
vasoconstriction.
5-HT 2C
Addiction, anxiety, appetite, GI motility, locomotion, mood,
perception, penile erection, sexual behavior, sleep.
5-HT 3
Addiction, anxiety, GI motility, learning, memory, nausea.
5-HT 4
Addiction, anxiety, GI motility, learning, memory, mood,
respiration.
5-HT 5A
Locomotion, sleep.
5-HT 6
Anxiety, cognition, learning, memory, mood.
5-HT 7
Anxiety, memory, mood, respiration, sleep.
Dopamine
D 1
Addiction, ADHD, autism, bipolar disorder, dissociative
disorder, depression, eating disorder, impulse control disorder,
obesity, obsessive compulsive disorder, Parkinson's disease,
somatoform disorder.
D 2
Addiction, bipolar disorder, depression, mania, Parkinson's
disease, schizophrenia, tardive diskinesia.
D 3
Addiction, ophthalmic disorders, schizophrenia.
D 4
Bulimia, erectile dysfunction, schizophrenia.
D 5
ADHD, autism, depression, dissociative disorder, eating
disorder, impulse control disorder, movement disorder,
obsessive compulsive disorder, somatoform disorder, tardive
diskinesia,.
The rational drug design process is based on the well established fundamental principle that receptors, antibodies, and enzymes are multispecific. Topologically similar molecules will have similar binding affinity to these biomolecules, and, therefore, are expected to elicit similar physiological response as those of native ligands, antigens, or substrates respectively. The aforementioned principle, as well as molecular modeling and quantitative structure activity relationship studies (QSAR) are quite useful for designing molecular scaffolds that target receptors in a “broad sense.” However, they do not provide sufficient guidance for targeting specific receptor subtypes, wherein subtle changes in molecular topology could have substantial impact on receptor binding profile. Moreover, this principle is inadequate for predicting in vivo properties of any compound. Hence, each class of molecules should be evaluated in its own right not only for receptor subtype affinity and selectivity, but also for efficacy and toxicity profiles in in vivo animal models. Thus, there is a sustained need for the discovery and development of new drugs that target neuroreceptor subtypes with high affinity and selectivity in order to improve efficacy and/or minimize undesirable side effects.
Serotonin and dopamine constitute the two major neurotransmitters that are implicated in numerous disorders. To date, fourteen serotonin and five dopamine receptor subtypes have been isolated, cloned, and expressed. The present invention is directed at targeting the serotonin 5-HT 2A and D 2 receptor subtypes for the treatment of CNS disorders that may be implicated by these receptor subtypes, including schizophrenia (cf. Table 1). Schizophrenia is an insidious mental disorder that affects about 1% of the world population. In the United States, the economic and social impact of this disease is enormous, and the cost of hospitalization, treatment, and medications coupled with loss of employment exceeds 60 billion dollars [4]. Schizophrenia manifests itself in two distinct, complex, and diverse symptoms. Positive symptoms comprise hallucinations, delusions, incoherence of speech, passivity, withdrawal, and incongruity of emotions. The negative symptoms include poverty of speech, reduced emotional response, inability to feel intimacy or initiate social contacts, lack of motivation, underachievement at school or work, and attention impairment. The overall description of the positive symptoms, according to clinical psychiatrists, is that it is a distortion or exaggeration of normal behavior while negative symptoms represent a diminution or loss of normal function.
Schizophrenia has been postulated to be the result of neurotransmitter dysfunction. In particular, 5-HT 2A and the D 2 receptors have been the most implicated in the etiology of Schizophrenia. Drugs that target dopamine receptors are referred to as ‘classical antispsychotics’, and include chlorpromazine (Thorazine) and haloperidol (Serenace). A serious shortcoming associated with the dopamine hypothesis is the fact that a large percentage of the patients do not respond to the first-time treatment with such drugs. Therefore, an alternate neurotransmitter hypothesis, known as the ‘serotonin hypothesis,’ has been proposed, and the selective 5-HT 2A antagonist, ketanserin, has been effective in alleviating the negative symptoms of Schizophrenia [5]. Because the central dopaminergic and serotonergic pathways are connected anatomically, and interact functionally in the ventral tegmental and the prefrontal cortex areas of the brain implicated in schizophrenia, a combination serotonin receptor and dopamine receptor antagonist was found to alleviate both the positive and negative symptoms as well as movement disorders in schizophrenic patients [6-9]. This observation provided the impetus for the development of an integrated molecular entity (referred to as ‘atypical antipyschotics) such as clozapine and olanzapine that target both 5-HT 2A and D 2 receptors. The serotonin-dopamine antagonist (SDA) hypothesis postulates moderate D 2 receptor blockade for the reduction of positive symptoms, and potent 5-HT 2A receptor blockade for attenuation of the negative symptoms and movement disorders.
Rajagopalan [10, 11] disclosed pyridoindolobenzodiazepine derivatives A-H, but the compounds bearing other heteroatoms such as O, S, SO, or SO 2 instead of NH in the B ring belong to novel heterocyclic systems that have not been disclosed before. The carbon analogs (X═CH 2 ) in the B-ring of A-H have been disclosed by Adams and De Witt [12, 13].
Moreover, as mentioned before, the receptor binding and pharmacological properties are very sensitive to the overall molecular topology, and these properties cannot be readily predictable just from the molecular structure. For example, the regioisomers A,C and B,D as well as their corresponding cis- and trans-reduced analogs E,F and G,H in both azepine and diazepine systems display different receptor binding profiles and activities.
SUMMARY
The present invention discloses pentacyclic compounds of Formula I,
wherein A is —CH(R 9 )—X—, —XCH(R 9 )—; —CO—X— or —X—CO—; X is —O—, —S—, —SO—, or —SO 2 —. Y is a single bond or a double bond. D and E are independently —(CH 2 ) n —, and ‘n’ varies from 0 to 2. R 1 to R 9 are various electron donating, electron withdrawing, hydrophilic, or lipophilic groups selected to optimize the physicochemical and biological properties of compounds of Formula I. These properties include receptor binding, receptor selectivity, tissue penetration, lipophilicity, toxicity, bioavailability, and pharmacokinetics. As will be evident from the sections that follow, some of the compounds of the present invention exhibit favorable in vivo biological properties that could not be ascertained from the prior art literature. Compounds of the present invention are useful for the treatment of individuals suffering from schizophrenia as well as other mental and peripheral disorders.
BRIEF DESCRIPTION OF FIGURES
FIG. 1 . Synthetic scheme for pyridindolobenzothiazepines.
FIG. 2 . Synthetic scheme for pyridoindolobenzoxazepines.
FIG. 3 . X-Ray crystallographic structure of pyridoindolobenzothiazepine 2.
FIG. 4 . In vivo rat schizophrenia model study: prepulse inhibition data.
DETAILED DESCRIPTION
The present invention relates to pentacyclic compounds of Formula I, wherein
A is —CH(R 9 )X—, —XCH(R 9 )—, —COX—, or —XCO—;
X is —O—, —S—, —SO—, or —SO 2 —;
Y is a single bond or a double bond;
D and E are independently —(CH 2 ) n —, and ‘n’ varies from 0 to 2;
R 1 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 1 -C 10 hydroxyalkyl, C 5 -C 10 aryl unsubstituted or substituted with electron donating groups (EDG) or electron withdrawing groups (EWG), C 6 -C 15 aroylalkyl, and C 1 -C 10 alkxoycarbonylalkyl, C 6 -C 10 arylalkyl unsubstituted or substituted with EDG or EWG;
R 2 to R 9 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, hydroxyl, C 1 -C 10 alkoxyl, —NR 10 R 11 , C 1 -C 10 hydroxyalkyl, halogen, trihaloalkyl, cyano, carboxyl, C 1 -C 10 acyl, C 1 -C 10 alkxoyalkyl, C 1 -C 10 alkxoycarbonyl, C 5 -C 10 aryl unsubstituted or substituted with EDG or EWG, and C 6 -C 10 arylalkyl unsubstituted or substituted with EDG or EWG; and
R 10 and R 11 are independently hydrogen or C 1 -C 10 alkyl, and R 10 and R 11 may optionally be tethered together from rings.
The phrase, ‘electron donating group (EDG)’ and ‘electron withdrawing group (EWG)’ are well understood in the art. EDG comprises alkyl, hydroxyl, alkoxyl, amino, acyloxy, acylamino, mercapto, alkylthio, and the like. EWG comprises halogen, acyl, nitro, cyano, trihaloalkyl, carboxyl, alkoxycarbonyl, sulfonyl, and the like.
The first embodiment of the present invention is represented by Formula I, wherein
A is —CH(R 9 )X—; X is —O—, —S—, —SO—, or —SO 2 —; Y is a single bond or a double bond; D and E are —(CH 2 ) n —, and ‘n’ is 1; R 1 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 1 -C 10 hydroxyalkyl, C 5 -C 10 aryl unsubstituted or substituted with electron donating or electron withdrawing groups, C 1 -C 15 aroylalkyl, and C 1 -C 10 alkxoycarbonylalkyl, C 6 -C 10 arylalkyl unsubstituted or substituted with EDG or EWG; R 2 to R 9 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, hydroxyl, C 1 -C 10 alkoxyl, —NR 10 R 11 , C 1 -C 10 hydroxyalkyl, halogen, trihaloalkyl, cyano, carboxyl, C 1 -C 10 acyl, C 1 -C 10 alkxoyalkyl; C 1 -C 10 alkxoycarbonyl; C 5 -C 10 aryl unsubstituted or substituted with EDG or EWG, and C 6 -C 10 arylalkyl unsubstituted or substituted with EDG or EWG; and R 10 and R 11 are independently hydrogen or C 1 -C 10 alkyl, and R 10 and R 11 may optionally be tethered together from rings.
The second embodiment is represented by Formula I, wherein
A is —XCH(R 9 )—; X is —O—, —S—, —SO—, or —SO 2 —; Y is a single bond or a double bond; D and E are —(CH 2 ) n —, and ‘n’ is 1; R 1 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 1 -C 10 hydroxyalkyl, C 5 -C 10 aryl unsubstituted or substituted with electron donating or electron withdrawing groups, C 6 -C 15 aroylalkyl, and C 1 -C 10 alkxoycarbonylalkyl, C 6 -C 10 arylalkyl unsubstituted or substituted with EDG or EWG; R 2 to R 9 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, hydroxyl, C 1 -C 10 alkoxyl, —NR 10 R 11 , C 1 -C 10 hydroxyalkyl, halogen, trihaloalkyl, cyano, carboxyl, C 1 -C 10 acyl, C 1 -C 10 alkxoyalkyl, C 1 -C 10 alkxoycarbonyl, C 5 -C 10 aryl unsubstituted or substituted with EDG or EWG, and C 6 -C 10 arylalkyl unsubstituted or substituted with EDG or EWG; and R 10 and R 11 are independently hydrogen or C 1 -C 10 alkyl, and R 10 and R 11 may optionally be tethered together from rings.
The third embodiment is represented by Formula I, wherein
A is —CH(R 9 )X—; X is —O—, —S—, —SO—, or —SO 2 —; Y is a single bond or a double bond; D and E are —(CH 2 ) n —, and ‘n’ is 1; R 1 is hydrogen, C 1 -C 10 alkyl, C 6 -C 10 arylalkyl, or C 6 -C 15 aroylalkyl; each of R 2 , R 3 , R 5 , R 6 , R 8 , and R 9 is hydrogen; and each of R 4 and R 7 are independently hydrogen, C 1 -C 10 alkyl, or halogen.
The fourth embodiment is represented by Formula I, wherein
A is —XCH(R 9 )—; X is —O—, —S—, —SO—, or —SO 2 —; Y is a single bond or a double bond; D and E are —(CH 2 ) n —, and ‘n’ is 1; R 1 is hydrogen, C 1 -C 10 alkyl, C 6 -C 10 arylalkyl, or C 6 -C 15 aroylalkyl; each of R 2 , R 3 , R 5 , R 6 , R 8 , and R 9 is hydrogen; and each of R 4 and R 7 are independently hydrogen, C 1 -C 10 alkyl, or halogen.
The compounds belonging to Formula I can be synthesized according to standard methods as outlined in FIGS. 1 and 2 starting from the known tricyclic dibenzoxazepine and dibenzothiazepine [14, 15]. Compounds of the present invention may exist as a single stereoisomer or as mixture of enantiomers and diastereomers whenever chiral centers are present. Individual enantiomers can be isolated by resolution methods or by chromatography using chiral columns. The diastereomers can be separated by standard purification methods such as fractional crystallization or chromatography. Compounds of the present invention may exist in the form pharmaceutically acceptable salts, including but not limited to acetate, adipate, citrate, tartarate, benzoate, phosphate, glutamate, gluconate, fumarate, maleate, succinate, oxalate, chloride, bromide, hydrochloride, sodium, potassium, calcium, magnesium, ammonium, and the like. The phrase “pharmaceutically acceptable” means those formulations which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of humans and animals without undue toxicity, irritation, allergic response and the like, and are commensurate with a reasonable benefit/risk ratio.
The compounds of the present invention represented by Formula I, commonly referred to as ‘active pharmaceutical ingredient (API)’ or ‘drug substance’ is typically formulated with pharmaceutically acceptable salts, buffers, diluents, carriers, adjuvants, preservatives, and excipients. The formulation technology for manufacture of the drug product is known in the art, and are described in “Remington, The Science and Practice of Pharmacy” [16], incorporated herein by reference in its entirety.
The final formulated product, commonly referred to as ‘drug product,’ may be administered enterally, parenterally, or topically. Enteral route includes oral, rectal, topical, buccal, ophthalmic, and vaginal administration. Parenteral route includes intravenous, intramuscular, intraperitoneal, intrasternal, and subcutaneous injection or infusion. The drug product may be delivered in solid, liquid, or vapor forms, or can be delivered through a catheter for local delivery at a target. It may also be administered alone or in combination with other drugs if medically necessary.
Compositions suitable for parenteral injection may comprise physiologically acceptable, sterile aqueous or nonaqueous isotonic solutions, dispersions, suspensions or emulsions, and sterile powders for reconstitution into sterile injectable solutions or dispersions. The compositions may also optionally contain adjuvants such as preserving, wetting, emulsifying, dispensing, and antimicrobial agents. Examples of suitable carriers, diluents, solvents, vehicles, or adjuvants include water; alcohols such as ethanol, propyleneglycol, polyethyleneglycol, glycerol, and the like; vegetable oils such as cottonseed, groundnut, corn, germ, olive, castor and sesame oils, and the like; organic esters such as ethyl oleate and suitable mixtures thereof; and phenol, parabens, sorbic acid, and the like.
Injectable formulations may also be suspensions that contain suspending agents such as ethoxylated isostearyl alcohols, polyoxyethylene sorbitol and sorbitan esters, microcrystalline cellulose, aluminum metahydroxide, bentonite, agar-agar and tragacanth, or mixtures of these substances, and the like. Prolonged absorption of the injectable pharmaceutical form can be brought about by the use of agents delaying absorption, for example, aluminum monostearate and gelatin. Proper fluidity can be maintained, for example, by the use of coating materials such as lecithin, by the maintenance of the required particle size in the case of dispersions, and by the use of surfactants. In some cases, in order to prolong the effect of the drug, it is desirable to slow the absorption of the drug from subcutaneous or intramuscular injection. This can be accomplished by the use of a liquid suspension. The rate of absorption of the drug then depends upon its rate of dissolution which, in turn, may depend upon crystal size and crystalline form. Alternatively, delayed absorption of a parenterally administered drug form is accomplished by dissolving or suspending the drug in an oil vehicle.
Injectable depot forms are made by forming microencapsulated matrices of the drug in biodegradable polymers. Depending upon the ratio of drug to polymer and the nature of the particular polymer employed, these compositions release the active ingredient(s) only, or preferentially, in a certain part of the intestinal tract, and optionally, in a delayed manner. Thus, the rate of drug release and the site of delivery can be controlled. Examples of embedding compositions include, but are no limited to polylactide-polyglycolide poly(orthoesters), and poly(anhydrides), and waxes. The technology pertaining to controlled release formulations are described in “Design of Controlled Release Drug Delivery Systems,” [17] incorporated herein by reference in its entirety.
Formulations for oral administration include capsules (soft or hard), tablets, pills, powders, and granules. Such formulations may comprise the API along with at least one inert, pharmaceutically acceptable ingredients selected from the following: (a) buffering agents such as sodium citrate or dicalcium phosphate; (b) fillers or extenders such as starches, lactose, sucrose, glucose, mannitol, and silicic acid; (c) binders such as carboxymethylcellulose, alginates, gelatin, polyvinylpyrrolidone, sucrose, and acacia; (d) humectants such as glycerol; (e) disintegrating agents such as agar-agar, calcium carbonate, potato or tapioca starch, alginic acid, certain silicates, and sodium carbonate; (f) solution retarding agents such as paraffin; (g) absorption accelerators such as quaternary ammonium compounds; (h) wetting agents such as cetyl alcohol and glycerol monostearate; (i) absorbents such as kaolin and bentonite clay and (j) lubricants such as talc, calcium stearate, magnesium stearate, solid polyethylene glycols, sodium lauryl sulfate, and mixtures thereof; (k) coatings and shells such as enteric coatings, flavoring agents, and the like.
Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups and elixirs. In addition to the API, the liquid dosage forms may contain inert diluents, solubilizing agents, wetting agents, emulsifying and suspending agents, sweetening, flavoring, and perfuming agents used in the art. Formulations for topical administration include powders, sprays, ointments and inhalants.
These formulations include the API along with suitable non-irritating excipients or carriers such as cocoa butter, polyethylene glycol or a suppository wax which are solid at room temperature but liquid at body temperature and therefore melt in the rectum or vaginal cavity and release the active compound.
Compounds of the present invention can also be administered in the form of liposomes. Any non-toxic, physiologically acceptable and metabolizable lipid capable of forming liposomes can be used. The present compositions in liposome form can contain, in addition to a compound of the present invention, stabilizers, preservatives, excipients and the like. The preferred lipids are natural and synthetic phospholipids and phosphatidyl cholines (lecithins) used separately or together. Methods to form liposomes are known in the art and are described in “Liposomes,” [18], which is incorporated herein by reference in its entirety.
The compounds of the present invention can also be administered to a patient in the form of pharmaceutically acceptable ‘prodrugs.’ Prodrugs are generally used to enhance the bioavailability, solubility, in vivo stability, or any combination thereof of the API. They are typically prepared by linking the API covalently to a biodegradable functional group such as a phosphate that will be cleaved enzymatically or hydrolytically in blood, stomach, or GI tract to release the API. A detailed discussion of the prodrug technology is described in “Prodrugs: Design and Clinical Applications,” [19] incorporated herein by reference.
The dosage levels of API in the drug product can be varied so as to achieve the desired therapeutic response for a particular patient. The phrase “therapeutically effective amount” of the compound of the invention means a sufficient amount of the compound to treat disorders, at a reasonable benefit/risk ratio applicable to any medical treatment. It will be understood, however, that the total daily usage of the compounds and compositions of the present invention will be decided by the attending physician within the scope of sound medical judgment. The specific therapeutically effective dose level for any particular patient will depend upon a variety of factors including the disorder being treated; the severity of the disorder; activity of the specific compound employed; the specific composition employed; age, body weight, general health, sex, diet of the patient; the time of administration; route of administration; and rate of excretion of the specific compound employed; and the duration of the treatment. The total daily dose of the compounds of this invention administered may range from about 0.0001 to about 1000 mg/kg/day. For purposes of oral administration, more preferable doses can be in the range from about 0.001 to about 5 mg/kg/day. If desired, the effective daily dose can be divided into multiple doses for optimal therapeutic effect.
The following examples illustrate specific embodiments and utilities of the invention, and are not meant to limit the invention. As would be apparent to skilled artisans, various modifications in the composition, operation, and method are possible, and are contemplated herein without departing from the concept and scope of the invention as defined in the claims.
Example 1
Synthesis of a Compound of Formula I, Wherein A is —CH 2 X—; X is —S—; Y is Double Bond; D and E are —CH 2 —; R 1 is Methyl; R 2 -R 9 are Hydrogens (2)
Step 1. To a well stirred solution of compound 1 (6.98 g, 32.7 mmol) in THF (30 mL) and AcOH (9 mL), a concentrated solution of NaNO 2 (7.03 g, 101.9 mmol) in water (12 mL) was added dropwise at ambient temperature. The reaction was stirred at ambient temperature for 20 min and treated with water (100 mL). The product was filtered, washed with water, and dried to give 7.67 g (97%) of the nitroso compound.
Step 2. To a stirred solution of nitroso compound from step 1 (14.6 g, 61.1 mmol) and N-methyl 4-pyridone (9.04 g, 79.9 mmol) in ethanol (150 mL) and acetic acid (20 mL) at 55° C., was added zinc dust (12.0 g, 183.5 mmol) in three equal portions allowing 10 mins between the additions. The reaction was stirred for another 5 minutes and filtered hot. The solid washed with ethanol, and the resultant solution was heated to reflux for 30 minutes, and thereafter the solvent was removed in vacuo. The residue was treated with 8 mL of acetic acid, and heated to reflux for about 16 hours. The solvent was removed in vacuo, and the residue was dissolved in methylene chloride (500 mL). The solid impurity was removed by filtration, and the filtrate was washed with 10% NaOH solution. The combined organic layer was washed with water and brine, dried over anhydrous sodium sulfate, filtered an the filtrate taken to dryness in vacuo. The crude product was purified by flash chromatography on silica gel using 0-5% MeOH/chloroform as the eluent to give 3.0 g (16%) of the desired product 2. LRMS: m/Z, 307 (M+H + ).
Example 2
Synthesis of a Compound of Formula I, cis isomer Wherein A is —CH 2 X—; X is —S—; Y is Single Bond; D and E is —CH 2 —; R 1 is Methyl; R 2 -R 9 are Hydrogens (3)
To a cold solution of compound 2 from Example 1 (0.50 g, 1.63 mmol) in trifluoroacetic acid (6.5 mL) at −5° C., was carefully treated with solid sodium cyanoborohydride (0.125 g, 1.99 mmol). The reaction mixture was then stirred at ambient temperature for 3 h, treated with 6N HCl solution, and heated under reflux for 30 minutes. The solution was cooled to ambient temperature, and excess trifluoroacetic acid was removed in vacuo. The residue was made alkaline treated with the treatment of 25% NaOH solution (10 mL), and the product extracted with chloroform. The combined organic layer was washed with water and brine, and dried over anhydrous sodium sulfate, filtered, and the filtrate evaporated in vacuo. The crude compound was purified by flash column chromatography on silica gel using 0-5% MeOH/Chloroform as the eluent to furnish 0.270 g (54%) of the cis isomer 3. LRMS: m/Z, 309 (M+H + ).
Example 3
Synthesis of a Compound of Formula I, Trans Isomer Wherein A is —CH 2 X—; X is —S—; Y is Single Bond; D and E is —CH 2 —; R 1 is Methyl; R 2 -R 9 are Hydrogens (4)
The compound 2 from Example 1 (0.306 g, 1 mmol) was treated with borane-THF (10 mL, 1.0 M) at ambient temperature, and the mixture was heated under reflux for 1 hour by which time the reaction mixture became clear. After cooling to ambient temperature, the solution was treated with water to quench excess reagent borane reagent. The solvents were removed under reduced pressure, and the residue was treated with conc. HCl (7 mL). The mixture was heated to reflux for 3 hours and evaporated to dryness in vacuo, and treated with 10% NaOH solution (10 mL). The product was then extracted with EtOAc, washed with water and brine, dried over anhydrous sodium sulfate, filtered, and the filtrate taken to dryness under reduced pressure. The crude product was purified by flash chromatography on silica gel using 0-5% MeOH/Chloroform as the eluent to give 0.202 g (66%) of the trans isomer 4. LRMS: m/Z, 309 (M+H + ).
Example 4
Single Crystal X-Ray Structure Determination of Compound 4
A sample of compound 4 was dissolved in methanol and allowed to cool slowly to give X-ray-quality crystals. The Projection Diagram shown in FIG. 3 confirms the structure of 2 as designated.
Example 5
Synthesis of a Compound of Formula I, Wherein A is —CH 2 X—; X is —S—; Y is Double Bond; D and E is —CH 2 —; R 2 -R 9 are Hydrogens (5)
The unsaturated compound 4 from Example 1 (1.0 mmol) was dissolved in methylene chloride (5 mL), and was treated with ethyl chloroformate ( ). The reaction mixture was stirred at ambient temperature for 24 hours. After complete decomposition, the solution was poured onto 1N sodium hydroxide, and extracted with methylene chloride. The combined organic extracts were washed with brine, dried over anhydrous sodium sulfate, filtered, and the filtrate evaporated in vacuo to give the crude material, which was then purified by silica gel flash chromatography to give the desmethyl compound 7. LRMS: m/Z, 293 (M+H + ).
Example 6
Synthesis of a Compound of Formula I, Wherein A is —CH 2 X—; X is —S—; Y is Double Bond; D and E is —CH 2 —; R 1 is 3-(4-Fluorobenzoyl)Propyl; R 2 -R 9 are Hydrogens
To a solution of 12 (0.292 g, 1.00 mmol) and 4-chloro-4′-fluoro-butyrophenone (0.216 g, 1.08 mmol) in DMF, was added sodium ioide (0.150 g, 1.00 mmol) followed by triethylamine (0.15 mL, 1.16 mmol). The reaction was heated under reflux for 3 hours. The reaction mixture was poured onto water and extracted with ethyl acetate. The combined organic layers were washed with water and brine, dried over anhydrous sodium sulfate, filtered, and the filtrate evaporated in vacuo. The crude compound was purified by flash chromatography. LRMS: m/Z, 457 (M+H + ).
Example 7
Synthesis of a Compound of Formula I, Wherein A is —CH 2 X—; X is —SO 2 —; Y is Double Bond; D and E is —CH 2 —; R 1 is Methyl; R 2 -R 9 are Hydrogens (7)
A solution of the thioether derivative in Example 3, (0.75 g, 2.4 mmol) in methylene chloride (20 mL) is cooled to 0° C., treated with trifluoroacetic acid (0.89 g, 7.8 mmol), and stirred at this temperature for about 30 minutes. Thereafter, 3-chloroperoxybenzoic acid (1.26 g 7.3 mmol) was added and the entire mixture was stirred at ambient temperature for 1 hour by which time the dark green solution turned into an orange slurry. The reaction mixture was then poured onto water (100 mL) and treated with 10% sodium hydroxide solution (30 mL). The organic layer was separated, washed with water, dried over anhydrous sodium sulfate, filtered, and the filtrated evaporated in vacuo. The greenish-yellow residue was purified by flash chromatography to give the desired sulfone 7. LRMS: m/Z, 339 (M+H + ).
Example 8
Synthesis of a Compound of Formula I, Wherein A is —CH 2 X—; X is —O—; Y is Double Bond; D and E is —CH 2 —; R 1 is Methyl; R 2 -R 9 are Hydrogens (9)
Synthesis of the oxazepine derivative 9 was prepared by nearly the same procedure as the one used for the preparation of the thiazepine analog 2 in Example 1.
Step 1. To a well stirred solution of compound 8 (7.10 g, 36 mmol) in ethanol (200 mL) and glacial acetic acid (25 mL), a concentrated solution of NaNO 2 (11.00 g, 159 mmol) in water (13 mL) was added dropwise at ambient temperature. The reaction was stirred at ambient temperature for 20 min and treated with water (100 mL). The product was filtered, washed with water, and dried to give 6.5 g (80%) of the nitroso compound.
Step 2. To a stirred mixture of nitroso compound from step 1 (5.62 g, 24.9 mmol) and N-methyl 4-pyridone (3.66 g, 32.4 mmol) in ethanol (125 mL) and acetic acid (22 mL) at −20° C., was added zinc dust (4.88 g, 74.63 mmol) in three equal portions allowing 10 mins between the additions. The reaction was stirred for another 30 minutes and filtered hot. The solid washed with ethanol, and the resultant solution was treated with acetic acid (15 mL) and heated to reflux for 16 hours. Thereafter the solvent was removed in vacuo. The residue was treated with 8 mL of acetic acid, and heated to reflux for about 16 hours. The solvent was removed in vacuo, and the residue was dissolved in methylene chloride-ether (1:2 v/v) (500 mL). The solid impurity was removed by filtration, and the filtrate was washed with 10% NaOH solution. The combined organic layer was washed with water and brine, dried over anhydrous sodium sulfate, filtered and the filtrate taken to dryness in vacuo. The crude product was purified by flash chromatography on silica gel using 0-5% MeOH/chloroform as the eluent to give 0.4 g of the desired product 9. LRMS: m/Z, 291 (M+H + ).
Example 9
In Vitro Serotonin and Dopamine Receptor Binding Results
The IC 50 values for 5-HT 2A , 5-HT 2C , and D 2 receptors are shown in Table 1. All the compounds tested showed excellent receptor binding activity with compound 4 being the most potent amongst all.
TABLE 1
Serotonin and dopamine receptor binding of compounds of Formula 1.
IC 50 (nM)
Compound
5-HT 2A
5-HT 2C
D 2
2
1
10
80
3
5
15
500
4
3
5
20
6
5
80
8
9
8
50
500
Example 10
In Vivo Behavioral Studies: Compound 4 Effects on Amphetamine-Induced Locomotion and Prepulse Inhibition
Doses of compound 2 for these studies were selected from a pilot study that revealed robust catalepsy (without a loss of right reflex) with 30 mg/kg ip DDD-016. Some locomotor reduction was seen with 10 mg/kg, and 3 mg/kg did not differentiate from vehicle (75% DMSO; pilot study data not shown). The in vivo data are shown in FIG. 4 .
Effects of compound 2 on amphetamine-induced motor activity ( FIG. 4 Graph). All rats were habituated to the motor box for 30 min followed by injection of compound 2 or vehicle. After 30 min all rats were injected with 1 mg/kg, i.p. amphetamine (a dose that is known to elevate locomotion in rats) and their motor activity was recorded for 2 hr. Even with the small sample size, there is a trend for 10 mg/kg of 2 to reduce the effects of amphetamine. ANOVA with post hoc Newman Keuls revealed a difference between 3 mg/kg and 10 mg/kg of 2 for horizontal activity (p<0.05).
Effects of compound 2 on amphetamine-induced sensorimotor gating deficits ( FIG. 4 Table). Once the compound 2 dose range was determined by motor assessments, a separate group of rats were used to study PPI. Rats were treated with vehicle (75% DMSO) or DDD-016 in the DMSO vehicle; 30 min later amphetamine (3 mg/kg ip) or saline was administered, and the startle session was initiated after an additional 30 min. (The 3 mg/kg dose of amphetamine is sufficient to induced robust deficits in PPI; 1 mg/kg is subtrheshold; data not shown.) Shown are startle data from a 120 dB pulse, preceded 100 ms by a 71 dB pre-pulse. Rats treated with compound 2 vehicle and amphetamine demonstrated a decrease in % PPI compared to saline pretreated rats. Compound 2 (1 mg/kg ip) blunted this deficit (ANOVA with post hoc Newman Keuls; p<0.01). A similar magnitude of the inhibitory effect was seen with 3 and 10 mg/kg of 2 (data not shown), suggesting that E max was obtained even with the 1 mg/kg dose.
REFERENCES
1. Fox, R. B.; Powell, W. H. Nomenclature of Organic Compounds: Principles and Practice , Second Edition. Oxford University Press, Oxford, 2001.
2. Hellwinkel, D. Systematic Nomenclature of Organic Chemistry: A Directory of Comprehension and Application of its Basic Principles . Springer-Verlag, Berlin, 2001.
3. American Psychiatric Association: Diagnostic and Statistical Manual of Mental Disorders, 4 th Edition. Washington, D.C., Association, A.P., 1994.
4. Veggeberg, S. K. The Major Mental Illnesses; Medications of the Mind . Allen and Unwin Pty Ltd. St. Leonards, 1996, pp 68
5. Duinkerke, S. J.; Botter, P. A.; Jansen, A. A.; van Dongen, P. A.; van Haaften, A. J.; Boom, A. J.; van Laarhoven, J. H.; Busard, H. L. Br. J. Psychiatry 1993, 163, 451.
6. Tork, I. Ann. N.Y. Acad. Sci. 1990, 600, 9.
7. Prisco, S.; Pagannone, S.; Espsito, E. J. Pharmacol. Exp. Ther. 1994, 271.
8. Iyer, R. N.; Bradberry, C. W. J. Pharmacol. Exp. Ther. 1994, 271.
9. Gelders, Y. G. Br. J. Psychiatry 1989, 155, S33.
10. Rajagopalan, P. U.S. Pat. No. 5,321,023; 1994.
11. Rajagopalan, P. U.S. Pat. No. 4,438,120; 1984.
12. Blumberg, H. U.S. Pat. No. 3,790,675; 1974.
13. Adams, C. W. U.S. Pat. No. 3,983,123; 1976.
14. Yale, H. L.; Sowinski, F. A.; Bernstein, J. U.S. Pat. No. 3,133,936, 1964.
15. Margolis, B. J.; Swidorski, J. J.; Rogers, B. N. J. Org. Chem. 2003, 68, 644-647.
16. Pharmaceutical Manufacturing. In Remington: The Science and Practice of Pharmacy . Lippincott Williams & Wilkins, Philadelphia, 2005, 691-1058.
17. Weissig, V. Liposomes: Methods and Protocols Volume 1 : Pharmaceutical Nanocarriers . Humana Press, New York, 2009.
18. Li, X. Design of Controlled Release Drug Delivery Systems . McGraw-Hill, New York, 2006.
19. Rautio, J. et al. Prodrugs: Design and Cinical Applications. Nature Reviews Drug Discovery 2008, 7, 255-270.
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The present invention discloses pyridoindolobenzox- and thiazepine compositions of Formula 1, wherein
A is —CH(R 9 )—X—, —XCH(R 9 )—; —CO—X— or —X—CO—; X is —O—, —S—, —SO—, or —SO 2 —. Y is a single bond or a double bond. D and E are independently —(CH 2 ) n —; and ‘n’ varies from 0 to 2. R 1 to R 9 are various electron donating, electron withdrawing, hydrophilic, or lipophilic groups selected to optimize the physicochemical and biological properties of compounds of Formula I.
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This is a continuation of application Ser. No. 07/304,869, filed Jan. 31, 1989, now allowed, itself a continuation of Ser. No. 07/115,269, filed Oct. 30, 1987, and now abandoned.
FIELD OF THE INVENTION
This invention relates to improved peroxy laundry bleaching compositions and improved laundry procedures employing the same. More particularly this invention concerns a peroxy bleaching composition which provides increased levels of active oxygen during the wash cycle but also achieves a delayed onset of active oxygen generation.
BACKGROUND OF THE INVENTION
In modern laundry settings, both commercial and domestic, it is increasingly desired to employ a plurality of cleansing aids. These can include soaps and detergents as primary surfactants, and bleaches, whiteners, stain removers and the like to achieve especially good wash performance. Although in some cases it is possible to add these materials sequentially so as to optomize their efficiency, more commonly in a domestic setting they are added at once. This can in some cases lead to antagonistic interactions. In particular, when an enzymatic stain remover is present, its effectiveness can be severely limited if a strong oxidizer which can destroy the enzymes is added. Similarly, a strong oxidizer can attack other wash aids such as fluorescent brighteners or fragrances, if present in the wash mixture.
Peracids, whether added as such or formed in situ from activated peroxygen mixtures, are examples of such oxidizers. Thus, with activated peroxygen bleach systems, it is generally necessary to use these wash aids before or after the peroxygen bleach. This can be an added complication which is not desirable.
Peroxygen bleach systems have been widely used in commercial laundries and are now becoming increasingly common in domestic laundry settings. Peroxygen materials, to be effective, must undergo reaction in the wash liquid to generate an active oxygen species which effects the desired bleaching action by oxidation. Peroxygen bleaches for domestic use include a peroxygen source, most commonly a perborate or the like, and an activator or precursor to promote or catalyze the generation of the active oxygen species. Representative prior patents and literature references to peroxygen bleach and/or the addition of quaternary ammonium materials to laundry preparations include
U.S. Pat. No. 4,412,934 of Chung et al;
Great Britain patent 1,557,568 of Procter & Gamble;
U.S. Pat. No. 4,005,029 of Jones;
U.S. Pat. No. 4,290,903 of MacGilp et al;
U.S. Pat. No. 4,397,757 of Bright et al;
U.S. Pat. No. 4,131,562 of Lutz et al;
U.S. Pat. No. 3,852,210 of Kiezanoski;
U.S. Pat. No. 3,475,493 of Diamond et al;
U.S. Pat. No. 3,265,624 of Inamorato;
U.S. Pat. No. 4,378,300 of Grey;
U.S. Pat. No. 4,443,352 of Broze et al;
U.S. Pat. No. 4,430,244 of Broze et al;
U.S. Pat. No. 4,079,015 of Paucot et al;
U.S. Pat. No. 3,130,165 of Brocklehurst et al; and
Journal of Chemical Education, Vol 55, No. 7, July 1978, page 429-433.
Representative disclosures of a percompound together with an activator and an enzyme include U.S. Pat. No. 3,637,339 and U.S. Pat. No. 3,840,466, both of Gray. An additional reference to Grey is U.S. Pat. No. 4,166,794, issued Sept. 4, 1979. The patent discloses and claims a liquid bleach/softener composition consisting essentially of a water soluble peroxy bleaching agent (of which at least 50% is hydrogen peroxide) and a water-soluble fabric softener compound (at least 50% cationic amino softener), and the balance, water, or a mixture of water and alcohol.
The reference states that bleaching agents useful in the composition include hydrogen perioxide and alkaline metal perborates, which can be activated. Also, the fabric softening compounds include aliphatic quaternary ammonium compounds, preferably hexadecyltrimethyl ammonium bromide.
In contrast with the invention contemplated in the present application, this reference does not appear to teach surface active activators to produce surface active peracids.
Also of interest is EP 140 648 (published May 8, 1985). It discloses hydrogen peroxide compositions which are contented to contain an emulsion with one part by weight emulsifier per part by weight of activator (enol ester). This reference relies on specific enol ester activators and requires at least an equal weight amount of emulsifier.
It is a general object of this invention to provide a peroxygen bleaching composition which can be added to a laundry mixture together with oxygen-sensitive wash aides and not destroy the effectiveness of such wash aids.
It is an additional object of this invention to provide a combination product which includes a peroxygen bleach and an oxygen-sensitive wash aid.
STATEMENT OF THE INVENTION
The present invention now provides peroxygen bleach compositions which can be used together with oxygen-sensitive wash aids. These bleach compositions include a peroxygen source, a surface active or hydrotropic bleach activator or catalyst and a quaternary ammonium salt. As compared to equivalent compositions not containing the quaternary ammonium salt, these bleach compositions are characterized by a delayed onset of active oxygen production when they are added to wash solutions. When these bleach compositions are used in combination with oxygen-sensitive wash aids, the sensitive wash aids have an initial period when they can act before the active oxygen level rises to levels that could interfere with their action.
The bleach compositions of this invention which contain the added quaternary ammonium salt are also characterized by achieving higher ultimate yields or levels of active oxygen than do equivalent compositions which do not contain the ammonium salt.
In one aspect, this invention provides a bleach composition which includes a peroxygen compound, a surface active or hydrotropic bleach activator and a quantity of quaternary ammonium salt sufficient to beneficially delay formation of peracid.
In an additional aspect, this invention provides a combination laundry product which includes a peroxygen bleach made up of a peroxygen compound, a surface active or hydrotropic bleach activator and a quaternary ammonium salt together with an oxygen-sensitive wash aid.
In a preferred aspect, this invention provides a combination laundry product which includes a peroxygen bleach made up of a peroxygen compound, a surface active or hydrotropic bleach activator and a quaternary ammonium salt together with an enzymatic wash aid.
In an additional aspect, this invention provides an improved method of laundering which involves forming an aqueous solution of the combination product described above and immediately contacting clothes in need of bleaching and whitening with the solution through an initial period during which the oxygen-sensitive wash aid is active in the solution and can achieve a whitening effect on the clothes and through a subsequent period during which the peroxygen bleach components of the combination product provide an effective bleaching level of active oxygen to the solution.
Detailed Description of the Invention
BRIEF DESCRIPTION OF THE DRAWINGS
In this specification, reference will be made to the accompanying drawings in which the three figures are graphs illustrating the delayed onset of active oxygen generation as well as the ultimately increased levels of active oxygen generation which are achieved when employing the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
This description is presented in the following sections:
The Quaternary Ammonium Salts
The Peroxygen Materials
The Activators
The Oxidation Sensitive Wash Aids
Optional Ingredients
The Overall Compositions
Typical Use Conditions
Examples
The Quaternary Ammonium Salt
The quaternary ammonium materials employed in the present compositions are quaternary ammonium salts, most commonly available as halides, especially chlorides. These materials are represented by the structural formula ##STR1## wherein X - is an anion, most commonly a halide such as chloride, bromide or the like and preferably a chloride or a bromide; R 1 through R 4 are organic groups, preferably hydrocarbyls including saturated and unsaturated alkyls of from 1 to 25 carbon atoms, aryls of 6 or 10 carbon atoms and alkaryls and aralkyls of from 7 to 12 carbon atoms. Thus, typical alkyl R groups can include methyl, ethyl, isopropyl, n-butyl and t-butyl, octyl, dodecyl, hexadecyl, octadecyl, eicosyl and the like as well as similar materials containing one or two olefinic linkages. Similarly, typical aryls can be phenyl or naphthyl groups; while typical aralkyls can include benzyl, methyl- or ethylbenzyls and the like; and alkaryls can include methylphenyl, t-butylphenyl and the like. It is also possible for the R groups to be materials which are supplied as mixtures or are defined as reaction products. For example, an R could be a mixed 6 to 8 carbon alkyl, a mixed 6 to 10 carbon alkyl, mixed 8 to 12 carbon alkyl, a mixed 12 to 16 carbon alkyl, a tallow derivative such as hydrogenated tallow, or the like. In preferred materials, at most, one of the R groups contains an aryl ring. Also in preferred materials, at least one of the R groups is a saturated or unsaturated alkyl of 4 or more carbon atoms or such an aryl-containing material.
The following are representative quaternary ammonium materials which can be used in the present invention:
methyl tri(C 8-10 ) alkyl ammonium chloride,
trimethyl (C 8-10 ) alkyl ammonium chloride,
dimethyl di(C 8-10 ) alkyl ammonium chloride,
tetrabutyl ammonium bromide,
methyl tributyl ammonium chloride,
dimethyl dibutyl ammonium chloride,
benzyl trimethyl ammonium chloride,
benzyl octyl dimethyl chloride,
trimethyl dodecyl ammonium chloride,
trimethyl coco ammonium chloride,
dimethyl dicoco ammonium chloride,
trimethyl octadecyl ammonium chloride,
trimethyl stearyl ammonium chloride,
trimethyl cetyl ammonium chloride,
dimethyl ethyl stearyl ammonium chloride,
trimethyl hexadecyl ammonium chloride,
trimethyl hydrogenated tallow ammonium chloride,
dimethyl dihydrogenated tallow ammonium chloride,
dimethyl ditallow ammonium chloride,
trimethyl tallow ammonium chloride,
dimethyl diisoya ammonium chloride,
trimethyl isoya ammonium chloride, and the like.
These materials are available commercially from sources such as Armak Industrial Chemicals Division, Chicago, Ill. and Sherex Chemical Company, Dublin, Ohio. These and other materials falling within the definitions set forth herein can also be prepared by conventional processes well known to the art.
Among the quaternary ammonium salts, preference is given to salts having three 1 to 3 carbon alkyls and one 4 to 25 carbon alkyl with a total number of carbon atoms being between 8 and 28, with special preference being given to alkyl trimethyl ammonium halides wherein the alkyl group is from 4 to 25 carbons and especially those wherein the alkyl group is from 8 to 16 carbons, inclusive.
An advantage of the present invention is that the addition of the quaternary ammonium compound not only delays but also enhances the generation of active oxygen species. This is in contrast to the teaching of U.S. Pat. No. 4,391,723 of Bacon, et al to the effect that one can add a bleach release delaying amount of surfactant (such as soap) to a pouched peracid and enzyme product and by so doing improve the performance of the enzyme component.
The present invention avoids the use of pre-formed peracids with their inherent instability and, at the same time, leads to enhanced perhydrolysis not suggested in the art.
The Peroxygen Materials
The present invention involves wash systems which contain a source of active oxygen. Such sources of active oxygen include a peroxygen material and a peracid-forming activator or catalyst.
The peroxygen material can be hydrogen peroxide, an H 2 O 2 adduct such as a peroxy solid such as an alkali metal (i.e. potassium or sodium) percarbonate, perpolyphosphate, persilicate, or perborate or mixtures thereof which is capable of releasing hydrogen peroxide into aqueous solution. Of these materials, the alkali metal perborates (anhydrous, mono- and tetrahydrated) are usually preferred because of their commercial availability and relatively low cost.
If liquid hydrogen peroxide is the peroxygen material, it may be necessary to keep it separated from the activator prior to addition to the wash liquid, so as to avoid premature decomposition and generation of active oxygen.
An example of a practical execution of a liquid delivery system is to dispense separately metered amounts of the precursor (in some nonreactive fluid medium) and liquid hydrogen peroxide in a container such as described in Beacham et al, U.S. Pat. No. 4,585,150, commonly assigned to The Clorox Company, and incorporated herein by reference.
The Activators
The bleach activators, also known as peracid precursors, employed are those organic peracid-forming compounds disclosed in the art for use in conjunction with such peroxide sources. The organic peracid precursors are typically compounds containing one or more acyl groups which are susceptible to perhydrolysis. The preferred activators are those of the N-acyl or O-acyl compound type containing an acyl radical R--CO-- wherein R is an aliphatic group having from 5 to 18 carbon atoms, or alkylaryl of about 11 to 24 atoms, with 5 to 18 carbon atoms in the allyl chain. If the radicals R are aliphatic, they preferably contain 5 to 18 carbon atoms and most preferably 5-12 carbon atoms. These types of surface active activators would provide surface active or hydrotropic peracids. Surface active peracids are generally classified as those peracids which can, similar to surfactants, form micelles in aqueous media. See U.S. Pat. No. 4,655,781, of Hsieh et al, of common assignment and incorporated herein by reference. An alternative definition is hydrophobic peracid, which is defined as one "whose parent carboxylic acid has a measurable CMC (critical micelle concentration) of less than 0.5M." See European Published Application EP 68 547; U.S. Pat. No. 4,391,725, of Bossu, both of which are incorporated herein by reference. Such peracids are particularly desirable for cleaning performance on fatty or oily soil and stains such as sebum and grease.
Another way of defining appropriate activators is to describe such activators' acyl portion as being the acyl moiety of a carboxylic acid having a log P oct of from about 1.9 to about 4.1, where P oct is the partition coefficient of the carboxylic acid between n-octanol and water at 21° C. This is described in A. Leo et al in Chemical Reviews, pp. 525-616 (1971) and in U.S. Pat. No. 4,536,314, of Hardy et al, at column 4, lines 20-27 and at lines 41-51, both of which are incorporated herein by reference.
Hydrotropic peracids are defined as those "whose parent carboxylic acid has no measurable CMC below 0.5M" as set forth in EP 68547; U.S. Pat. No. 4,391,725, of Bossu, both of which are incorporated herein by reference. An example of a bleach activator which can deliver a hydrotropic peracid is shown in Diehl, U.S. Pat. Nos. 4,283,301 and 4,367,156, namely: ##STR2## wherein R' is a hydrocarbyl of 4-24 carbons, optionally ethoxylated, and each Z is a leaving group selected from enols, carbon acids and imidazoles.
R may be unsubstituted or substituted with C 1-3 alkoxy groups, halogen atoms, nitro or nitrilo groups. Aromatic radicals, in particular, may be chloro and/or nitro substituted.
Activators also contain leaving groups which are displaced during the perhydrolysis as a result of attack upon the activator by perhydroxide ion from the peroxygen source. Generally, to be an effective leaving group it must exert an electron-attracting effect. This facilitates the attack by the peroxide ion and enhances the production of the desired peracid. Such groups generally have conjugate acids with pKas in the range of from about 6 to about 13. These leaving groups can be selected broadly from among enols, carbon acids, N-alkyl quaternary imidazoles, benzoxys, and the like.
Examples of typical suitable surface active activators coming within this definition include, for example:
(a) Carbonyl materials of the formula ##STR3## such as disclosed in U.S. Pat. No. 4,412,934 where R is an alkyl group of up to about 18 carbon atoms and L is a leaving group having a conjugate acid with a pKa in the range of 6 to 13. These types of activators were previously disclosed in U.K. patent 864,798.
(b) Activators of the general structure ##STR4## wherein R is an alkyl chain containing about 5 to 13 carbon atoms, and Z is a leaving group selected from enols, carbon acids and imidazoles, as exemplified in U.S. Pat. Nos. 4,283,301 and 4,367,156, both of Diehl.
(c) Alpha-substituted alkyl or alkenyl esters of the general structure ##STR5## wherein R is a straight or branched alkyl or alkenyl group having from about 4 to 14 carbon atoms, R' is H or C 2 H 5 , X is Cl, OCH 3 or OC 2 H 5 and L is a leaving group selected from substituted benzenes, amides, carbon acids, imidazoles, enol esters, and sugar esters, exemplified by U.S. Pat. No. 4,483,778 of Thompson et al, and U.S. Pat. No. 4,486,327, of Murphy et al.
(d) Activators of the general structure ##STR6## wherein R is a hydrocarbyl or alkoxylated hydrocarbyl group, preferably C 6-20 alkyl; X is a heteroatom selected from O, SO 2 , N(R') 2 , P(R') 2 , (R')P-->O or (R')N-->O; when m=1, A is ##STR7## and X is 0 to 4, Z is 0 to 2, (R') is alkyl and R" is branched-chain alkylene; when m=2, A is ##STR8## such activators being exemplified in European Published Patent Application EP 166,751;
(e) Carbonate esters of the general structure ##STR9## wherein R is C 6-10 alkyl, such as disclosed in European Published Patent Application EP 202,698 (also apparently disclosed in U.S. Pat. Nos. 3,272,750, of Chase, 3,256,198, of Matzner, and 3,925,234and 4,003,841, both of Hachmann et al.)
(f) Substituted phenylene mono- and diester activators of the general structure: ##STR10## wherein R 1 is preferably C 4-17 alkyl, R 2 is OH, ##STR11## and X 1 , X 2 , Y and Z are substituents, as exemplified in European Published Patent Application EP 185,522, of common assignment herein.
Each of the foregoing references listed in subparagraphs (a) through (f) above are incorporated herein by reference.
The Oxidation-Sensitive Wash Aids
The compositions of this invention offer the advantage of a delayed onset of active oxygen generation. This makes them attractive for use in conjunction with oxygen-sensitive wash aides.
Representative wash aids include enzymatic stain removers. Such materials include enzymes capable of hydrolyzing substrates, e.g., stains. Under the International Union of Biochemistry, accepted nomenclature for these types of enzymes is hydrolases. Hydrolases include, but are not limited to, proteases, amylases (carbohydrases), lipases (esterases), cellulases, and mixtures thereof. Proteases, especially so-called alkaline proteases, are commonly employed as wash aids, since they attack protein substrates and digest them, e.g., troublesome stains such as blood and grass.
Commercially available alkaline proteases are derived from various strains of the bacterium Bacillus subtilis. These proteases are also known as subtilisins. Nonlimiting examples thereof include the proteases available under the trademarks Esperase®, Savinase®, and Alcalase®, from Novo Industri A.S., of Bagsvaerd, Denmark; those sold under the trademarks Maxatase® and Maxacal® from Gist-Brocades N.V. of Delft, Netherlands; and those sold under the trademark Milezyme® APL, from Miles Laboratories, Elkhart, Ind. Mixtures of enzymes are also included in this invention. See also U.S. Pat. No. 4,511,490, issued to Stanislowski et al, incorporated herein by reference. These commercially available proteases are supplied in prilled, powdered, or comminuted forms. These enzymes can include a stabilizer, such as triethanolamine, clays, or starch.
Other enzymes may also benefit from the practice of the invention. Thus, lipases, which digest fatty substrates, and amylases, which digest starch substrates, can be used in the compositions. These two types of enzymes are available commercially. Lipases are described in U.S. Pat. No. 3,950,277, column 3, lines 15-55, the description of which is incorporated herein by reference. Suitable amylases (and their sources) include Rapidase® (Societe Rapidase, France), Maxamyl® (Gist-Brocades), Termamyl® (Novo Industri), and Milezyme® DAL (Miles Laboratories). Cellulases may also be desirable for incorporation and description of exemplary types of cellulases is found from the specifications of U.S. Pat. No. 4,479,881, issued to Tai; U.S. Pat. No. 4,443,355, issued to Murata et al; U.S. Pat. No. 4,435,307, issued to Barbesgaard et al; and U.S. Pat. No. 3,983,002, issued to Ohya et al, all of which are incorporated herein by reference.
Another class of wash aid which can benefit from the practice of the invention is the fluorescent whiteners or optical brighteners although, as a rule these materials take effect more quickly than enzyme stain removers and thus are less prone to attack by rapid onset of active oxygen. Representative fluorescent whitening agents include the naphtholtriazol stilbene and distyryl biphenyl fluorescent whitening agents sold by the Ciba-Geigy Corporation under the names Tinopal® RBS and Tinopal® CBS-X respectively, and the stilbene materials also marketed by Ciba-Geigy under the name Tinopal® 5BMX. Other useful whiteners are disclosed in columns 3, 4, and 5 of U.S. Pat. No. 3,393,153 and further useful whiteners are disclosed in ASTM publication D-553A, List of Fluroescent Whitening Agents for the Soap and Detergent Industry, which disclosures are incorporated herein by reference.
Yet another class of wash aids which can benefit are the fragrances which can be selected from materials of the art.
Optional Ingredients
The compositions of this invention may, if desired, contain additional components such as buffers, colorants, primary cleansing agents (surfactants), detergency builders and bulking agents. In addition, peroxide stabilizers, such as heavy metal chelating ligands, for example EDTA, can be added, if desired.
Colorants can be selected from materials of the art.
Representative surfactants include conventional nonionic, ampholytic and zwitterionic surfactant materials as are described in the art. Examples of suitable surfactants for use in these formulations may be found in Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd Edition, volume 22, pages 247-387 (1983) and McCutcheon's Detergents and Emulsifiers, North American Edition (1983). These two disclosures are incorporated herein by reference. One generally preferred group of surfactants are the nonionic surfactants such as are described at pages 360-377 of Kirk-Othmer. Nonionic materials include alcohol ethoxylates, alkyl phenol ethoxylates, carboxylic acid esters, glycerol esters, polyoxyethylene esters, anhydrosorbitol esters, ethoxylated anhydrosorbitol esters, ethoxylates of natural fats, oils and waxes, glycol esters of fatty acids. carboxylic amides, diethanolamine condensates, monoalkanolamine condensates, polyoxyethylene fatty acid amides, polyalkylene oxide block copolymers, poly(oxyethylene-co-oxypropylene) nonionic surfactants and the like. A wide range of such materials are available commercially, including the Shell Chemical Neodols®, the Union Carbide Tergitols®, the ICI Tween's® and Spans® and the like.
Detergency builders which may optionally be added to the bleach compositions can be selected from the detergency builders commonly added to detergent formulations. Useful builders include any of the conventional inorganic and organic water-soluble builder salts. Useful inorganic builder salts include, for example, water-soluble salts of phosphates, pyrophosphates, orthophosphates, polyphosphates, silicates, carbonates, and the like. Organic builders include water-soluble phosphonates, polyphosphonates, polyhydroxysulfonates, polyacetates, carboxylates, polycarboxylates, succinates, and the like.
Specific examples of inorganic phosphate builders include sodium and potassium tripolyphosphates, pyrophosphates, and hexametaphosphates. The organic polyphosphonates specifically include, for example, the sodium and potassium salts of ethane-1-hydroxy-1,1-diphosphonic acid and the sodium and potassium salts of ethane-1,1,2-triphosphonic acid. Examples of these and other phosphorous builder compounds are disclosed in U.S. Pat. Nos. 3,213,030; 3,422,021; 3,422,137; and 3,400,176. Pentasodium tripolyphosphate and tetrasodium pyrophosphate are especially preferred water-soluble inorganic builders.
Specific examples of nonphosphorous inorganic builders include water-soluble inorganic carbonate, bicarbonate, and silicate salts. The alkali metal, for example, sodium and potassium, carbonates, bicarbonates, and silicates are particularly useful herein.
Water-soluble organic builders are also useful. For example, the alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarboxylates, and polyhydroxysulfonates are useful builders for the compositions and processes of the invention. Specific examples of polyacetate and polycarboxylate builders include sodium, potassium, lithium, ammonium, and substituted ammonium salts of ethylene diaminetetraacetic acid, nitrilotriacetic acid, benzene polycarboxylic (i.e., penta- and tetra-) acids, carboxymethoxysuccinic acid and citric acid.
Water-insoluble builders may also be used, particularly the complex sodium alumino silicates such as zeolites, e.g., zeolite 4 A, a type of zeolite molecular sieve wherein the univalent cation is sodium and the pore size is about 4 Å. The preparation of such type zeolite is described in U.S. Pat. No. 3,114,603. The zeolite may be amorphous or crystalline and have waters of hydration as is known in the art.
Fillers or bulking agents may also be included in the bleaching compositions of the invention. A preferred filler salt is an alkali metal sulfate, such as potassium or sodium sulfate, the latter being especially preferred.
The Overall Compositions
The overall composition of the bleaching products of this invention can vary widely depending upon the amount of optional ingredients such as builders, surfactants, and bulking agents. Therefore the actual composition of the products themselves is not considered to be as important as the ratios between the various components and the concentrations of the various components achieved in the laundry solution. Accordingly, the overall compositions and use level will often be expressed in terms of these ratios and these laundry solution concentrations. From these numbers, the amounts of material to be used can be calculated based on a typical laundry liquid volume of 72,000 mL.
The quaternary ammonium salt is present in the bleaching compositions in "an effective active oxygen generation-delaying amount." Such an amount is an amount which when added to (or otherwise made up into) a laundry wash solution yields a concentration of the quaternary ammonium salt which will delay the generation of substantial levels of active oxygen. This amount has the unexpected advantage of increasing the yield of active oxygen as well. Such concentrations can be as low as about 250 mg/L or as high as 3000 mg/L. Preferred effective active oxygen generation-delaying amounts yield concentrations of from about 300 mg/L to about 2500 mg/L with more preferred amounts yielding concentrations of from about 400 mg/L to about 2000 mg/L.
As will be detailed in the examples, levels below about 250 mg/L do not appear to have the desired effect. Levels in the 300 and greater ml/L range give increased yields when sampled after 24 minutes. Higher levels such as 700 mg/ml or greater show increased yields when sampled after 12 minutes.
The amount of peroxygen source is provided to yield a concentration of peroxygen source in the wash liquid of from about 0.0001 to about 0.01 molar, and preferably from about 0.0002 (3 ppm) to about 0.005 molar (80 ppm). The molar ratio of the activator to the peroxygen source can vary, depending upon the number of reactive acyl groups per molecule of the activator, but usually the molar ratio of the two components falls in the range from about 4:1 to about 1:20, preferably from about 2:1 to about 1:8.
The amount of oxygen-sensitive wash aid, when present in the compositions is such as to yield concentrations of from about 1 to about 50 ppm in the wash liquid. When the wash aid is an enzymatic stain remover, it is commonly present at levels to yield concentrations of from about 5 to about 40 ppm in the wash liquid and preferably concentrations of from about 7 to about 30 ppm in the wash liquid. When the wash aid is a fluorescent brightener, it is commonly present at levels to yield concentrations of from about 1 to about 30 ppm in the wash liquid and preferably concentrations of from about 5 to 20 ppm in the wash liquid.
The amount of optional surfactant will depend upon whether or not this composition is to be the sole source of surfactant for the washing. Commonly, surfactant is present in wash liquids at about 750 to 2000 ppm levels and especially about 1000 to 2000 ppm levels. This total amount or some fraction of it can be provided by the present compositions.
The materials of the invention should yield wash solutions having pHs which are alkaline, i.e., pH 7 to 13. Preferably, they yield pHs in the 8 to 13 range and especially in the 9 to 12 range. Buffers, e.g., carbonates, etc., if present, should accommodate these ranges.
Typical overall compositions can comprise
______________________________________Peroxygen material 5-30% wt.Activator 5-30% wt.Quaternary ammonium material 15-45% wt.Builder 0-75% wt.Peroxygen material 5-30% wt.Activator 5-30% wt.Quaternary ammonium material 15-40% wt.Oxygen-sensitive wash aid 0.1-5% wt.Builder 0-70% wt.Peroxygen material 5-25% wt.Activator 5-25% wt.Quaternary ammonium material 20-40% wt.Enzymatic stain remover 0.2-4% wt.Builder and/or surfactant 10-˜70% wt.______________________________________
A variety of specific compositions in accord with this invention are provided in the Examples, as well.
The bleaching compositions of the invention are prepared by admixing the ingredients. When preparing solid combination products containing the bleaching composition in combination with oxygen-sensitive wash aids and/or with surfactants and/or builder salts, the peroxygen compound and activator can be mixed either directly with the wash aid, surfactant, builder, and the like, or peroxygen compound and activator can be separately or collectively coated with a coating material to prevent premature activation of the bleaching agent. The coating process is conducted in accordance with procedures well known in the art. Suitable coating materials include compounds such as magnesium sulfate, polyvinyl alcohol, lauric acid or its salts, and the like.
Typical Use Conditions
The materials of this invention find application in commercial and domestic laundry settings. The materials can be added to the prewash segment, the wash segment or a rinse segment of the overall cycle. Most commonly, it is preferred to add the materials to the wash segment of the cycle.
The conditions of use can include cold water and hot water wash conditions with water temperatures ranging from a low of about 33° F. to about 45° F. to a high of about 200° F. being possible, temperatures of from about 50° F. to about 150° F. being preferred and temperatures of from about 60° F. to about 140° F. being more preferred in a domestic laundry setting. The conditions of use can also include the use of alkaline wash liquid, for example one having a pH of from about 7.5 to about 13 and preferably from about 9 to about 12.
In most laundry cycles, the wash period is from about 8 to about 20 minutes, with wash times of from about 10 to about 15 minutes being most common. It is to be noted that an aspect of this invention is its ability to delay the generation of bleaching levels of active oxygen, for example 6 ppm active oxygen, or greater and especially 8 ppm active oxygen, or greater). The delay is on the order of 3 to 10 minutes. Thus, the segment of the cycle when the composition of this invention is added should be long enough to accommodate this delay and still provide a suitable period for subsequent bleaching action once the active oxygen concentration has risen to effective bleaching levels. The aforesaid wash times will accommodate the delay period and provide a good bleach period, as well.
Since the invention permits a delay in the bleaching action during which sensitive materials may be at work, it is generally the practice to contact the soiled clothes with the wash solution promptly (typically at once or within a minute or two) upon forming the wash solution.
EXAMPLES
This invention will be further illustrated by the following Examples. These are presented to show modes of practicing the invention and are not to be construed as limiting its scope.
EXAMPLE 1
A pair of aqueous laundry liquids are prepared in the laboratory. One is for comparison purposes. It contains a peroxygen source (hydrogen peroxide) at a concentration of 0.0013 molar, an activator (sodium octanoyloxy benzene sulfonate--"SOBS") in a molar ratio relative to the peroxygen source of 1:1.5, 1.52 g/L of a commercial laundry detergent (Tide®) and 1.06 g/L of sodium carbonate. The solution has a pH of 10.5 and a temperature of 72° F.
The second solution, which is a solution prepared in accord with this invention, is identical to the first with the exception that it contains 0.47 g/L of quaternary ammonium salt (lauryl trimethyl ammonium chloride).
As soon as each solution is assembled, samples are periodically drawn and analyzed by iodometric titration. The titration is carried out by adding 10% H 2 SO 4 and excess potassium iodide and back-titrating with sodium thiosulfate to determine the concentration of active oxygen they contain. The titration method employed is described generally in the text Oxidation, Vol. 1, (Marcel Dekker, Inc. New York, 1969) Chapter 5, "Peracid and Peroxide Oxidations" by Sheldon N. Lewis, pages 221, et seq., (incorporated herein by reference) with the modification that the samples are iced before and during titration to eliminate interference from unreacted hydrogen peroxide. From previous experiments it is known that such a solution has a theoretical maximum level of active oxygen from peracid formation of about 14 ppm.
It is observed that in the comparison sample, the active oxygen level is at 8 ppm within 2 minutes and stays between 8 and 9 ppm throughout the test. In contrast, the solution prepared in accord with this invention has lower active oxygen levels (3-4 ppm) for at least 6 minutes after which the levels rise. The level reaches 8 ppm at about 10 minutes and is still rising past 13 ppm at 18 minutes. These results are shown graphically in the figure where line "A" is a curve showing the active oxygen levels of the material of the invention and "Comparative Experiment" is a curve showing the active oxygen levels of the comparative material.
Thus it can be seen that the present invention provides a way to obtain high levels of bleaching from a peroxygen bleach but at the same time delay the onset of the active oxygen generation so as to permit oxidation-sensitive wash aids to be used as well.
EXAMPLE 2
The experiment of Example 1 is repeated with the change that instead of 0.47 g/L of quaternary ammonium salt, 0.94 g/L of quaternary ammonium salt is used. This use level shows the same general effect as observed in Example 1 with the onset of active oxygen being somewhat more rapid. These results are given in the Figure as curve "B".
EXAMPLES 3-5
The experiment of Example 1 is repeated three times with the change that instead of 0.47 g/L of quaternary ammonium salt, 0.045, 0.095, and 0.235 g/L of quaternary ammonium salt are used. The mole ratio of peroxygen material to activator is also varied to 2:1. These use levels show the same general effect as observed in Example 1 with the ultimate levels of active oxygen attained being somewhat lower.
EXAMPLE 6
To demonstrate that the delayed onset of the present invention is the result of the addition of the quaternary ammonium salt, a series of 72° F. test solutions are prepared containing SOBS, hydrogen peroxide, and an additive selected from a quaternary ammonium salt and a range of ionic and nonionic surfactants. Samples are taken after 4 minutes and analyzed for peracid as a measure of their active oxygen levels. Each experiment is run in duplicate. The results of this series of experiments are provided in Table 1. They illustrate that the quaternary ammonium salt depresses the level of active oxygen but that the other materials do not.
TABLE 1__________________________________________________________________________[C.sub.8 SOBS], × 10.sup.-4 M [H.sub.2 O.sub.2 ], × 10.sup.-3 M Additive [Peracid], × 10.sup.-4 M %__________________________________________________________________________ Yield8.76 1.31 Lauryl trimethyl ammonium chloride.sup.1 2.94 34" 1.31 None 5.61 64" 1.74 " 6.67 76" 1.31 K Palmitate 5.83 66" " K Myristate 5.69 65" " K Stearate 5.65 64" " Lauric Acid 5.40 61" " Octylphenoxypolyethoxy ethanol.sup.2 5.56 63" " Linear C.sub.12 --C.sub.15 -alcohol ethoxylate sulfonate.sup.3 6.11 70" " Linear C.sub.12 --C.sub.15 -alcohol ethoxylate sulfonate.sup.4 5.71 65" " Lauryl dimethylamine oxide.sup.5 5.31 61" " Sulfated ethoxylated alcohol, Na 5.68.sup.6 65" " Lauryl aryl sulfonate.sup.7 5.53 63__________________________________________________________________________ .sup.1 Kodak Chemical .sup.2 Rohm & Haas .sup.3 Shell Chemical Co. .sup.4 Shell Chemical Co. .sup.5 Continental Chemical Co. .sup.6 Continental Chemical Co. .sup.7 Pilot Chemical Co.
EXAMPLE 7
A series of products in accord with this invention are prepared. They have the following compositions:
______________________________________Product CSodium perborate monohydrate 16% wtSOBS 17% wtHexadecyl trimethyl ammonium 35% wtchlorideBuilder 38% wtProduct ESodium perborate monohydrate 16% wtSOBS 17% wtDodecyl trimethyl ammonium 30% wtchlorideAlkaline protease 0.7% wt(enzyme)Sodium hexametaphosphate 36% wtProduct FSodium perborate monohydrate 16% wtSodium decanoyloxy benzene 18% wtsulfonate (activator)Dodecyl trimethyl ammonium 30% wtchlorideMilezyme .sup.® (enzyme) 1.0% wtBuilder 35% wtProduct GSodium perborate monohydrate 16% wtSOBS 17% wtHexadecyl trimethyl ammonium 35% wtchlorideAlcalase .sup.® (enzyme) 0.7% wtTinopal .sup.® 5BMX (whitener) 0.5% wtSodium tripolyphosphate 31% wt(builder)______________________________________
If these products were tested in the manner shown in Example 1 they would exhibit the delayed onset of active oxygen production observed there.
If these products were added to the wash cycle of test washes, they would perform as effective peroxygen bleaches, whitening the test materials and removing stains. Products D and G would be observed to offer the additional advantage of enhanced brightener or whitener or other wash aid performance because these sensitive materials had a substantial period at the beginning of the cycle where the active oxygen level was depressed and could not appreciably interfere.
Products E through H should display enhanced stain removal because the delay in peracid formation allows the hydrolytic enzymes to attack specific stains before degradation due to the peracid.
EXAMPLE 8
A series of bleach compositions are prepared. These materials are tested for active oxygen levels and % recovery of active oxygen when used under laundry conditions (70° F., pH 10.5, 100 ppm Ca +2 /Mg +2 3:1, 8.2% Tide detergent, 1.06 g/L Na 2 CO 3 , 0.200 g/L sodium perborate tetrahydrate, i.e., 10.5% active oxygen and 0.282 g/L C8 sodium alkanoyloxy benzene sulfonate ("SOBS"), mole ratio perborate/SOBS=1.5. The levels of quaternary amine were varied by adding various levels of dodecyltrimethylammonium chloride.
Samples were drawn after 12 and 24 minutes and analyzed for active oxygen levels. The results of the various test are given in Table 2 and are presented graphically in FIGS. 2 and 3. They verify the unexpected result that the quaternary ammonium salt, when added at certain levels, not only delays onset of active oxygen generation, but also gives higher ultimate levels of active oxygen.
TABLE 2______________________________________ QuaternaryRun # Time (min) Ammonium Salt ppm A.O. % Recovery______________________________________1. 12 0 g 10.0 72 24 10.9 782. 12 .050 g 10.2 73 24 10.1 733. 12 .300 g 6.8 49 24 10.5 754. 12 .350 g 6.7 48 24 11.2 805. 12 .400 g 7.0 50 24 12.3 886. 12 .450 g 6.5 47 24 12.5 897. 12 .500 g 6.3 45 24 12.0 868. 12 .550 g 7.2 51 24 12.9 929. 12 .750 g 10.3 74 24 13.6 9710. 12 1.000 g 15.2 109 24 14.0 100______________________________________
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Peroxygen bleach compositions which can be used together with oxygen-sensitive wash aids are disclosed. Combination products comprising these bleach compositions together with the oxygen sensitive wash aids are disclosed as well as are methods of laundering employing them. The bleach compositions include a peroxygen source, a surface active or hydrotropic bleach activator or catalyst therefor and a quaternary ammonium salt. As compared to equivalent compositions not containing the quaternary ammonium salt, these bleach compositions are characterized by a delayed onset of active oxygen production when they are added to wash solutions. When these bleach compositions are used in combination with oxygen-sensitive wash aids, the sensitive wash aids have an initial period when they can act before the active oxygen level rises to a level that it interferes with their action. The bleach compositions of this invention which contain the added quaternary ammonium salt are also characterized by achieving higher ultimate levels of active oxygen than do equivalent compositions which do not contain the ammonium salt.
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BACKGROUND OF THE INVENTION
This invention relates to tufting machines and more particularly to tufting machines having A.C. motor drives and means for controlling the starting and stopping of the tufting machine mainshaft so that the needle bar may be gradually reciprocated when the machine is started and may be gradually stopped and when stopped positioned at the top of its stroke.
Tufting machines include a rotatable mainshaft which carries a plurality of drive members including those for reciprocably driving a needle bar carrying a plurality of needles and for oscillating the loop seizing members which cooperate with the needles to form stitches. The mainshaft is rotatably driven by one or two electric motors which conventionally may be substantially fixed speed A.C. motors, or variable speed A.C. or D.C. motors. Selection of the type of motor drive is a matter of preference dependent upon a number of factors, and although some of these factors are subjective, cost enters into the selection process. Since A.C. motor drives without variable speed features are somewhat less expensive than the other drives, a substantial number of tufting machines utilize these motors.
A difficulty exists in the tufting process when it is desired to stop the machine, as for example, to thread those needles wherein the thread may have been broken or otherwise unthreaded from the needles. In order to thread the needles, they must be in a raised position above the fabric being tufted, and because threading is most convenient when the needles are at the uppermost portion of the needle bar stroke, it is highly desirable to be able to stop the rotation of the mainshaft when the needle bar is at the top of its stroke. Additionally, and more critical to the appearance of the carpet product being manufactured, particularly loop pile fabric, is that when the machine is stopped rapidly and started rapidly, and especially when stopped at varying locations above the fabric, a distinct line or lines will appear in the fabric which is known in the art as "stop marks." Such "stop marks" are less apparent in cut pile fabric, but in the case of loop pile fabric, it can result in defective product resulting in waste or reduced quality product.
Although "stop marks" are a relatively small problem when the more expensive variable speed A.C. motors or variable speed D.C. motors are used, it remains a difficulty in those situations. When variable speed A.C. motors are used, the motors and thus the mainshaft can be slowed gradually and when the shaft has reached a predetermined speed, a speed sensor actuates a relay to engage a brake to stop rotation of the shaft. The motors and thus the mainshaft can subsequently be restarted gradually. Variable speed D.C. motors are even more expensive than the variable speed A.C. motors, but are less reliable and thus less popular.
The most significant "stop marks" problem results when using the popular constant speed A.C. motors, i.e., induction motors. Tufting machines driven by these motors utilize a single disk brake, air actuated through a solenoid valve receiving an electrical signal when the motor stop button is depressed. However, the motor and thus the mainshaft is rapidly brought to an uncontrolled stop and the needle bar may come to rest randomly at any position. Thereafter, the machine operator uses the "jog" button to position the needle bar at or close to the top of the needle stroke and then may turn a large wheel on the end of the mainshaft to adjust the position of the needle bar at the top of the stroke. When the machine is thereafter started, and the needles form the first stitches, "stop marks" inherently result. One prior art attempt to solve this problem is described in Owens U.S. Pat. No. 3,753,061 wherein a D.C. voltage is applied to the windings the A.C. motors for stopping the motors after the stop button has been depressed. For various reasons, however, this proposal does not appear to have been adapted, and in any event, is not known to now be used.
SUMMARY OF THE INVENTION
Consequently, it is a primary object of the present invention to provide a tufting machine driven by A.C. motor means and incorporating means for substantially reducing "stop marks" from occurring in the fabric being tufted when the machine is stopped and thereafter started.
It is another object of the present invention to provide a tufting machine driven by A.C. motor means and incorporating means for providing gradual starting and stopping characteristics to the tufting machine for positioning the needle bar at the top of its stroke when stopped.
It is a further object of the present invention to provide a tufting machine having a needle bar driven from a mainshaft powered by A.C. motor means, the machine having first and second brake means, the first brake means being activated to slow the mainshaft when power is removed from the motor means, and the second brake means being activated after the mainshaft has slowed to a predetermined speed to stop rotation of the shaft at a predetermined position with the needle bar at the top of its stroke.
Accordingly, the present invention provides a tufting machine having a mainshaft rotatably driven by one or more A.C. motors for reciprocably driving a needle bar, the tufting machine including a first brake operatively connected to the mainshaft and energized upon removal of electrical power to the motors so as to slow the mainshaft, a speed sensing switch for sensing the speed of the mainshaft, a second brake operatively connected to the mainshaft and electrically energized by circuitry including a proximity switch, the proximity switch circuitry being activated by the speed sensing switch when the mainshaft has been slowed to a predetermined speed by the first brake, thereby resulting in the proximity switch sensing a predetermined position of the mainshaft to activate the second brake to stop the rotation of the mainshaft with the needle bar at the top of its stroke.
To accomplish the aforesaid objects, the present invention uses a simple A.C. circuit including the speed sensing switch, the proximity switch, and first and second brakes.
Thus, the present invention provides a solution to a long existing problem merely by incorporating a second brake together with actuating circuitry including a position or proximity sensor activated when the first brake has reduced the speed of the mainshaft to a predetermined low value such that the second brake may stop the mainshaft at a precise angular position corresponding to the uppermost position of the needle bar.
In carrying out the invention simple A.C. circuitry is utilized, as aforesaid, such circuitry being incorporated into the conventional tufting machine A.C. motor circuit together with circuit means for slowly starting the motor(s) when the machine is to be restarted. Thus, the slow or soft stopping provided by actuation of the brakes in seriatim with the second brake actuation occurring at a predetermined low speed together with the physical stopping of the needle bar at the top of its stroke and the slow or soft starting results in substantial reduction of "stop marks" in the product tufted by the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a fragmentary perspective view of one end of a tufting machine incorporating apparatus constructed in accordance with the principles of the present invention;
FIG. 2 is a fragmentary perspective view of the machine illustrated in FIG. 1 showing the opposite end of the machine; and
FIG. 3 is a schematic view of the electrical circuitry utilized to control the starting and stopping of the tufting machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings, FIG. 1 illustrates a portion of a tufting machine 10 incorporating apparatus constructed in accordance with the principles of the present invention. The tufting machine includes a head 12 within which a main drive shaft 14 is journally mounted and which extends out at least one end and preferably both ends thereof. The drive shaft 14 is driven by one or more A.C. motors, 16, only one of which is illustrated in FIG. 1, the motor being mounted on the frame of the machine and drivingly connected to an extending portion of the main drive shaft by conventional means such as pulleys 18, 19 and belts 20. Mounted on the main drive shaft 14 within the head 12 of the machine are a plurality of eccentrics 21, only one of which is illustrated, each of which is drivingly connected in conventional manner through push rods 22 to a needle bar 23 which carries a plurality of yarn carrying needles 24 defining at least one needle bank substantially aligned transversely across the machine. Upon rotation of the mainshaft, endwise reciprocation is imparted to the needles for penetrating a backing material B and projecting loops of yarn therethrough.
As is notoriously well known in the art, beneath the head 12 the frame of the machine includes a bed 26 which carries a needle plate (not illustrated) over which the backing material B is fed by feed rollers and beneath which oscillatory hooks or loopers are adapted to cooperate individually with a respective one of the needles 24 to seize the loops formed by the needles in conventional manner and to form pile, the hooks or loopers, feed rollers and all of the other driven elements of the machine being driven by drive means driven from the mainshaft. As known in the art loop or uncut pile, cut pile or both loop and cut pile may be formed. However, "stop marks" are generally more discernible and a greater problem in conjunction with loop pile forming machines.
Conventionally, as aforesaid, the A.C. motor driven tufting machines include a disk brake which is actuated by an air solenoid when the motor or motors are deenergized. Thus, a disk or rotor 28 is mounted on the mainshaft 14 adjacent the pulley 19 and a disk brake caliper 30 is supported by a bracket 32 fastened to the frame of the tufting machine, the caliper conventionally carrying brake pads for grasping the faces of the rotor 28 when the brake is applied. A pneumatic solenoid valve 33 is energized by an electrical signal when the motors are deenergized to rapidly bring the mainshaft and the components driven thereby to a halt. In loop pile machines, possibly because of the inertia of the moving members, or for other reasons, when the motors are again energized and the brake released to drive the mainshaft, the "stop marks" result.
To overcome this problem, the present invention provides a second air actuated brake system comprising a second caliper 34 hereinafter referred to as the "second brake" controlled by a separately energized air solenoid valve 35, the first caliper 30, hereinafter referred to as the "first brake," and the second brake being actuated at distinct times after the motors are deenergized as hereinafter described. Additionally, the first brake may be actuated by lower pressure air than the second brake for reasons which will become clear, the pressure being in the order of 25 psi and 125 psi respectively.
Preferably at the other end of the machine, i.e., the end remote from the rotor 28 and the brakes 30, 34, a multitooth gear 36 and a disk 38 are fastened to the mainshaft so as to rotate therewith. A bracket 40 secured to the adjacent end of the tufting machine frame extends from the frame spaced from the peripheries of the gear 36 and disk 38. The bracket 40 has a portion 41 which carries another bracket 42 which fixedly supports a speed sensing switch 44 with the sensing end closely adjacent the periphery of the teeth of the gear 36, while the housing 46 of a conventional proximity switch 48 is carried by the bracket 40 and extends toward the disk 38 with the sensing end closely adjacent the periphery of the disk 38. The disk 38 may be formed from an aluminum or plastic material, or other non-magnetic material, having a small steel or other ferrous metal insert 50 secured at a location on the periphery, the proximity switch 48 being adapted to sense the insert as a positioning reference or timing point for the mainshaft when the proximity switch is activated so as to provide an electrical signal when the insert is sensed. The speed sensing switch 44 is a conventional device that senses the rotation of the teeth of the gear 36 and when a predetermined rotational speed is sensed acts to close its contacts and make a circuit.
Referring to FIG. 3, two motors 16a and 16b are illustrated in the control circuit for driving the mainshaft. The motors are connected in parallel and supplied with 3-phase 440 volt A.C. from a source by leads 52, 53, 54 which are connected to normally open contacts 56-1, 56-2, 56-3 and 58-1, 58-2, 58-3 of the starters 56, 58 associated with the respective motors 16a, 16b. Each motor is connected in series with a circuit comprising a respective resistance load 60-1, 60-2, 60-3 and 62-1, 62-2, 62-3 which are connected in parallel with respective motor contacts 64-1, 64-2, 64-3 and 66-1, 66-2, 66-3 of respective electro-magnetic contactors, 64, 66. When the coils of the respective motor contactors 64, 66 are energized, the respective contacts 64-1, 64-2, 64-3, and 66-1, 66-2, 66-3, close to by-pass or short-out the resistance from the motor circuit.
Two of the leads, e.g., 52, 53 are also connected to the primary winding 68 of a transformer to drop the voltage at the secondary winding 70 to 110 or 120 volts which is supplied to a parallel circuit including the coils of the starters 56, 58, the coils of the motor contactors 64, 66, the speed sensing switch 44, the solenoids 72, 74 of the respective air valves 33, 35 associated with the first and second brakes 30, 34, respectively and a control relay 76 for energizing the second brake 34, together with various contact. Additionally, the voltage at the secondary winding 70 is connected to the primary winding 78 of a second transformer and is stepped-down to a low voltage, e.g., 12 volts, at its output winding 80 which is supplied to a parallel circuit which includes a motor activating control relay 82 in series with the start button 84 and the normally closed stop button 85, a timer 86 in series with normally open contacts 56-4 and 58-4 of the starters 56 and 58, and a normally open contact 82-1 of the relay 82, and another control relay 88. Another normally open contact 82-2 of the relay 82 is connected in the higher voltage portion of the circuit in series with the starters 56 and 58 while a normally open contact 88-1 of the relay 88 is connected in series with the coil of the motor contactors 64 and 66.
Thus, when the start button 84 is depressed, the timer 86 and the control relay 82 are energized. The normally open contacts 82-1 and 82-1 close and the normally closed contact 82-3 is opened. The closing of the contact 82-2 energizes the parallel connected starters 56 and 58 to initiate motor starting with the resistance 60-1, 60-2, 60-3 and 62-1, 62-2, 62-3 in series with the respective motor, and the opening of the contact 82-3 deenergizes the first brake solenoid 72 while the second brake solenoid 74 is deenergized by opening of a normally closed starter contact 56-5 to deenergize the relay 76 and thus its normally open contacts 76-1 and 76-2. After a preselected period of time, the timer 86 times out to close its normally open contact 86-1 which energizes the control relay 88. This closes the normally open contact 881 to energize the coils of the motor contactors 64 and 66 to close the contacts 64-1, 64-2, 64-3 and 66-1, 66-2, 66-3 to shunt and thus effectively remove the resistance from the circuits of the motors 16a and 16b and permit the motors to attain full speed. Consequently, the motors are started slowly and after a predetermined interval are permitted to reach full speed.
When it is desired to stop the machine, the stop button is depressed which opens the circuit to the motor activating control relay 82 and the timer 86 thereby opening the normally open contacts 82-1 and 82-2 to remove power from the motors 16a and 16b while closing the normally closed contact 82-3 of the relay 82 and opening the timer contact 86-1. The latter deactivates the control relay 88 to open the contact 88-1 and deactivate the motor contractors 64 and 66 to place the resistance 60-1,60-2, 60-3 and 62-1, 62-2, 62-3 in series with the respective motor. The closing of the normally closed contact 82-3 energizes the solenoid 72 of the valve 33 to port air to and thereby actuate the first brake 30 to slow the mainshaft of the tufting machine. After the speed of the mainshaft decreases to a predetermined speed, e.g., approximately 100 rpm, the contacts of the speed sensing switch 44 close to energize the proximity switch 48. The proximity switch may thereafter sense the location of the insert 50 on the disk, and when it does, its contacts close so as to energize control relay 76 which results in closing of its normally open contact 76-1 This results in the energizing of the solenoid 74 of the valve 35 to port air to and activate the second brake 34 to stop the rotation of the mainshaft with the needle bar disposed at the top of its stroke.
Accordingly, when the stop button is depressed, the machine is gradually slowed until it reaches the preselected speed and is then stopped quickly by.. the second brake 34. This together with the gradual starting of the machine acts to alleviate and substantially reduce the occurrence of the unsightly "stop marks" which have plagued the tufting industry and in particular loop pile fabrics produced by tufting machines having prior art apparatus.
Other elements in the circuitry illustrated in FIG. 3 are for jogging the machine in step-wise fashion and for safety purposes as known in the art. For example, when the jog button or switch 90 is closed it activates a relay 92 to close its contacts 92-1 and 92-2 for starting the motor and when the button is released the contacts open to stop the machine. Other elements are activated to automatically open the circuit when the pressure of the oil fed to the machine is too low and when there is an overload, and to manually stop the machine when something is disposed within the danger zone of the machine.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A tufting machine having a mainshaft rotatably driven by one or more A.C. motors reciprocably drives a needle bar carrying a multiplicity of needles. Two brakes are associated with the shaft, the first brake being actuated when the motors are deenergized, and the second brake is actuated after the speed of the shaft has been reduced to a predetermined speed which permits the shaft to be stopped with the needle bar and the needles at the top of the reciprocating stroke. The motors may also be gradually started so that attainment of full speed is not reached until after the expiration of a predetermined time interval. Thus, "stop marks" may be substantially eliminated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a so-called outdoor portable gas cooking stove, and more particularly, to a burner structure of a portable gas cooking stove.
2. Description of the Related Art
FIG. 1 shows an example of a portable gas cooking stove known in the art.
Normally, the portable gas cooking stove 10 includes a gas cartridge 11 filled with compressed combustible gas, and a gas burner 12 mounted detachably on the gas cartridge 11 . The gas cartridge 11 and the gas burner 12 are coupled to each other in a hermetically sealed condition through a gasket 13 .
The gas burner 12 is comprised of a plug fitting 14 which is connected to the gas cartridge 11 and through which combustible gas supplied from the gas cartridge 11 passes, a gas flow adjusting spindle 15 which adjusts a degree of opening of a gas passage formed inside the plug fitting 14 to thereby adjust a flow of the combustible gas passing through the plug fitting 14 , a burner head 16 with a number of openings 16 a formed on a surface thereof, a mixing tube 17 connecting the plug fitting 14 to the burner head 16 , kettle holders 18 that are fixed on the mixing tube 17 and extend over the burner head 16 , and an igniter 19 mounted on a support 19 a.
The combustible gas is filled in the gas cartridge 11 in a pressurized condition. Hence, when the gas passage is opened by the gas flow adjusting spindle 15 , the combustible gas in a pressurized condition enters the mixing tube 17 from the gas cartridge 11 through the plug fitting 14 . Thus, the combustible gas enters the mixing tube 17 with a gas flow thereof being adjusted by the gas flow adjusting spindle 15 .
The mixing tube 17 is formed with a number of openings 17 a (only one of them is illustrated in FIG. 1 ). External air is absorbed into the mixing tube 17 through the openings 17 a by virtue of negative pressure produced when the combustible gas passes through the mixing tube 17 . The combustible gas is mixed with air entering the mixing tube 17 through the openings 17 a , into a gas mixture of the combustible gas and air.
After the gas mixture enters the burner head 16 , the gas is discharged through the openings 16 a , and is ignited by the electric igniter 19 located in the vicinity of the burner head 16 .
The flame of the burning gas mixture heats an object to be heated such as a pan, kettle, food, etc., put on the kettle holders 18 .
In general, outdoor appliances, not limited only to portable gas cooking stoves, are required to be small. Regarding a portable gas cooking stove, the gas cartridge 11 cannot be fabricated smaller in size than a practical limit determined to ensure a volume of gas to maintain a gas-burning time required for practical use. Consequently, in a portable gas cooking stove, miniaturization has been focused mainly on the gas burner 12 , and more particularly, on the burner head 16 .
However, if the burner head 16 is simply reduced in size, a flow of the gas mixture may exceed the proper gas burning rate, because a volume of the burner head 16 becomes smaller relative to a gas flow from the gas cartridge 11 , resulting in a greater rate of the gas mixture discharged through the openings 16 a of the burner head 16 .
If the gas mixture is discharged at a great rate, the gas mixture is rarely ignited by the spark generated by the igniter 19 , resulting in incomplete combustion of the gas mixture.
In addition, in the gas burner illustrated in FIG. 1, the igniter 19 is supported only by the support 19 a , resulting in that the igniter 19 cannot be stably fixed relative to a gas flow of the gas mixture discharged through the openings 16 a . This also causes incomplete combustion of the mixture gas.
SUMMARY OF THE INVENTION
In view of the above-mentioned problems in the conventional gas burners, it is an object of the present invention to provide a burner which is capable of stably igniting a gas mixture discharged from a burner head, and is capable also of stably supporting an igniter to thereby ensure ignition of the gas mixture.
There is provided a burner to be used for a portable gas cooking stove, including (a) a gas mixture pipe having an open end through which a mixture gas of combustible gas and air is exhausted, (b) a burner head connected to the mixture gas pipe in a hermetically sealed condition and having at least one opening at a surface thereof, the gas mixture blowing out through the opening, and (c) an igniter igniting the gas mixture blowing out through the opening of the burner head, the igniter generating a spark in a direction perpendicular to a flow of the gas mixture blowing out through the opening of the burner head.
As illustrated in FIG. 1, the igniter 19 is positioned facing the burner head 16 in the conventional burner. Accordingly, the igniter 19 generates spark in parallel with a flow of a gas mixture discharged through the openings 16 a of the burner head 16 . Thus, a contact area between the spark and the gas mixture flow is relatively small. As a result, if the gas mixture had a great velocity, it was difficult to ignite the gas mixture by spark generated by the igniter 19 .
In contrast, the burner in accordance with the present invention includes an igniter which is positioned perpendicularly to a flow of gas mixture discharged through openings of a burner head. As a result, the spark is generated in a direction perpendicularly to a flow of gas mixture. Hence, a contact area between the spark and a flow of gas mixture in the burner in accordance with the present invention is greater than the same in the conventional burner illustrated in FIG. 1 .
Hence, the burner in accordance with the present invention makes it possible to stably ignite a gas mixture, even if the gas mixture has a great flow velocity.
It is preferable that the igniter is supported at lower and upper ends thereof by the mixture gas pipe.
It is preferable that the burner further includes an igniter cover in which the igniter is accommodated. The igniter cover is designed to have a projecting portion projecting in a direction, the projecting portion being formed with an opening having a diameter almost equal to a diameter of the mixture gas pipe. The igniter cover is fixed relative to the mixture gas pipe by engaging the projecting portion to the mixture gas pipe.
The igniter may be comprised of (a) a base block extending in a first direction, (b) a pillar extending in a second direction perpendicular to the first direction, (c) an igniter section extending from a summit of the pillar, and (d) a switch movable in the first direction, and the igniter cover may be comprised of (a) a first cover portion covering the base block therewith, and (b) a second cover portion covering the pillar therewith.
It is preferable that the first cover portion has a portion located above the switch and bent upwardly and obliquely.
It is preferable that the igniter is supported by the mixture gas pipe through an igniter support which is comprised of a ring engageable to the mixture gas pipe and a projection fittable into the second cover portion of the igniter cover, the projection being formed with an opening into which the pillar is to be fit.
There is further provided a burner to be used for a portable gas cooking stove, including (a) a gas mixture pipe having an open end through which a gas mixture of combustible gas and air is exhausted, (b) a burner head connected to the mixture gas pipe in a hermetically sealed condition and having at least one opening at a surface thereof, the gas mixture blowing out through the opening, (c) an igniter igniting the gas mixture blowing out through the opening of the burner head, the igniter generating a spark in a direction perpendicular to a flow of the gas mixture blowing out through the opening of the burner head, and (d) a generator comprised of a pipe through which the combustible gas flows, the generator being arranged outside and close to the burner head.
The burner includes the generator. Combustible gas supplied from the gas cartridge passes through the generator, and then, passes through the mixture gas pipe, and is mixed with air into the gas mixture while passing through the mixture gas pipe. Since the generator is located close to the burner head, the generator is heated by burning the gas mixture blowing out of the burner head. Accordingly, the gas mixture passing through the generator is also heated, and is discharged from the burner head at a high temperature.
The gas mixture of combustible gas and air at a higher temperature is more likely to be ignited. Thus, the gas mixture which has been heated during passing through the generator can be readily ignited by the spark generated by the igniter.
It is preferable that the igniter generates the spark between the burner head and the generator.
By arranging the burner head, the generator and the igniter in this order, these three parts can be arranged in a smallest space, ensuring reduction in the size of the burner.
It is preferable that the generator is reverse U-shaped, and that the igniter is positioned surrounded by the generator when viewed from a front of the generator.
By arranging the igniter within the generator, the generator acts as a windscreen for the igniter. As a result, a flow of the gas mixture discharged through the openings of the burner head can be stabilized, ensuring stable ignition of the gas mixture.
The above and other objects and advantageous features of the present invention will be made apparent from the following description made with reference to the accompanying drawings, in which like reference characters designate the same or similar parts throughout the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a conventional portable gas cooking stove.
FIG. 2 is a front view of a gas cooking stove including the burner in accordance with the present invention.
FIG. 3 is a top plan view of the gas cooking stove illustrated in FIG. 2 .
FIG. 4A is a top plan view of an igniter.
FIG. 4B is a front view of the igniter illustrated in FIG. 4 A.
FIG. 4C is a side view of the igniter illustrated in FIG. 4 A.
FIG. 5A is a top plan view of an igniter cover.
FIG. 5B is a side view of the igniter cover illustrated in FIG. 5 A.
FIG. 6 is a plan view of an igniter support.
FIG. 7A is a top plan view of a generator.
FIG. 7B is a front view of the generator illustrated in FIG. 7 A.
FIG. 7C is a side view of the generator illustrated in FIG. 7 A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 2 and 3 illustrate a gas cooking stove including the burner in accordance with a preferred embodiment.
As illustrated in FIGS. 2 and 3, the gas cooking stove is comprised of a gas cartridge 20 (illustrated only in FIG. 3) filled with pressurized combustible gas, a gas burner 21 to which combustible gas is supplied from the gas cartridge 20 and which burns the combustible gas, a plug fitting 22 adjusting a flow of the combustible gas supplied from the gas cartridge 20 , and a gas tube 23 through which the combustible gas is supplied from the gas cartridge 20 to the gas burner 21 .
The gas burner 21 is comprised of a joint block 24 to which the gas tube 23 is connected, a burner head 25 having a number of openings 25 a at a surface thereof, a saucer-shaped windshield 25 b surrounding the burner head 25 , a mixing tube 26 connecting the joint block 24 to the burner head 25 , kettle holders 27 connected to the mixing tube 26 , and an igniter 28 igniting the gas mixture of air and the combustible gas, discharged from the burner head 25 through the openings 25 a.
Each of the kettle holders 27 is wound at one end thereof around the mixing tube 26 , and is designed to be swingable in directions indicated with arrows A in FIG. 3 .
FIGS. 4A to 4 C illustrate a structure of the igniter 28 . The igniter 28 is comprised of a base block 28 a in the form of a square pole, a cylindrical pillar 28 b upwardly extending from the base block 28 a , an igniter section 28 c upwardly extending from an upper end of the pillar 28 b and generating a spark, and a switch 28 d activating the igniter 28 when pushed relative to the base block 28 a.
The igniter 28 is accommodated in an igniter cover 29 illustrated in FIGS. 5A and 5B. The igniter cover 29 is comprised of a first cover portion 29 a and a second cover portion 29 b.
The first cover portion 29 a is open at a bottom thereof. The base block 28 a of the igniter 28 is accommodated in the first cover portion 29 a.
As illustrated in FIG. 5A, the first cover portion 29 a is formed at an upper surface thereof with a projecting portion 29 c . The projecting portion 29 c is formed with a circular opening 29 d . The igniter cover 29 is fixed relative to the mixing tube 26 by inserting the mixing tube 26 into the circular opening 29 d.
The first cover portion 29 a is formed at an upper surface at an end through which the switch 28 d is inserted, with an inclined portion 29 e obliquely, upwardly and outwardly inclining. Hence, the switch 28 d can be readily pushed.
The pillar 28 b of the igniter 28 is accommodated in the second cover portion 29 b . The second cover portion 29 b has a rectangular cross-section, and is open at a side. As illustrated in FIG. 5A, the second cover portion 29 b is formed at upper ends thereof with hookers 29 f formed by inwardly bending walls of the second cover portion 29 b.
The second cover portion 29 b is formed with vertically arranged oval openings 29 g for diffusing heat from the igniter 28 .
The igniter cover 29 can be formed by, for instance, separately fabricating the first cover portion 29 a and the second cover portion 29 b , and welding them to each other.
FIG. 6 is a plan view of an igniter support 30 which supports the igniter 28 at an upper end thereof.
The igniter support 30 is comprised of a ring 30 a and a rectangular portion 30 b outwardly projecting from the ring 30 a.
The ring 30 a is designed to have such an inner diameter that the ring 30 a can be engaged to the mixing tube 26 just below the burner head 25 .
The rectangular portion 30 b is designed to have the same size as a rectangular cross-section of the second cover portion 29 b . Hence, the rectangular portion 30 b can be inserted into the second cover portion 29 b.
The rectangular portion 30 b is formed centrally with a circular opening 30 c . The circular opening 30 c is designed to have a diameter equal to a diameter of the pillar 28 b of the igniter 28 . Accordingly, the pillar 28 b can be fit into the circular opening 30 c of the rectangular portion 30 b.
When the igniter 28 is to be accommodated in the igniter cover 29 , the ring 30 a is engaged to the mixing tube 26 and the rectangular portion 30 b is inserted into the second cover portion 29 b . Then, the igniter 28 is positioned below the igniter cover 28 , and then, is upwardly inserted into the igniter cover 29 . Thus, the base block 28 a is accommodated in the first cover portion 29 a , and the pillar 28 b is accommodated in the second cover portion 29 b.
Then, as illustrated in FIG. 3, pillar 28 b is inserted in the vicinity of an upper end thereof into the circular opening 30 c of the igniter support 30 .
Thus, the opening 29 d formed in the projecting portion 29 c is fit around the mixing tube to thereby ensure that the igniter 28 is fixed at a lower end thereof relative to the gas burner 21 and hence the mixing tube 26 , and the opening 30 c formed in the rectangular portion 30 b is fit into the pillar 28 b of the igniter 28 to thereby ensure that the igniter 28 is fixed at an upper end thereof relative to the gas burner 21 and hence the mixing tube 26 .
FIGS. 7A to 7 C illustrates a generator 31 . The generator 31 is comprised of a hollow, reverse-U shaped pipe, and is connected at a free end thereof to the joint block 24 .
The combustible gas having been supplied from the gas cartridge 20 through the plug fitting 22 and the gas tube 23 passes through the joint block 24 , and then, through the generator 31 , and returns to the joint block 24 . Thereafter, the combustible gas is supplied to the mixing tube 26 from the joint block 24 .
As illustrated in FIGS. 2 and 3, the windshield 25 b is formed with a cutout 25 c . The generator 31 is positioned close to the burner head 25 in the cutout 25 c . The generator 31 is designed to have such a height that a summit of the generator 31 is either almost level with or slightly higher than a summit of the burner head 25 .
When viewed from the burner head 25 , the igniter 28 is located slightly outside the generator 31 . When viewed horizontally, the igniter 28 is completely surrounded by the generator 31 .
As illustrated in FIG. 2, the burner head 25 is formed at a surface thereof with a flame hole 32 as well as the openings 25 a . The flame hole 32 has a greater size than a size of the opening 25 a . A mesh sheet is arranged all over the flame hole 32 . The igniter 28 is positioned such that the igniter section 28 c faces the flame hole 32 . In this embodiment, the igniter section 28 c is slightly inclined towards the flame hole 32 .
The gas cooking stove in the instant embodiment is used as follows.
The combustible gas under pressure is adjusted in a flow rate in the plug fitting 22 , and then, is supplied to the joint block 24 through the gas tube 23 . Then, the combustible gas is supplied to the generator 31 from the joint block 24 .
Since the generator 31 is positioned close to the burner head 25 as mentioned earlier, the generator 31 is heated by burning combustible gas blowing out from the burner head 25 . Accordingly, the gas mixture passing through the generator 31 is also heated, and then, supplied to the mixing tube 26 .
The mixing tube 26 is formed at a surface thereof with a plurality of openings 26 a . External air is absorbed into the mixing tube 26 through the openings 26 a by virtue of negative pressure generated when the combustible gas passes the mixing tube 26 . Thus, the combustible gas is mixed with air into a gas mixture of air and combustible gas.
After entering the burner head 25 , the gas mixture blows out through the openings 25 a , and is ignited by the igniter 28 located in the vicinity of the burner head 25 . The thus ignited gas mixture is burnt, and as a result, flame blows out through the openings 25 a.
The flame heats cooking appliances and/or food (not illustrated) put on the kettle holders 27 .
In the instant embodiment, the igniter section 28 c is positioned perpendicular to a flow of the gas mixture discharged through the openings 25 a . Hence, the spark generated by the igniter section 28 c flies perpendicularly to a flow of the gas mixture.
In the conventional burner illustrated in FIG. 1, the spark generated by the igniter 19 flies in parallel with a flow of the gas mixture. Hence, a contact area of the spark with the gas mixture was relatively small.
In contrast, the spark flies perpendicularly to a flow of gas mixture in the instant embodiment. As a result, a contact area of the spark with the gas mixture is greater than the same in the conventional burner. Hence, even if the gas mixture had a great velocity, it would be possible to stably ignite the gas mixture.
The gas mixture of combustible gas and air at higher temperature is more likely to be ignited. Thus, the gas mixture which has been heated during passing through the generator 31 can be readily ignited by the spark generated by the igniter 28 .
While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.
The entire disclosure of Japanese Patent Application No. 11-2872 filed on Jan. 8, 1999 including specification, claims, drawings and summary is incorporated herein by reference in its entirety.
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There is provided a burner to be used for a portable gas cooking stove, including (a) a mixture gas pipe having an open end through which a gas mixture of combustible gas and air is exhausted, (b) a burner head connected to the mixture gas pipe in a hermetically sealed condition and having at least one opening at a surface thereof, the gas mixture blowing out through the opening, and (c) an igniter igniting the gas mixture blowing out through the opening of the burner head, the igniter generating a spark in a direction perpendicular to a flow of the gas mixture blowing out through the opening of the burner head. The burner makes it possible for the spark to make contact with the gas mixture flow in a larger contact area than that of a conventional burner. Accordingly, it is possible to stably ignite the gas mixture, even if the gas mixture has a great flow velocity.
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FIELD OF THE INVENTION
[0001] The present invention relates to software for creating, defining, generating and modifying complex patterns and behaviors in computer-generated music content.
BACKGROUND OF THE INVENTION
[0002] Music composition and generation has been largely an artistic endeavor involving composers, musicians, recording engineers and the like to create melodies for pleasure or commercial use. Computer-generated music has been pursued in recent years for two reasons: academic curiosity and commercial demand for inexpensive, textural music for a variety of media applications including film, video, web sites, games and wireless applications. It is the latter reason that has economic implications, for a number of companies and consumers are looking for textural or ambient music that is inexpensive, easy to produce, as rights-free as possible and that follows essential psychoacoustic principles in composition. Computer music generation systems typically use MIDI (Musical Instrument Digital Interface) to control the electronic musical instruments.
[0003] Computer-generated music in real time has used a variety of systems or methodologies in an attempt to achieve these goals. Current systems, such as Sseyo's Koan system or the method as described in U.S. Patent Application Publication No. 20010025561 to Milburn use stochastic methods or metrics. Using the stochastic method, music is generated using random numbers to determine a variety of musical parameters within user specified constraints. The Koan system is an embodiment of this approach. The issues with the stochastic method are that the music may not be complex enough to adhere to the psychoacoustic principles that make the music sound as if it was composed and played by humans. In addition, this system can be difficult to use for those not conversant in music.
[0004] Milburn's approach to automatic music generation relies on pre-specified musical phrases, which are then analyzed using a metrics technique which allows the composer to morph between two different phrases. This technique requires a higher level of specification than the Cellular Automata Music Generator (CAMG) system described herein, in that the musical phrases must be pre-composed.
[0005] Another system used in music generation is the mathematical model cellular automata (CA). CA methodology lends itself to music generation because of the nature of this mathematical model. The CA theory stems from the notion that simple systems can generate complex behavior or patterns. This makes it ideal for music generation that requires complex output using simple and lightweight systems. In addition, CA systems are easy to modify on a global basis. Under a CA model, one parameter change can result in global dynamic behavior that is either predictable, complex, periodic or random. The system is also deterministic; therefore given the same parameters, the same musical piece will be generated and evolve in the same way each time, giving the user an element of necessary control.
[0006] There has also been work in music generation using CA, but it has been either using 2-dimensional models or applying simple 1-dimensional CA to a specific musical content, such as rhythm, to create simply a general beat or a series of notes. The issues with 2-dimensional models is that the systems are complex to use and have memory and processing requirements that are too high for average personal computer, wireless device or console systems. A number of authors have published related techniques to CAMG on the Internet (for example, Reiners, Millen, and Miranda). Reiner's system, named Automatous Monk, relies upon elementary 1D CA to generate musical parameters, however his currently published work is far more primitive in its application. For example, 1D CA are only used to generate pitch values for the composition, resulting in a far less complex final output.
[0007] Miranda's CAMUS is a generative music system in that it is based upon CA technology, but relies on complex 2D CA implementations. Milburn's approach to generative music employs a technique which creates a metric between two pre-composed musical phrases and allows the user to morph between them.
[0008] Sseyo's Koan uses purely random or stochastic techniques with constraints provided by the composer in areas such as which scale to use, and the range of note choices. Koan has a steep learning curve and requires the user to have musical knowledge. Koan is concentrated on the mobile and web site market.
[0009] Leach (U.S. Patent Application Publication No. 20030183065) employs a strictly rule based networking approach that does not use any CA based techniques Georges (U.S. Patent Application Publication No. 20030131715) employs a rule-based approach that does rely on stochastic variables. This approach is more closely related to Koan.
SUMMARY OF THE INVENTION
[0010] The CAMG is a software engine that allows users to create and modify an entire musical composition in real-time based on a selection of parameters. These compositions are non-looping (i.e. the same few bars of music do not repeat over and over), can be any length, can have low memory and processing requirements compared to looping WAV or MP3 files, and follow psychoacoustic principles. The innovative and unique aspect of this invention is the use of 1-dimensional CAs modules that are networked together to form an overall unifying framework to produce complex musical compositions. Once an initialization string is selected and implemented, the system does not require further human intervention to create a complex, fully developed piece of ever-evolving music. The initialization string can be any digital input including, but not restricted to, number sequences, game play sequences, real time MIDI input or previously composed MIDI files. CAMG uses MIDI to control the digital musical instruments for the compositions.
[0011] CAMG is built such that a single parameter change can have a global effect upon the entire composition. Unlike random systems, these changes can be controlled to produce the complex output required. In the case of CAMG, because of the CA methodology, a single parameter change, or just one byte of data, can have an effect on the flow of the entire piece of music. For example, this parameter change could be used to quickly or gradually change the density of the notes in the composition. A piece which is very ‘chaotic and busy’ would then evolve into a much more “repetitive and sparse” musical texture, or vice versa.
[0012] Due to the nature of CAs and the use of networked modules to control various aspects of the composition, such as scale selection, tempo, velocity, orchestration, timbre modification, rhythmic patterns, accompaniment and melody creation, CAMG has the following characteristics:
[0013] Fully interactive—Because the CAMG engine is generating music in real time, rather than playing back pre-composed music loops, the programmer can easily change the musical output in an interactive environment based upon user input.
[0014] Real time music generation—One key benefit of the CAMG engine is that the music it generates is composed in real-time, dispensing with the need to pre-arrange a number of different pre- composed MIDI or audio files, saving programmers for games or wireless applications from having to interface with numerous music cues.
[0015] Generates textural music—The primary content of the first version of CAMG is well suited toward creating music that serves a textural, ambient, background function often referred to incidental music.
[0016] Composer creates a process—The entire approach toward using CAMG is fundamentally different than the traditional model of music composition, where a composer relies on a number of different systems, such as MIDI sequencers, audio looping tools or digital audio workstations to provide a finished piece of music which the programmer must then integrate into a game or wireless application. In the CAMG model, the composer creates a process, which is then employed within the game or wireless application to generate the musical layer at runtime.
[0017] CAMG does the actual composition, saving valuable production time—In a traditional approach to music composition, where a composer has to pre-specify all aspects of the piece such as rhythm, melody and dynamics. CAMG allows composers to concentrate on the high level aspects of the musical content without having to specify the lower level details, such as choice of note value, rhythmic motif or dynamics. This shortens the composition cycle, saving production time.
[0018] Modifications simple and quick—CAMG uses algorithms which, based upon a single parameter, generate a variety of dynamic behaviors, including repetition, randomness and true complexity. This means modifications are simply parameter changes that require only a few keystrokes instead of recoding and re-recording audio files.
[0019] API is easy to use—Another inherent benefit of the CAMG engine is that the API layer is very easy to use. In many cases, all that the programmer has to specify is a bit string which determines the initial state of the CAMG. The CAMG itself then generates the music in real time based upon the initial bit string and subsequent modifications of the string to change the music in an interactive fashion.
[0020] Psychoacoustic principles embedded in algorithms, making music sound more realistic—Due to the nature of the algorithms that CAMG uses, human beings can inherently identify that the music being generated by the engine is not entirely random or overly predictable, depending upon the constraints that the composer chooses. Of course, CAMG does have the ability to produce music that is random or predictable if necessary.
[0021] Completely deterministic—CAMG generates musical output which is completely deterministic, unlike other more random music generation systems which typically derive their initial input using a random seed value, such as the current system time. This means that the music generated by CAMG will play exactly the same way every time given the same parameter inputs and initialization string.
[0022] Easily interfaced to other generative systems—Although CAMG is primarily designed to generate real time MIDI data, it can be easily adapted to interface with another generative music engine, such as Microsoft's Direct Music.
[0023] Can be used by non-musicians—Because CAMG does not use a traditional approach to music generation, non-musicians can quickly learn how to interact with the user interface to produce high level compositions, which can then be interactively guided or modified by the user in real time. A number of musically naive beta testers have reported that they found the experience of working with CAMG to be “very engaging” and “highly addictive” primarily because they get immediate feedback as they change the parameters of the composition.
[0024] Easily scalable to different levels of music generation—The CAMG engine can be employed to address any layer of music generation, such as parameter modification of the sound itself (using CAMG to determine the amount of vibrato in a note for example), direct generation of the music at the note level, re-arranging musical themes at the phrase level and finally re-arranging and re- orchestrating at the section (verse, chorus) level. CAMG can also be used as a real time mixer, to mute or solo individual instruments within the piece.
[0025] Generates arbitrary lengths of music—CAMG can be used to create essentially to create ever- evolving compositions, which can be synchronized with other digital content. For example, the music can change if a game player commits a series of moves or if a user performs a different task or function in a wireless application. In a wireless application example, the ringtone automatically changes with each telephone number received.
[0026] The underlying CAMG model could be extended to create more thematic, foreground musical content by allowing the composer to access the ‘building blocks’ which make up the engine itself, rather than relying on the user-interface to the pre-assembled initial CAMG engine. In other words, it is possible to broaden the CAMG's scope to produce a software development kit (SDK) for programmers to build their own engines for music.
[0027] A version of CAMG is also used to generate ringtones for mobile devices, such as cellular telephones. These musical compositions can be used as an audio caller identification system, a musical game or simply as a ringtone.
[0028] A method of real-time generation of music using networked 1-dimensional cellular automata and a number of other timing, selection and processing components is provided, including networking multiple cellular automata to generate various musical parameters to create and modify complex musical compositions. At the highest level, the CAMG uses a network of interconnected CA to generate all aspects of a musical composition. At the top of the hierarchical structure, a single 1-dimensional CA is used to determine the on-going arrangement of the composition by selectively updating a network of multiple 1-dimensional CA structures, or “virtual musicians”, which determine the low level musical parameters for the composition, such as pitch, rhythm, velocity, duration, MIDI controller values, and arrangement. CAMG is scalable to include any arbitrary number of virtual musicians based upon the composer's input. The midlevel of the hierarchy is referred to as a “virtual musician” and consists of the individual self contained CA network which is responsible for actually creating the musical phrasing.
[0029] A method of generating rhythmic values using CA is provided, including a 1-dimensional CA is used to provide the rhythmic pattern for the real time creation of a musical phrase. Each active bit (value=1) in the CA corresponds to a single beat within a musical phrase. Each active bit also triggers other CA in the network to produce their associated parameter value, such as pitch, velocity and other controller parameters like volume or modulation. The generated pattern can be modified in a variety of ways by altering the delay values for the parallel delay line which provides the actual timing values of the rhythm. Each bit within the CA is associated with a variable length timing delay. If each delay is set to a time of 0 milliseconds, the rhythm output will consist of a chord that consists of as many notes as there are active bits in the CA (i.e. if the CA has 4 active bits then a 4 note chord will be generated). In a similar vein, a rhythm of single notes can be generated by assigning each timing delay to a fractional, cumulative value of the overall rhythm CA based upon the master rhythm update clock, which controls the rhythm CAs update status, divided by the lattice size of the CA (i.e. if the rhythm CA is being updated every 4000 milliseconds and its lattice size is set to 16 bits then each delay associated with each bit in the CA will have incremental values, starting at 0 milliseconds for the most significant bit (the first note in the musical phrase) and setting subsequent delays to incremental values of 250 milliseconds. (4000/16=250, delay values would increase in 250 millisecond increments from left to right: 0, 250, 500, 750 etc.)
[0030] A method of generating pitch values using CA is provided including using the decimal value of the CA to pick a particular note from a lookup table. In this instance the CA generates a note value between 0 and 127 , which is then mapped to a lookup table which can constrain the note value into a particular scale or mode. A parameter associated with this function allows the CA generated value to be further constrained by introducing a ‘slew’ control which prevents the CA output from instantaneously generating its latest value. For example, assume the CA has generated a series of values; 23, 66, 44 based upon its transition rule and current state. Normally these values would be used to directly select the corresponding note value from the scale lookup table. The slew function limits the speed and step size for making the transition between the values. Using 23 as the staring value, and assuming the CA is being updated every 100 milliseconds; if the slew rate was set to 200 milliseconds and the step size to 1, the resulting CA value would be approximately 44 on the second update (halfway between 23 and 66). Essentially this function provides a continually varying output as opposed to the discrete value output that characterize CA. The bit position is used to select a note from a list of corresponding notes in a musical phrase. In this instance the CA which generates the rhythm pattern is also used to select a note value from a list of values which correspond to a single predetermined phrase of music. This approach associates each bit in the CA to a particular note value from the phrase. Using this approach allows the composer to specify an exact sequence of pre-determined notes to be used for the generation of a musical phrase.
[0031] A method of generating velocity values using CA is provided including using a CA to generate a decimal value between 0 and 127 for the MIDI velocity of the associated note. The value generated by the CA is further constrained with a specified high and low value. A slew function is also provided to enable a continually varying-value rather than the discrete values generated by the CA.
[0032] A method of generating generic MIDI controller data using CA is provided, including using a CA to generate a range a values which can be associated with an arbitrary 8 bit or 16 bit MIDI controller value, such as volume, modulation, and pitch bend. The value generated by the CA is further constrained with a specified high and low value. A slew function is also provided to enable a continually varying value rather than the discrete values generated by the CA.
[0033] A method of generating timing fluctuations using CA is provided, including using a CA to generate a decimal value between −X, 0, X number of milliseconds to offset the final timing value of the associated note. This function causes the note to be “behind or ahead” of the beat by a varying value. The value generated by the CA is further constrained within a specified high and low value. A slew function is also provided to enable a continually varying value rather than the discrete values generated by the CA.
[0034] A method of generating multiple musical parameters using bit fluctuations within the current CA state is provided, including relying upon the sequence of bits within the current CA state to generate a time varying continuous range of values which can be applied to most of the other low level parameters within the virtual musician. The CA generates a serial stream of bits which serve to alter the direction of a continuously changing value in a similar manner to the slew function mentioned above. The difference is that this technique employs the active bit to change the current direction of the values vector (i.e. a vector of values starting at a low value of 25 and incrementing to a high value of 66 at a rate of 20 milliseconds per step (25, 26, 27 . . . 66) would change the direction of the vector upon receiving an active bit from the serial bit stream being generated by the CA). Upon the occurrence of this active bit event, the continuous value would now start decrementing toward the low value of 25 and would continue decrementing until another active bit event causes the direction to change again.
[0035] A method of generating note duration values using CA is provided, including using a CA to generate a decimal value between 0 and X for determining the duration value of the associated note. The value generated by the CA is further constrained with a specified high and low value. A slew function is also provided to enable a continually varying value rather than the discrete values generated by the CA. A specialized “legato” module is provided to assist in generating duration values which are determined by the rhythm pattern generated by the rhythm CA. This function calculates the appropriate duration values associated with the active bits within the current CA state by examining the distance between the active bits. For example, in the case that the rhythm CA has generated a bit string “1000100010001000”, with an update clock of 4000 milliseconds, this function would assign each active bit a value of 1000 milliseconds. In another case, a CA state of “1111111111111111” would assign each active bit a value of 250 milliseconds (4000/16). This value also has a constraint which allows the duration value to be shortened or lengthened (i.e. above examples could be 90 (staccato) or 1100 (legato with overlap) milliseconds). Note that the virtual musician must be capable of polyphonic output in the event of duration overlapping.
[0036] A method of generating phrase level musical arrangement using CA is provided, including using CA to determine the high level musical arrangement of the composition. This function uses 1-dimensional CA to control whether a particular virtual musician will play during the current phrase or not. At its simplest level, this function employs a CA to mute or unmute an individual virtual musician. More complex aspects of the arrangement can be determined by building a CA hierarchical structure which uses multiple, parallel CA to provide low level parameter initialization values, such as pitch and velocity to the virtual musicians structure. In this implementation, each virtual musician has an associated “master” CA, which is itself controlled by a “global CA”.
[0037] A method of generating CA which have related evolutionary properties, including allowing for the automatic generation of related CA transition rules based upon the nature of the seed CA rule's evolutionary behavior. This function calculates related rules by simple manipulation of the binary expression of the transition rules unique number. For example, rule 255 (11111111) would become rule 0 (00000000) if each active bit in the rule table was inverted. Both rules exhibit class 1 behavior. As a further example rule 30 (00111110) would become rule 86 (11100001).
[0038] A method of generating a unique musical composition based upon a user input phone number digit sequence is provided, including using CAMG to create a musical composition that is determined by the sequence of digits contained in a 10 digit phone number utilized as initial parameters for a subset of CAMG referred to as the “ring tone application”. This embodiment of CAMG is intended to enable the user to generate a musical composition of indeterminate length based upon the input phone number. Each phone number will create a different piece resulting in a total of 10 billion different compositions.
[0039] A method of generating a real time telephone ring tone using the incoming phone number digit sequence is provided, including intercepting the incoming 10 digit phone number on a typical polyphonic ringtone enabled cellphone and to replace the default ringtones with a new musical composition that is unique for every possible phone number and is generated in real time. The resulting ring composition will play until the user's answering service feature is invoked, typically in the neighborhood of 10 to 20 seconds. Because each possible phone number input will have a different composition associated with it, the user will ultimately be able to distinguish the incoming caller by recognizing the composition that is generated
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1 is a block diagram of a CAMG according to the invention;
[0041] FIG. 2 is an example of a representation of a cellular automata generator module according to the invention;
[0042] FIG. 3 is an example of a representation of a serial/parallel delay module according to the invention;
[0043] FIG. 4 is an example of a serial/parallel delay module with 16 event output triggers;
[0044] FIG. 5 is an example of the inputs thereof;
[0045] FIG. 6 is an example of a representation of a range module according to the invention;
[0046] FIG. 7 is an example of a representation of a MIDI generator module according to the invention;
[0047] FIG. 8 is an example of a representation of a MIDI generator module for a drum/single note according to the invention;
[0048] FIG. 9 is an example of a representation of the values of a field generator module according to the invention;
[0049] FIG. 10 is an example of a representation of a lag generator module according to the invention;
[0050] FIG. 11 is an example of a representation of a serial lookup table module according to the invention;
[0051] FIG. 12 is an example of a representation of a threshold/counter module according to the invention;
[0052] FIG. 13 is an example of a representation of a clock module according to the invention;
[0053] FIG. 14 is an example of a representation of a history module according to the invention;
[0054] FIG. 15 is an example of a representation of a MIDI controller module according to the invention;
[0055] FIG. 16 is an example of a representation of a phrase event duration module according to the invention;
[0056] FIG. 17 is an example of a representation of a complex rules module according to the invention;
[0057] FIG. 18 is an example of a representation of a rule matrix module according to the invention;
[0058] FIG. 19 is an example of a representation of a global initialization module according to the invention;
[0059] FIG. 20 is an example of a representation of phrase generator module according to the invention;
[0060] FIG. 21 is an example of a representation of a 1 bit controller module according to the invention;
[0061] FIG. 22 is an example of a representation of a parameter matrix module according to the invention;
[0062] FIG. 23 is a representation of the CAMG module interconnections according to the invention;
[0063] FIG. 24 is a representation of the CAMG module interconnections for a ringtone application according to the invention;
[0064] FIG. 25 is a representation of the initialization and master arrangement components thereof;
[0065] FIG. 26 is a representation of the rhythm repeat function thereof;
[0066] FIG. 27 is a representation of an actual instrument thereof;
[0067] FIG. 28 is a representation of a 1 bit shifter module according to the invention;
[0068] FIG. 29 is a block diagram of the activation process of the ringtone application according to the invention;
[0069] FIG. 30 is a block diagram of an alternative activation process of the ringtone application according to the invention;
[0070] FIG. 31 is a block diagram of the composer mode and the number selection process in the ringtone application according to the invention;
[0071] FIG. 32 is a block diagram showing the composer mode and the tempo selection process in the ringtone application according to the invention; and
[0072] FIG. 33 is a block diagram showing the composer mode and the save process in the ringtone application according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0073] In this document, the following terms will have the following meanings:
[0074] C-Ionian, Dorian mode: Ionian mode refers to a type of musical scale consisting of eight notes. The white keys on a piano: C,D,E,F,G,A,B,C are the pitches used in this mode. The mode itself is based upon the intervals between each note in the following sequence, with a whole tone representing 2 steps and a semi tone, 1 step: 2,2,2,1,2,2,2,1. C Ionian means that the note sequence begins on the note C, D Ionian would begin on the note D and have the following pitch sequence: D,E,F#,G,A,B,C#,D.
[0075] Cellular Automata (CA): A mathematical model that employs computationally simple systems that can evolve into a series of patterns, some of which are inherently random or complex. Cellular automata are a simple model of parallel computation. The model comprises a matrix of cells, which can be turned on or off (e.g. black or white) and a transition rule. Based on the transition rule and the state of its neighboring cells, a cell will update its state (on/off) over time. It is the turning on and off of these cells that generate patterns over time.
[0076] Chromatic mode: A mode based on the chromatic scale. The chromatic scale divides an octave into twelve equal steps equivalent to the 12 keys within one octave of a piano keyboard.
[0077] Delay line: The delay line is used to delay an event trigger by a specified number of milliseconds. The delay line is central to the CAMG system for generating rhythm values.
[0078] Event Triggers: In CAMG, an event trigger refers to a signal which is usually generated by a clock or delay line that is used to update the CA receiving the event trigger to its next CA state. An event trigger can be though of as equivalent to the pulse of a timing source, such as a clock tick.
[0079] Fletcher-Munson curves: A series of curves that present the sensitivity of humans to various sound frequencies.
[0080] Legato: The smooth movement of one note to the next with no audible space or break between notes.
[0081] Melodic Range: This determines the lowest and highest note values for a particular instrument.
[0082] Metronomic Clock: A means of generating the exact tempo of a musical piece. MIDI (Music Instrument Digital Interface): A standard method of interfacing computers and synthesizers developed in the early 1980's. MIDI is widely used throughout the audio and music production industry.
[0083] MS Offset: This component adds a continuously varying value expressed in milliseconds to the duration parameter. Used to provide a more organic, human feel to the rhythmic phrase.
[0084] Orchestration: Arranging a piece of music for an orchestra or band and the assignment of musical parts to different instruments.
[0085] One-dimensional Elementary (ID) Cellular Automata: This is the simplest network or matrix of cells. In this configuration, each cell has one of two possible states, on or off, and only two neighboring cells to affect its updates over time. The cells are arranged in a linear one- dimensional array.
[0086] Phrase Generator: The phrase generator associates a pre-determined sequence of notes (a melody) with a particular index value, much like the serial lookup table but able to store multiple values with a single index.
[0087] Pitch: The property of a tone determined by its frequency or number of vibrations.
[0088] Psychoacoustic: Refers to the subjective way in which humans perceive sound, including music.
[0089] Serial Lookup Table: A serial lookup table associates a unique address location, or index with a particular numeric value. The size of the table determines how many addresses are contained within the table. The serial lookup table is used to constrain pitch values into particular musical scales.
[0090] Staccato: The opposite of legato, the notes are short in duration, regardless of the notes that follow in the rhythmic phrase.
[0091] Stochastic: Exhibiting varying degree of randomness.
[0092] Tempo: The speed at which a musical composition is played, measured in beats per minute.
[0093] Timbre: The sonic quality of a musical note. Different instruments and voices have distinctive qualities or timbres.
[0094] Transition Rule: The unique rule that defines how the cells will update over time. Each rule specifies how every cell in the CA will be updated based upon the current state of the cell in question and the state of it's left and right neighbors. There are 256 possible transition rules in the ID elementary CA employed in CAMG. Some rules, like rule 30 generate random patterns, whereas others, like rule 110 , generate complex patterns.
[0095] Two-dimensional (2D) Cellular Automata: This is a more complex matrix of cells. In this configuration, each cell has eight neighboring cells in two dimensions to affect its updates over time.
[0096] Velocity (in reference to music): The loudness or softness of a note's volume.
[0097] VM Control: A Virtual Musician Controller, this component determines a variety of initialization parameters for the virtual musician section of CAMG.
[0098] WAV files: Utilizing a sound format developed by Microsoft, WAV files have CD sound quality.
[0099] Wolfram Classes: Stephen Wolfram, in the 1980's, discovered that 1 dimensional elementary CAs could be categorized into four classes that based on the types of patterns each transition rule generated. These categories include homogenous or constant state (Wolfram Class I), periodic limit cycles or repeating (Wolfram Class II), chaotic or random (Wolfram Class III) and finally true complexity (a mix of periodic and chaotic behavior—Wolfram Class IV).
[0100] ZenRings: Brand name for the ringtone or audio caller identification application.
Cellular Automata Music Generator Software—Component Modules
[0101] The following describes the various component modules of a CAMG according to a preferred embodiment of the invention. The end result of the modules is shown in FIG. 1 as the CAMG takes a global initialization and from that generates output of MIDI notes for a plurality of virtual musicians. The modules are preferably implemented by a computer having a memory, input and output means and a processor. In alternative embodiments of the invention not all of the modules need to be present.
Cellular Automata Generator (CAG or CA) Module
[0102] The CAG module is the central signal generation component of the CAMG. The core algorithm is a one dimensional elementary K=2, R=1 cellular automata with periodic boundary conditions. A preferred implementation has a variable lattice size of between 3 to 16 cells. The transition rule determines the future evolution of the CA based upon its current state. The 256 possible transition rules exhibit a variety of dynamic behaviors such as convergence to a homogenous state (Wolfram Class I), periodic limit cycles (Wolfram Class II), chaotic (Wolfram Class III) and finally true complexity (a mix of periodic and chaotic behavior—Wolfram Class IV). Wolfram classified the various CA behaviors as outlined in his book “Cellular Automata and Complexity”.
[0103] The inputs to this module allow the user to set the lattice size, transition rule and initial state value. The initial state value must be less than or equal to 2 ̂ Lattice size— 1 , (i.e. a size 3 lattice can only accept an initial state value in the range 0 . . . 7).
[0104] The Update Input causes the CA to advance to its next state based upon the current state value and transition rule.
[0105] The Output of the CAG module is a decimal number within the current lattice size range that corresponds to the binary value of the CA lattice.
Inputs:
[0106] Size: Lattice size of ID CA ( 3 - 16 )
[0107] Rule: Transition Rule ( 0 - 255 )
[0108] Init: Initial state ( 0 - 65535 based upon lattice size)
[0109] Update: Update CA to next state
Outputs:
[0110] State: Current CA state ( 0 - 65535 )
[0111] Live Cells: Number of current cells equal to “1”
[0112] A representation of a CAG module is shown in FIG. 2 .
Serial/Parallel Delay (DLY) Module
[0113] The DLY module is the primary timing and rhythmic component of the CAMG. The primary function of the DLY module is to accept a decimal CA state value as input and transform that value into a series of delayed event triggers based upon an internal lookup table. The process involves converting the decimal value into a binary value and using each bit to generate an event trigger that is subsequently passed through a series of parallel delay lines. Each bit in the binary value has a dedicated delay line. The user can input the global delay time, which is divided by the current size value to determine the delay time of each individual delay line. This value can be overridden by a Delay Lookup Table, which consists of different multiplicand values for the delay times. FIG. 3 shows a representation of a DLY module.
[0114] As seen in FIG. 4 , the serial/parallel delay (DLY) module converts the CA state on input into a rhythmic phrase of a number of beats equal to the “size” parameter.
[0115] A Serial/Parallel Delay with 16 event output triggers is shown in FIG. 5 . Note the left most event trigger (darker) represents the serial output.
Inputs:
[0116] State: Current CA state ( 0 - 65535 )
[0117] Delay: Total delay time in Msec (divided by Size to determine cell delay time
[0118] Size: Range of input values (2 ̂ N power) determines number of delay cells
[0119] Delay LookUp: Set current delay values to Delay Lookup Table values
Outputs:
[0120] Serial Trigger: (red)
[0121] Parallel Trigger # 1
[0122] Parallel Trigger #N (Size)
Range (RNG) Module
[0123] The RNG module is used to constrain the input state to a new user specified range of values. Example, an 8 bit CA will generate a value between 0-255. If the input state is 128, range “lo” value is set to 60 and range “hi” is set to 85, the new output value is 72. It is important that the size value is greater than the highest value for the input state (i.e. input of 235 would create an error if size was set to 7 bits, which has a maximum value of 127).
[0124] The RNG module is designed to restrict the range of notes that the CA can generate. For example, the parameters can be set to limit the CA to a range of a single octave to ensure that a bass line stays within a lower set of note values. The RNG module is also used to restrict the range of MIDI velocities or the loudness of a particular note. FIG. 6 shows a representation of a RNG module.
Inputs:
[0125] State: Current CA state ( 0 - 65535 )
[0126] Range Lo: Minimum value for scaled range
[0127] Range Hi: Maximum value for scaled range
[0128] Size: Range of input values (2 ̂ N power)
Outputs:
[0129] State: Current CA state scaled to RangeLo<=State<=RangeHi
MIDI Generator (MIDI) Module
[0130] The MIDI module is the primary MIDI playback engine in the CAMG. All input parameters can be replaced with CA generated values.
Inputs:
[0131] Note In: MIDI Note # ( 0 - 127 )(pitch value)
[0132] Trig In: Trigger a note (play the note)
[0133] Velocity: MIDI velocity value ( 0 - 127 ) (loudness)
[0134] MIDI Ch: MIDI channel ( 0 - 16 ) (which instrument)
[0135] Duration: Duration in Msec (duration of note)
[0136] Pg Chg: MIDI Program change ( 0 - 127 ) (change instrument)
Outputs:
[0137] MIDI Note to MIDI port (sends Note On MIDI message to synthesizer)
[0138] FIG. 7 shows a representation of a MIDI module. A drum/single note version of the MIDI module is shown in FIG. 8 .
Field Generator (FG) Module
[0139] The FG module is a simple binary to decimal converter that accepts event triggers as input bit values. One common application is to use multiple field generators to derive a number of different decimal values from a single CA binary state output.
[0140] Example: CA state input value is 29 (binary value is 11101) a 3 bit field generator attached to bits 1 - 3 would output 5 ( 101 ), a 2 bit field generator attached to bits 4 , 5 would output 3 ( 11 ) and a 5 bit field generator would output 29 . The Most Significant Bit (MSB) is the leftmost bit within the binary value. The Least Significant Bit (LSB) is the rightmost value. The FG module can be used to generate initialization values for multiple modules from a single CA output. For example the output of a 16 bit CA could be divided into 4 equal sections of 4 bits each, which could then be used to provide an initial state value, between 0 and 16 for 4 other CA's that are used to generate pitch values.
Inputs:
[0141] Bit # 12 : MSB of a 12 bit number (bit 12 )
[0142] Bit #N: Bits 11 through 2
[0143] Bit # 1 : LSB of a 12 bit number (bit 1 )
[0144] Reset: reset all bits to 0
Outputs:
[0145] DecValue: Decimal value of 12 bit input state
[0146] FIG. 9 shows a sample representation of a FG module.
Lag Generator (LAG) Module
[0147] The LAG module provides a ramp function between successive input values. Lag time determines how much delta time will elapse between new input state and previous input state. Lag resolution determines how fine each lag increment will be. Once the new value has been reached the Reflected value output will begin counting in the reverse direction until reaching the previous value and then reversing again. The Limited output option will remain at the new value until a newer value is received.
[0148] Example: state value on previous input was 200, new value is 300. If lag time is set to 1000 Msec, the output value will ramp from 200 to 300 over a period of 1 Sec. If lag resolution is set to 1, lag sequence will be 200,201,202 . . . 300. If lag resolution is set to 20, lag sequence will be 200,220,240 . . . 300. Lag Value Reflected output will cause lag value to begin counting in opposite direction once new value is achieved, 220,240,260 . . . 300, 280, 260, . . .200, 220
[0149] Limited output will cause lag value to remain at new value once new value is achieved, 220,240,260 . . . 300, 300,300 . . .
[0150] The LAG module can be used to generate more “lyrical” melodies by preventing large jumps between notes. Most typical humanly composed melodies exhibit this characteristic.
Inputs:
[0151] State: Current CA state
[0152] Lag Time: Ramp value for lag time in Msec
[0153] Lag Resolution: Number of interpolation points between lag Values
Outputs:
[0154] Lag Value—Reflected: Current lag value. If boundary value is Reached, lag reverses direction and continues.
[0155] Lag Value—Limited: Current lag value. If boundary value is Reached, lag remains at boundary value until a new input state occurs
[0156] FIG. 10 shows a sample representation of a LAG module.
Serial Lookup Table (SLT) Module
[0157] The SLT module is used to provide a lookup table for constraining pitch values into particular scales. The input value is a decimal number between 0-127. The output value will be the lookup table value at the input value's address.
[0158] Example: input values 60 , 61 , 62 would output 60 , 62 , 62 if table was set to C-Ionian mode. Chromatic mode is a one to one mapping of input value to output value, 1 - 1 , 2 - 2 , 3 - 3 etc.
[0159] The SLT module is important for generating melodies which conform to a particular musical key. If the CA output was not constrained using the SLT module, the resulting melodies would sound much more random.
Inputs:
[0160] CA State: current CA state (must be scaled to 0-127)
[0161] Lookup Table: read lookup table
Outputs:
[0162] CA State: New CA state conformed to current lookup table
[0163] FIG. 11 shows a sample representation of a SLT module.
Threshold/Counter (TCT) Module
[0164] The TCT module is used as a general purpose threshold trigger and counter. The module inputs can be either an event trigger or a CA state value. The event trigger input is used in counter mode to count the number of times an event trigger has been received as input. When the count has been reached the module generates an event trigger output. In threshold mode, the module uses the CA state value as input to determine whether it satisfies one of several logical evaluations, <,=or > and generates an event trigger based upon if the condition is satisfied. The inhibit/excite parameter determines whether the event trigger will only occur the first time the condition is true (inhibit) or every time (excite).
Inputs:
[0165] CA State: Current CA state
[0166] T/C Value: Threshold or Counter Maximum Value
[0167] Trig In: Trigger input (advance counter)
[0168] >, =, <: Comparison state (less than, equal, greater than)
[0169] Inhibit/Excite: Excite—Trigger every time threshold is exceeded
Inhibit—Trigger only the first time threshold is exceeded
[0171] Reset: Reset counter to 0
Outputs:
[0172] Trigger:
[0173] Count: Current counter value
[0174] FIG. 12 shows a sample representation of a TCT module.
Clock (CLK) Module
[0175] The CLIK module provides a metronomic clock that outputs event triggers at a particular clock speed, set in Msec.
Inputs:
[0176] Start/Stop: Start or stop current clock (toggle)
[0177] MSec: Clock value in Msec
Outputs:
[0178] Trig: Clock trigger (event trigger)
[0179] MSec: Current clock value in Msec
[0180] FIG. 13 shows a sample representation of a CLK module.
History (HIST) Module
[0181] The HIST module provides a history of previous CA states. Each time a new state is received, each state shifts to the right by one position and replaces the previous state in that position.
Inputs:
[0182] CA State: Current CA state
Outputs:
[0183] Current CA State
[0184] Previous CA State (Time— 1 ) (Bucket brigade)
[0185] Previous CA State (Time— 2 )
[0186] Previous CA State (Time— 7 )
[0187] FIG. 14 shows a sample representation of a HIST module.
MIDI Controller (CTRL) Module
[0188] The CTRL module provides a general purpose MIDI controller generator. Each of the 4 controller values can be set to a different MIDI controller # (i.e. CTL # 7 is MIDI volume). The CA State value for each input is translated into the appropriate MIDI controller data on the MIDI channel set by the user. MIDI controllers are used to generate a variety of continuously varying values, such as instrument volume or pitch bend. This is useful for creating musical phrases which sound more organic and human.
Inputs:
[0189] CA State 1 : CA State (must be scaled to 0 - 127 )
[0190] CA State 2
[0191] CA State 3
[0192] CA State 4
[0193] CTL 1 : Midi Controller # ( 0 - 127 )
[0194] CTL 2 : Midi Controller # ( 0 - 127 )
[0195] CTL 3 : Midi Controller # ( 0 - 127 )
[0196] CTL 4 : Midi Controller # ( 0 - 127 )
[0197] MIDI CH: MIDI channel for controllers
Outputs:
[0198] CAState 1 mapped to MIDI Controller # N value
[0199] CAState 2 mapped to MIDI Controller # N value
[0200] CAState 3 mapped to MIDI Controller # N value
[0201] CAState 4 mapped to MIDI Controller # N value
[0202] FIG. 15 shows a sample representation of a CTRL module.
Phrase Event Duration (PED) Module
[0203] The PED module is used to calculate MIDI event duration times based upon the CA state used as input, combined with the current master clock value. The master clock value is used to calculate the overall duration of one ‘bar’ of 16 beats (equivalent to one CA state output of 16 cells). Internally this module divides the master clock value by 16 and multiplies each individual cell's value by an integer based upon the number of cells to the right of the current cell which have a state of 0 plus the current non zero cell value of 1.
[0204] Example: Assume CA input state is 65535: (1111111111111111) and current master clock value is 10000 Msec. Duration value for left most cell will be 10000/16=625 Msec . Because there are no cells with a value of 0, all durations for each of the 16 beats in the bar will be 625
[0205] Msec (1*625).
[0206] Now assume input state is 34952 (1000100010001000). The leftmost cell will now have a duration value of 625*4=2500 Msec (i.e. current cell=1+3 “0” cells to the right=4). Note that all other non-zero cells will have the same value.
[0207] As a final example of a more complex input state, assume CA inputs state is 37090 (1001 0000 1110 0010), duration value for each non zero cell starting from the left will be: 1875 Msec (3*625), 3125 Msec (5*625), 625 Msec (1*625), 625 Msec, 2500 Msec (625*4) and 1250 Msec (625*2).
[0208] In musical terms, this module is responsible for determining the rhythmic value of each note in a phrase base upon the rhythmic position of the notes that follow. By varying this parameter, the articulation of the notes can be varied between legato to staccato.
Inputs:
[0209] CA State: Current CA state
[0210] MSec: Clock value in Msec
[0211] Event Trigger # 1 : usually associated with Module 2 -Serial Parallel
Delay; Parallel Delay Trigger # 1
[0213] Event Trigger #N: usually associated with Module 2 -Serial Parallel
Delay; Parallel Delay Trigger #N
Outputs:
[0215] Msec: Legato duration value associated with Event trigger position from Serial/Parallel Delay trigger
[0216] FIG. 16 shows a sample representation of a PED module.
Complex Rules (CR) Module
[0217] The CR module uses a simple lookup table to constrain the possible CA transition rules to a subset of rules which exhibit complex, chaotic or periodic behaviors. Rules which tend to evolve into homogenous states are replaced by rules that exhibit more complex evolutions. (i.e. Rule 0 will always arrive at a homogenous state of “0000000” after one CA update, Rule 255 will always arrive at a homogenous state of “11111111” after one update). This module will output a new CA transition rule based upon the input rule's associated value in the lookup table (i.e. if input is Rule 0 , output for new rule becomes Rule 30 ). The assignment of associated values is based upon a manually constructed look up table which has no underlying algorithm for generating the appropriate values.
Inputs:
[0218] Rule: Transition Rule ( 0 - 255 )
Outputs:
[0219] Rule: Constrained Transition Rule (subset of 0 - 255 )
[0220] FIG. 17 shows a sample representation of a CR module.
Rule Matrix (RM) Module
[0221] The RM module calculates various transformations of the original transition rule used as input. The transformations consist of 3 variations of the input rule based upon the methods outlined in “The Global Dynamics of Cellular Automata”, A. Wuensche ISBN 0-201-55740-1, pg 18-20, which is hereby incorporated by reference. The purpose of this module is to generate a group of related transition rules which have similar global behaviors.
[0222] A—Complemented Transition Rule: The complemented rule is the binary complement of the original (i.e. Rule 0 becomes Rule 255 , Rule 193 (11000001) becomes Rule 110 (00111110).
[0223] B—Negated Transition Rule: The negated rule will generate a negative space time pattern (i.e. Rule 193 (11000001) becomes Rule 124 (01111100)).
[0224] C—Reflected Transition Rule: The reflected rule will generate a reflected (mirror image) space time pattern (i.e., Rule 193 (11000001) becomes Rule 137 (10001001)).
Inputs:
[0225] Rule: Transition Rule ( 0 - 255 )
Outputs:
[0226] Rule: Original Transition Rule ( 0 - 255 )
[0227] Rule: Complemented Transition Rule ( 0 - 255 )
[0228] Rule: Negated Transition Rule ( 0 - 255 )
[0229] Rule: Reflected Transition Rule ( 0 - 255 ))
[0230] FIG. 18 shows a sample representation of a RM module.
Global Initialization (GI) Module
[0231] The GI module performs the global initialization of the CAMG system. Every module contained within CAMG has associated initialization parameters such as CA transition rule, Serial/Parallel Delay time and Serial Lookup Table scale selection. The GI module effectively determines the entire initial state of the CAMG environment. The current global state of CAMG can be saved in order to perfectly replicate the musical composition being generated at that point in time. This module allows the user to create a specific “song” and recall that song at a later time. For example, CAMG may be initially configured to generate an “ambient techno piece” that the user wishes to save. The current song can be saved in the global initialization table and a different song such as a “chromatic fantasy” can be recalled.
Inputs:
[0232] Table of global initialization strings
Outputs:
[0233] All initial state parameters for every module within CAMG, such as Pitch CA size, transition rule and initial state.
[0234] FIG. 19 shows a sample representation of a GI module.
Phone Initialization (Ringtone Application) (PINIT) Module
[0235] The PINIT module is a special purpose module that is not part of the general CAMG toolkit. It is specifically used to provide the global initial parameters for a ringtone application. Different digits within the phone number input are used to provide the initial values for every component within the ring tone application. For example the last digit of the phone number could provide the CA melody module # 1 with an initial state setting of 7, the area code could provide the initial state for the CA rhythm module # 2 .
Inputs:
[0236] 10 digit phone number: e.g. (604-555-5555)
[0237] Outputs: (all integer values except where noted)
[0238] CA Melody initialization: 4 digit value divided by 40 (0 to 250)
[0239] CA Duration init: 1 digit value (1 to 10)
[0240] CA Velocity init: 1 digit value (1 to 10)
[0241] CA Rhythm init: 4 digit value (0000 to 9999)
[0242] MIDI Program select: 2 digit value (00-99)
[0243] Scale select: 1 digit value (0-9)
[0244] Legato select: 2 digit floating point value (0.00-0.99)
[0245] Global Rule: 3 digit value (0-255)
[0246] Global Clock init: 4 digit value (6000-20000)
[0247] Melodic Range select: 1 digit value (0-9) See Appendix A
Phrase Generator (PHGEN) Module
[0248] This module is designed to generate pitch values based upon a look up table that associates a particular pitch with a corresponding active bit output by the Serial/Parallel Delay Module. Unlike the Serial Lookup Table, which constrains the CA state output of the CA used to generate pitch values, this module uses the parallel bit outputs from the delay module as its input. For example assume that the CA used as input has generated a CA state value of 65535 (1111111111111111), the Phrase Generator has been initialized with a phrase table consisting of the sequential series of pitch values: C 3 , D 3 , E 3 , F 3 , G 3 , A 3 , B 3 , C 4 , D 4 , E 4 , F 4 , G 4 , A 4 , B 4 , C 5 , D 5 . Because each bit in the input CA is active, the Phrase Generator would play an ascending C major scale of 16 notes beginning on C 3 . If the CA state value was 34952 (1000100010001000), the Phrase Generator would play a 4 note sequence consisting of the pitch values: C 3 , G 3 , D 4 , A 4 .
Inputs:
[0249] Parallel Trigger # 1
[0250] Parallel Trigger #N (Size)
[0251] Select phrase table—choose which note values are associated with each bit
Outputs:
[0252] MIDI pitch value ( 0 - 127 )—Pitch value associated with a specific bit in
[0253] Serial/Parallel Delay Module
[0254] FIG. 20 shows a sample representation of a PHGEN module.
1 Bit Controller (IBIT) Module
[0255] The 1BIT module is used to generate a continuously varying value which can be applied to a variety of other module's inputs such as velocity, duration or MIDI continuous controller value. This module is related to the Lag Generator module in that its output continuously varies over time. The 1BIT module generates a serial stream of bits which serve to alter the direction of a continuously changing value in a similar manner to the Lag Generator Module described above. The difference is that this technique employs the active bit to change the current direction of the values vector (i.e. a vector of values starting at a low value 25 and incrementing to a high value of 66 at a rate of 20 milliseconds per step ( 25 , 26 , 27 . . . 66 ) would change the direction of the vector upon receiving an active bit from the serial bit stream being generated by the CA). Upon the occurrence of this active bit event, the continuous value would now start decrementing toward the low value of 25 and would continue decrementing until another active bit event causes the direction to change again
Inputs:
[0256] CA State 1
[0257] Lag Time: Ramp value for lag time in Msec
[0258] Lag Resolution: Number of interpolation points between lag values
Outputs:
[0259] Lag Value—Reflected: Current lag value. If boundary value is reached, lag reverses direction and continues
[0260] Lag Value—Limited: Current lag value. If boundary value is reached, lag remains at boundary value until a new input state occurs
[0261] FIG. 21 shows a sample representation of a 1 BIT module.
Parameter Matrix (PM) Module
[0262] The PM module provides an alternative method of globally reconfiguring CAMG to create a network of CA and other modules that can be specified by the user. In this mode the user is able to select any combination of module inputs and outputs via a matrix which lists all possible input parameters on the X axis of the matrix and all possible output assignments on the Y axis. Using this module allows the composer to create customized configurations of CAMG for specific purposes other than the default CAMG structure.
Inputs:
[0263] CA 1 State input
[0264] CA 1 Size
[0265] CA 1 Transition rule
[0266] DLY 2 Delay time
[0267] Lag Generator lag time
[0268] (inputs for every module)
Outputs:
[0269] CA 1 state output
[0270] CA 2 state output
[0271] (outputs of every module)
[0272] FIG. 22 shows a sample representation of a PM module.
Bit Shifter Module
[0273] This module is uses 2 CAG modules and 2 CLK modules to generate a random walk function. CA 1 is used to implement the final output state of this module which generally consists of a binary number containing only one significant bit, such as 1, 2, 4 up to the lattice size as a power of 2. The module also outputs the bit number as a value based upon the bits position, i.e. binary 1 is position 1 , binary 4 is position 3 and so forth. CA 2 provides the rate of change control, which determines which of the transition rules is applied to CA 1 . The rules that are used by CA 1 , 170 , 240 and 204 are specifically selected to provide a left shift, right shift and identity function. The number of live cells contained in CA 2 state provide the input value which determines which transition rule will be applied to CA 1 . The input threshold value determines when to apply each individual change of transition rule to CA 1 .
Inputs:
[0274] CA 1 Shift Size: Lattice size of 1D CA ( 3 - 16 )
[0275] CA 1 Shift Init: Initial state ( 0 - 65535 based upon lattice size)
[0276] CA 2 Change Size: Lattice size of 1D CA ( 3 - 16 )
[0277] CA 2 Change RuleRule: Transition Rule ( 0 - 255 )
[0278] CA 2 Change Init: Initial state ( 0 - 65535 based upon lattice size)
[0279] Clock value for Shift CA: controls rate at which output bit is generated
[0280] Clock value for Change CA: controls how often Shift CA will change
[0281] Start/Stop Clocks: Start or Stop the internal clocks
[0282] Threshold Value: Determines when CA 1 will change transition rule
Outputs:
[0283] State: Current CA state ( 0 - 65535 )
[0284] Bit Number ( 0 - 16 )
[0285] FIG. 28 shows a representation of a bit shifter module.
Module Interconnections
[0286] The above described modules can be arranged to create a single virtual musician as shown in FIG. 23 .
CAMG—Module Interconnections (Ringtone Application)
[0287] As shown in FIGS. 24 , 25 , 26 and 27 , an application of CAMG may be designed to generate unique cell phone ring tones in real time, based upon the incoming phone number. When using this “ring mode”, the length of the ring tone composition is determined by the cell phone's internal setting that determines the number of “rings” to generate before answering the call, or branching to the “leave message” feature. One variant of the application, “play mode”, would allow the user to input the phone number manually and have the cell phone play the resulting composition for a more extended period, as determined by the listener.
[0288] Cellular automata are used extensively to provide the primary parameter generation within the “ringtone” composition. The initial input for the application consists of a 10 digit phone number (999-999-9999), which is used to determine all of the initial CA parameter settings for the music composition.
[0289] Unlike stochastic approaches to generative music, such as Sseyo's Koan, the CAMG methodology is completely deterministic, meaning that the composition based upon the unique phone number input will always “sound the same” and develop in exactly the same way over time.
CA Module Components:
[0290] CA 1 (Master Arranger—section 1 ) is used to provide the “master instrument arrangement” function. CA 1 determines the input state for a delay module, DLY 1 . Each cell (bit) in CA 1 is used to update the current state of CA 4 x, the “rhythm generator”. Bit 16 is used to update CA 4 a, the lead instrument. Bits 15 and 14 update CA 4 b and CA 4 c, the harmony instruments and Bit 13 updates CA 4 d, the bass instrument.
[0291] CA 1 is updated by CLK 1 (the master clock module) at a rate determined by the input phone number.
[0292] The initial parameter settings for CA 1 are size= 16 , rule= 30 and init= 1 .
[0293] CA 2 (Rhythm Repeat—section 2 ) is used to implement a “rhythm repeat” function, which provides a degree of redundancy to the rhythms that each of the “instruments” used.
[0294] CA 2 essentially acts a linear position counter based upon very specific initial CA parameter settings of size= 4 , rule= 170 and init= 8 . Each update causes the current state to shift 1 cell to the right. By using an initial state setting of “8” (1000) with a lattice size of 4 bits, this CA causes a second delay module, DLY 2 to trigger successive events that shift from right to left, starting at bit 13 output from DLY 2 , then shifting to bit 14 , 15 , 16 , 13 . . . on each update clock.
[0295] The update clock is provided by clock module CLY 2 , which runs synchronously with master clock CLK 1 , but updates 4 times as often. (i.e. if master clock CLK 1 is set to 320 OMsec, CLK 2 will update every 800 Msec). Bit 13 of DLY 2 is used to update CA 7 , which provides the “melody range setting”. Bits 14 - 16 are used to provide the “drum repeat” function, which causes DLY 3 x (another delay module) to retrigger its current rhythm using the current state stored in DLY 3 x. Note that Bits 14 - 16 retrigger all DLY 3 x modules simultaneously, i.e. “drum repeat” is a global retrigger for ALL instruments. CA 3 x (Melody Initialize—section 3 ) is used to provide an initial state value for CA 5 x, which provides the melodic values for MIDI Module MID 1 x. CA 3 x is initialized by a portion of the input phone number only at the start of the composition. CA 3 x is updated by the CA 1 /DLY 1 modules. CA 3 a is updated by Bit 16 of DLY 1 . CA 3 b is updated by Bit 15 etc.
[0296] The initial parameter settings for CA 3 x are size= 8 , rule= 30 and init is based upon phone number.
[0297] CA 4 x (Rhytlm Generator—section 3 ) is used to provide the rhythm pattern for one “bar” of music consisting of 16 beats. CA 4 x provides the input for DLY 3 x which is further processed by Legato Module to provide the rhythmic sequencing and duration values for MID 1 x. DLY 3 also provides the update trigger for CA 5 x (melody) and CA 6 x (velocity).
[0298] The initial parameter settings for CA 4 x are size= 16 , rule and init are based upon phone number.
[0299] CA 5 x (Melody Generator—section 3 ) is used to provide raw pitch values to RNG 1 x (a range module), which constrains the value to a range determined by CA 7 (Melodic Range Setting). RNG 1 x is then filtered through Serial Lookup Table module to further constraint the final pitch value to a particular musical mode, such as Ionian or Dorian modes. The final pitch value is used to provide the “note” input for MID 1 x.
[0300] The initial parameter settings for CA 5 x are size= 8 , rule is based upon phone number and init is determined by the current output state of CA 3 x.
[0301] The phone number input for initialization is constrained by Complex Rules module to ensure that the transition rule used for melody generation is not a member of Wolfram's Class 1 CA (Limit Points such as Rule 0 , 255 , 204 etc.).
[0302] NOTE: The phone number only determines the actual transition rule used by CA 5 a, the “Lead” instrument. The other instruments have transition rules which are determined by the Rule Matrix module as follows:
[0303] Harmony instrument 1 (CA 5 b ) is the complement of the original rule, used by CA 5 a;
[0304] Harmony instrument 2 (CA 5 c ) is the reflection of the original rule; and
[0305] Bass instrument (CA 5 d ) is the negation of the original rule.
[0306] For example, if phone# selects Rule 193 for CA 5 a, CA 5 b uses rule 110 , CA 5 c uses rule 137 and CA 5 d uses rule 124 .
[0307] CA 6 x (Velocity Generator—section 3 ) is used to provide raw velocity values to RNG 2 x (a range module) which constrains the velocity to a new value based upon the Hi & Lo parameter settings of RNG 2 x. These RNG 2 x settings are not based upon the phone number, but instead are fixed for all possible compositions to a range of values which are loosely based upon psycho-acoustic principles pertaining to the human ear's frequency response pattern, i.e. the Fletcher Munson curves
[0308] The initial parameter settings for CA 6 x are size= 8 , rule and init are based upon phone number.
[0309] The phone number input for initialization is constrained by Complex Rules module to ensure that the transition rule used for melody generation is not a member of Wolfram's Class 1 CA (Limit Points such as Rule 0 , 255 , 204 etc.).
[0310] CA 7 (Melodic Range Setting—section 4 ) is used to provide a list of parameters which select the Hi and Lo range values for RNG 1 a -RNG 1 d. Each RNG 1 x will receive a different range that determines the note values that a particular instrument will be able to use. For example, Instrument 4 -“Bass” (RNG 1 d ) has a range value of note # 36 for LO and note # 55 for HI (1.5 octaves) when melodic range is set to “C Ionian”.
[0311] CA 7 generates a value between 0 and 7 (000-111). The value generated by CA 7 is then converted to a 3 bit binary value (via DLY 4 ) and reconverted to decimal (via FG 1 ). The output of FG 1 is used to pick one of 8 “lists” which provide input for RNG 1 a - d
[0312] CA 7 is updated by bit 13 of CA 2 (Rhythm Repeat)
[0313] The initial parameter settings for CA 6 x are size= 3 , rule= 82 and init is based upon phone number.
[0314] NOTE: initial parameter is preset to be between the values of 1 through 6, a 0 or 7 input would cause 3 bit CA 7 to enter a static state (always 000, 111 or alternating between these two states).
[0315] Rule 82 was chosen because any value between 1 and 6 will cycle through all states (other than 0 and 7). The cycle is a period 6 . Increasing the size of CA 7 would allow a greater number of possible values for the RNG 1 x parameter lists, beyond 6 .
[0316] DLY 4 and FG 1 could be removed from this section and the output of CA 7 could be directly input into the code that implements the actual list selection
Ringtone Application Functions and User Interface
Sequencing using Standard User Interface (UI) Components
[0317] The examples below illustrate the sequencing to perform tasks for ZenRings in a ringtone application, such as audio caller ID. It uses standard UI components, however to make the UI more concrete. These use cases are based on the Series 60 phones: Symbian OS 7.0s although the CAMG can be adapted for use with other phone models.
Sequence 1 : ZenRings,Activation
[0318] As shown in FIGS. 29 and 30 , the ringtone application (referred to as ZenRings) may be started using the following process:
[0000]
Trigger
Task
Sequence
Comments
Launch
Find ZenRings
1. Activates “Menu”
1. Activation may be
Program
application on cell
from default screen.
pressing preset
phone
2. Uses arrows or
button or require
joystick to cycle menu
another mode
until “Applications”
depending on phone.
folder is highlighted.
3. “Select” label
3. Activates “Select” to
may be “Open”
open “Applications”
depending on phone.
folder.
4. The 4 th step may
4. Uses arrows to cycle
be skipped on some
menu until “Select
phones.
Application” is
highlighted.
5. Activates “Select” to
get applications listing.
6. Uses arrows or
joystick to cycle through
available applications
until “ZenRings” is
highlighted.
Decides to
Get back to
1. Activates “Back” item
2. This process may
abort plans to
default Phone
available on the screen.
be avoided on some
launch
Screen.
2. Repeats activating
phones by holding
ZenRings*
“Back” until default
down “Disconnect”
screen is reestablished.
button on the cell
phone.
Chooses to
Enter ZenRings
7. Activates “Options” to
7. “Options” may not
continue with
Interface.
open list of application
be universal for all
Launching
info: Open, Delete, Web
phones.
Program.
Access, Check Version.
8. Uses arrows or
joystick to cycle through
available applications
until “Open” is
highlighted.
9. Activates “Select” to
start ZenRings Interface.
Status of Zen Rings
Application is provided.
It reads “ZenRings
Status: Off”.
Decides to
Get back to
1. Activates “Exit”
1. Pressing
Quit
Default Screen
available on the screen.
“Disconnect”
Application*
2. Activates “Back”
button does same
item available on the
function.
screen.
3. This process
3. Repeats activating
may be avoided on
“Back” until default
some phones by
screen is reestablished.
holding down
“Disconnect”
button on the cell
phone.
Chooses to
Activate
10. Activates “Options”
10. Composer
continue and
ZenRings
available on the screen.
Mode is a
activate
program
Screen:
alternative Label to
Program.
Activate ZenRings
Play Mode.
Composer Mode
Although labels
11. Use Arrows or
can change
joystick to toggle
throughout
between Start ZenRings
development.
and Composer Mode
13. Pressing
until Start ZenRings is
“Disconnect”
selected.
button does same
12. Activates “Select”
function.
item available on the
14. This process
screen.
may be avoided on
Screen pops up to the
some phones by
one displayed in step 8.
holding down
It now displays:
“Disconnect”
“ZenRings Status: On”.
button on the cell
13. Activates “Exit”
phone.
available on the screen.
14. Activates “Back”
item available on the
screen.
15. Repeats activating
“Back” until default
screen is reestablished.
*These triggers indicate possible aborting of the primary task, and do not represent a step in the required sequence to achieve the primary task. After a sequence is aborted, the user will need to begin a step one of the sequence.
Sequence 2 : Composer Mode (See FIGS. 29, 30 and 31 )
[0319] FIGS. 31 , 32 and 33 show how the user can use the CAMG in a “composer mode” to save selected music and associate that music with a particular phone number, using the steps below:
[0000]
Trigger
Task
Sequence
Comments
Activate
Find ZenRings
Same as Sequence 1-9
Sequence 1-9 may
Composer
and enter
The status of the
be set at the OS
Mode
interface.
ZenRings application
level.
may be ON or OFF
Activate/Enter
10. Activates
Composer
“Options” available on
Mode
the screen.
Screen:
Activate ZenRings
Composer Mode
11. Use Arrows or
joystick to toggle
between Start
ZenRings and
Composer Mode until
Composer Mode is
selected.
12. Activates “Select”
item available on the
screen.
Composer Mode UI is
presented:
Enter Phone Number
From Phone Book
New Phone Number
Chooses
13. Use Arrows or
Number From
joystick to toggle
Phone Book
between “From Phone
Book” and “New
Phone Number” until
“New Phone Number”
is selected.
14. Activates “Select”
item available on the
screen.
Phone Book UI on
screen.
15. Searches or
Browses for stored
phone number using
default UI
mechanisms.
16. Activates “Select”
16. Details and
available on screen.
Back are the
default UI
mechanisms in the
Phone book UI. It
is preferable to use
an instance of the
phone book in
order to have our
own functionality
within the familiar
phone book UI.
Plays Music
17. New Menu
Displayed:
604-555-1212
Play
Tempo
Restart
Advanced
Save as Ringtone
18. Uses Use arrows
or joystick to cycle
through menu until
“Play” is highlighted.
19. Activates “Select”
It may be useful to
available on screen.
have a time
ZenRings Music
indicator on
Plays.
screen, when the
Menus Changes on
music is playing.
Screen to now display:
604-555-1212
Pause
Tempo
Restart
Advance
Save as Ringtone
Restart Music
20. User uses Arrows
Screen does not
from
or joystick to cycle
change. Music
Beginning
through until “Restart”
restarts and Time
is highlighted.
Counter resets
Changes
21. User uses Arrows
Tempo
or joystick to cycle
through until “Tempo”
is highlighted.
22. Screen Changes to
Music will begin
provide a meter. With
or restart once
present indicator being
Tempo is selected
at midpoint. User uses
depending on
arrows or joystick to
play/pause status.
adjust tempo.
Tempo changes in
“Up” (or suitable icon)
real-time as per
to Increase Tempo
user input.
“Down” (or suitable
icon) to decrease
Tempo.
Chooses
23. Activates “Select”
Music remains
Tempo
Available on Screen.
Playing at new
Screen is back to:
Tempo.
604-555-1212
Pause
Tempo
Restart
Advance
Save as Ringtone
Saves
24. User uses arrows
Ringtone
or joystick to cycle
through menu until
“Save as Ringtone” is
selected.
25. Activates “Select”
Available on Screen.
Screen displays:
Save As: <Data Field>
26. User inputs name
27. Activates “Save”
New Ringtone for
available on screen.
phone is set, and a
Screen goes back to:
copy of the
604-555-1212
Ringtone is sent to
Pause
Ringtone folder
Tempo
with the saved.
Restart
name.
Advance
Save as Ringtone
User Exits
28. Activates “Back”
Application
available on the
screen.
Screen back to:
Activate ZenRings
Composer Mode
29. Activates “Back”
Available on Screen.
Screen back to:
“ZenRings Status:
On”.
30. Activates “Exit”
Screen Back to
Applications Folder
[0320] Alternatively, it may be possible to provide restart function in the tempo window. Also it could be possible to adjust tempo, by using Left/Right arrows, keeping the Up/Down arrows reserved for menu navigation.
[0321] The above system is designed for use on a 176×208 display screen with 16 bit colour, although it could be adapted for use on other displays. It is also designed for use with the following inputs: two soft keys, five-way navigator, and several dedicated keys dependent on phone; although it could be easily adapted for other inputs.
[0322] Preferably the application is comfortably manageable in one hand using the user's thumb. This has important implications since it is convenient for users on the move. Since single applications fill the available screen, an application switcher is available via a long press of the menu button, which greatly enhances productivity on the device. Any user with mobile phone experience will grasp the workings of this intuitive UI very quickly.
[0323] Although the particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus lie within the scope of the present invention. As an example the CAMG is useful in video games wherein actions by the game player provide the inputs to initialize the CAMG.
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The Cellular Automata Music Generator (CAMG) is a software platform, application and engine that generates and modifies musical compositions in real-time using a system of networked modules that utilize the 1 -dimensional cellular automata (CA) mathematical model. The music compositions are non-looping (i.e. the same few bars of music do not repeat over and over), can be any length, can have low memory and processing requirements compared to looping WAV or MP 3 files, and follow psychoacoustic principles. The music generated is ever evolving and can be globally altered based on one-parameter change. The music engine can be utilized in computer games or to generate unique ringtones or any musical composition for cell phones or other mobile devices based on ten-digit inputs, such as telephone numbers. The ringtones or musical pieces can be generated automatically based on the telephone number of the in-coming telephone call, or manually by the user, who inputs a selected numerical sequence. It can also be used as an audio caller identification system.
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This is a division, of application Ser. No. 722,418, filed Sept. 13, 1976.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a and vulcanization mold for the production of laminated bodies, especially shaped shoe soles, from several layers of different and/or differently colored rubber or plastic, which mold includes several superimposed, shaped, mold cavities for preshaping the individual layers and which are separated from one another by intermediate plates removable from the vulcanization mold in order to unite the preshaped layers.
2. Description of the Prior Art
From German AS No. 1236771, a vulcanization mold for the production of a structured heel from rubber or an equivalent raw material, the heel having a heel-tap made from a rubber which is different as compared to the rubber of the heel, is known. The mold consists of a lower mold, a middle mold having a chamber for the heel and an upper mold, and a moveable intermediate plate which can be inserted loosely between the middle mold and the lower mold having a chamber for the heel-tap. With this vulcanization mold, blanks of different working material are molded simultaneously under pressure and temperature and are prevulcanized and are thereafter united following removal of the intermediate plate and are fully cured under pressure and temperature into a laminated body. Additionally, a vulcanization mold has been proposed for the production of elastic bottom parts of shoes of two layers of different composition. The layers are prefabricated in nests of molds separated from one another by an intermediate plate and are hardened together after removal of the intermediate plate, the flat, intermediate plate being developed more thinly at one end corresponding to the angle of deviation running differently from the plane of the mold separation.
With such molding tools for vulcanization, however, only layers with flat, i.e., planar contact, or interfacial, surfaces can be joined because of the shaping of the intermediate plate as a plate of essentially constant thickness, but not layers where the interfacial surfaces between the different working materials run in spatial separating surfaces deviating from the plane.
For the production of laminated bodies, especially of multilayered rubber molded soles, it is also known to harden individual layers in separate individual molds and then to join these layers in a common mold, possibly with the aid of an adhesive. This method however must be carried out in steps requiring much labor and is too expensive, therefore, for large scale production. Additionally, the joining together of the layers by means of adhesives creates ugly and poor transition areas between the layers which increases the quota of rejects, and the correction of which (transition areas) requires an expensive mechanical, secondary processing. Moreover, the bonded areas are endangered insofar as they can separate under load.
The present invention is based on the object of developing a form of vulcanization such that the production of laminated bodies from different work materials is made possible, the interfacial surfaces of which run in planes deviating from one another, or are non-planar. With this method of vulcanization, it is to be possible to manufacture laminated bodies of more than two layers on a large scale with a small technical and apparatus expenditure. There should be the possibility for interfacial surfaces on opposing sides of the middle layer to deviate from one another. It is an object to provide a vulcanization mold with which it is possible to produce multilayered molded soles, wherein the individual layers are developed with perfect transition areas.
SUMMARY OF THE INVENTION
The foregoing objects are accomplished according to the present invention by the provision of a vulcanization mold consisting of a lower mold, an upper mold, two intermediate plates which limit and define a mold cavity for one layer, the upper and lower separating surfaces running spatially variably in relation to the adjacent layers, whereby the two intermediate plates are separated from one another by a center plate freely moveable in the direction of opening and closing of the vulcanization mold, which center plate has a recess, or opening, producing the lateral boundary of the molded part of the hollow space, or mold cavity, and surfaces corresponding to the adjacent surfaces of the adjacent intermediate plates.
With a vulcanization mold developed in such a way, it is possible to produce in a profitable manner laminated bodies with varying dimensions of thickness of the individual layers but with precisely fitting adjacent border surfaces. I.e., it is possible to produce a structure of a laminated body, which is particularly attractive for modern rubber, respectively, plastic, shoe soles. With this vulcanization mold it is possible to produce rationally and simply in one operating cycle molded soles from more than two layers with different interfaces.
In order to reduce the weight of the laminated body and, at the same time, to make it more elastic, which can be important particularly for shoe soles of sports shoes, provision is made in a further development or embodiment, of the invention for a displacer or displacing means, which projects into the mold cavity for the middle layer and is moveable in the direction of opening and closing of the vulcanization mold. The displacer, for the formation of ribs in the layer, is equipped with pegs, or projections, which are disposed at a distance from the recess of the middle plate. At the same time, the displacer can be lifted or lowered by means of a wedge shiftable in the lower part of the mold and can be encompassed with a snug fit by the recess of the intermediate plate covering the mold cavities of and resting on the lower part of the mold.
In order to safeguard against undesirable horizontal movement of the individual components of the vulcanization mold during the production process as a result of operating pressures and pressure changes, there are provided according to a further embodiment of the invention, guiding and/or centering bolts between the two halves of the mold.
A further embodiment of the invention is characterized by the fact that adjacent to the front ends of a mold cavity located in the lower part of the mold, bolts, pegs or elevations are provided during prefabrication in order to anchor the work material.
So that one need not fear any adhesion of the prevulcanizates or of the finished product to the walls of the mold cavity, the intermediate plates and the center plate can be chrome-plated, polished steel or light metal plates provided with non-sticking surface coatings, or release coatings, e.g., of polytetrafluoroethylene.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings an embodiment of the vulcanization molding tool according to the invention for the production of a multilayered shoe sole is shown.
FIG. 1 shows a side view of a multilayered sole;
FIG. 2 shows individual parts in perspective of the vulcanization mold ready for operation;
FIG. 3 shows a cross-section through the closed vulcanization mold in the area of the heel during prevulcanization; and
FIG. 4 shows a cross-section of the closed mold taken along line IV--IV of FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a side view of a rubber molded sole 1, which consists of layers of rubber mixtures of different elasticity and color. The actual walking layer 2 consists of a synthetic rubber mixture or else of an extender with high abrasion resistance and with good feel and great resistance to cutting. It extends in approximately constant thickness from the heel part 8 (pulled in a rounded manner) to the tip of the sole. Above it lies a wedge shaped intermediate layer 3 which extends to the tip of the sole and which has a semi-circular tip protector 6 in front. It consists of natural rubber, has good damping properties and has been dyed differently as compared to walking layer 2. On the middle layer 3 lies a layer 4 of an edge strip which extends only in the area of the edge of the molded sole and which serves for the connection of the molded sole with the upper part of the shoe 7, shown in broken line.
In the central area of the molded sole 1, the surface of the middle layer 3 projects upwardly. The layer 3 has vertical ribs 5 in the area of the heel. The ribbing of the middle layer 3 of the sole produces a desired savings in weight of the molded sole and moreover improves the elasticity in the area of the heel. The individual layers 2, 3 and 4 are separated from one another by exact demarcation lines.
FIG. 2 shows a vulcanization mold for the production of the molded sole according to FIG. 1, shown in a wide open state. Between an upper mold component 10 and a lower mold component 11, there are a first intermediate plate 12, a middle plate 13 mounted freely moveable in the direction of separation of the mold and a second intermediate plate 14. In the lower mold component 11 of the mold on the top side mold cavity 15 is milled out for the layer 4 of the edge strip, which is followed by a mold cavity 16 for the semicircular tip protector 6. The two mold cavities 15 and 16 are divided from one another by a threshold 17. The mold cavity 15 limits a wedgeshaped displacer 18 open toward the top which serves for the production of the rib part of the heel of the molded sole. The displacer 18 is provided with diverging pegs 19 and decreases in height in the direction toward the tip of the molded sole. In the area in which the mold cavity 15 ends, bolts 20 have been disposed, the purpose of which will be explained below. The separation of the mold component 11 of the mold is made to correspond to the course of the level of the edge strip layer 4 of the molded sole 1, i.e., in the drawing, it runs from left to right gradually sloping downwards. The wedgeshaped displacer 18 is mounted moveably in the lower part of the mold, i.e., it moves toward the lower part of the mold in the direction of the arrow 21. The intermediate plate 12 is placed onto the lower mold component 11 of the mold. The intermediate plate corresponds in its outline to the curved surface of the lower part of the mold.
The intermediate plate 12 has an opening 22 which fits snugly over the displacer 18 in such a way that it covers up completely the mold cavity 15.
The middle plate 13 is situated on top of the intermediate plate 12 and the lower side 23 is adapted to the outline of the upper side 23' of the intermediate plate 12 and, respectively, the top side of the molded lower part 11. The middle plate 13 extends over the entire length of the lower part of the mold and in its middle area it has an opening for the formation of the mold cavity 24 which corresponds to the middle layer 3 of the molded sole 1. Since the shape of the middle layer 3 as a result of the configuration of the sole and as a result of the rounded formation of the heel is not of a uniform thickness, the thickness of the middle plate is also adapted to the shape of the middle layer 3. In the area of the tip of the sole, the middle layer 3, is quite thin, in the middle area it gradually becomes thicker, while it again becomes thinner corresponding to curvature 25 of the middle plate 13 toward the end of the sole. The outline of the mold cavity 24 is dimensioned such that the displacer 18 of the lower part of the mold 11 projects through the intermediate plate 12 up to the level of the upper surface of the middle plate 13.
The intermediate plate 14 is situated on the middle plate 13 and is curved negatively corresponding to the upper surface of middle plate 13. I.e., the curvature 25' on the bottom side of the intermediate plate 14 corresponds to curvature 25 on the upper side of middle plate 13. Intermediate plate 14 is otherwise of approximately uniform thickness and completely covers the mold cavity 24 in the middle plate 13.
The upper mold component 10 of the mold fits onto the intermediate plate 14, which contains the mold cavity 26 for forming the walking layer 2 of the sole. In view of the rounded part 8 of the heel of the molded sole 1, the upper mold component 10 also has a curvature 27. The mold cavity 26 for forming the walking layer 2 is covered in its entirety by the top side of the intermediate plate 14.
In the upper part of the mold or in the lower part of the mold, centering means such as centering pegs, respectively, centering bolts 28, are provided as customary. The centering pegs 28 project through corresponding bores 29 and 30 in the intermediate plates and in the middle plate to secure the positioning of the plates.
For the production of a molded sole 1, blanks roughly synchronized in volume to the individual layers and made of variable rubber mixtures are inserted into the individual mold cavities. Into mold cavity 15 a blank corresponding to layer 4 is inserted; into mold cavity 16 a blank for the tip protector is inserted; and after that the intermediate plate 12 is placed over displacer 18 onto the lower mold component. Then follows middle plate 13 until it rests flush on intermediate plate 12 and the displacer 18 is submerged into mold cavity 24. A blank for the middle layer 3 is placed into mold cavity 24. Intermediate plate 14 is then placed onto middle plate 13. A blank for the walking layer 2 is inserted into mold cavity 26 and the upper mold component 10 is moved downwardly until the individual parts fit directly one against the other.
The vulcanizing mold, or molding tool, ready for operation is shown in FIGS. 3 and 4. From FIG. 3 it can be seen how the individual mold cavities 15, 16, 24 and 26 are separated by the intermediate plate 12 and 14.
In the middle plate 13, the mold cavity 24 for the middle layer 3 of the molded sole 1 and the displacer 18 with its pegs 19, extending therein, becomes recognizable. For a better separation of the mold cavity 15 from the mold cavity 24, the displacer 18 is provided with curvatures 30 preventing an overflowing of the rubber materials. The moveability of the displacer 18 is guaranteed, e.g., by the shiftable wedge 31, which by its shape pushes out the displacer 18 or allows it to slide back.
In FIG. 4, the vulcanizing mold of FIG. 3 is shown in a cross-section along the edge of the mold cavity 15 (IV -- IV). In FIG. 4 it is seen how the threshold 17 acts to separate the mold cavity 15 for the edge strip 4 and the mold cavity 16 for the tip protector 6. As a result of the fact that the intermediate plate 12 with its bottom side rests on threshold 17, mold cavity 16 is separated from mold cavity 15. The upper side of the displacer 18 extends up to the underside of the intermediate plate 14. Pegs 19 are formed in the body of the so-called displacer 18 to provide hollow spaces for the ribs 5 of the molded sole 1. In this way, the rubber mixture flows in the hollow spaces.
After the mold is assembled, the individual parts of the sole are prevulcanized at vulcanization temperatures between 140° - 170° C in the closed vulcanization molding tool, until they are partially branched and have assumed a solid shape.
The necessary vulcanization time is determined especially by the physical value of the Mooney scorching. This value assures a lasting processibility of the mixtures used to the point that the heating times needed for the vulcanization will reach a safe value without there being any danger that a mixture in an unprocessed state could begin to branch spontaneously at ambient temperature.
After the time for prevulcanization, the vulcanization is interrupted, the vulcanization mold is opened and the intermediate plates 12 and 14 are removed. The middle plate 13 in which the middle layer 3 is molded and held, remains in the mold. When the vulcanizing mold is reclosed, the prevulcanized layers fit intimately against one another. As a result of the fact that the intermediate plate 12 has been removed, the displacer 18 is pushed back a distance corresponding to the thickness of the intermediate plate 12 into the inside of the lower mold component 11. Otherwise it would extend into the mold cavity 26.
The individual layers of the molded sole now fit against each other, adhere to one another and are cured. The total operating cycle is generally less than 10 minutes, a value which could not be achieved heretofore in the case of manufacturing such molded soles.
The prevulcanization of the blanks is carried out generally at a temperature of about 140° to 170° C, preferably at about 150° to 160° C. The removal of the intermediate plate generally takes place after about 0.5 to 5 minutes, preferably about 2 to 4 minutes. After that the final curing is accomplished generally at a temperature of about 150° to 180° C, preferably about 160° to 170° C over a time period of about 2 to 7 minutes, preferably about 3 to 6 minutes. The period of prevulcanization simultaneously guarantees that the prevulcanized blanks have a solid consistency but retain an adhesive capacity sufficiently strong to lastingly and firmly combine in the final curing. The pressure during the prevulcanization and final curing steps generally amounts to about 40 to 120 kg/cm 2 , and preferably about 50 to 100 kg/cm 2 .
As soon as the vulcanization is complete, the mold is opened and the now finished molded sole is taken out. As a result of the function of the intermediate plates, necessarily perfect separating surfaces of the individual layers from one another are guaranteed. Additionally, the arrangement of the pegs 20 in the lower part of the mold has assured that the free ends of the edge strips 4 cannot be pressed out sideways but are anchored on these pegs.
Employing the apparatus of the invention, differently colored molded soles with a highly decorative effect can be produced. The raw material mixtures used can have different compositions and characteristics. The prevulcanization in separate molding cavities guarantees that no coallescing what ever or displacement of the various working material mixtures can take place.
The vulcanization molding tools are developed effectively in the customary manner always for one pair of soles.
The removable intermediate plate and the moveably mounted middle plate are effectively made of a light metal sheet or a steel sheet which has been provided with antiadhesive, or releasable, surface coatings to ensure that upon opening of the mold after prevulcanization no adhesion of the prevulcanizates to the mold occurs.
The moveable mounting of the displacer 18 is made possible by providing the displacer 18 with an attachment which compensates for the thickness of the intermediate plate 12, which attachment is removed during the curing. Alternatively, the displacer 18 can be attached directly to the intermediate plate 12. For the curing of the molded sole, the displacer is not absolutely required.
In the molding tool according to the present invention, any given rubber and/or plastic molded article can be produced. In the above description the production of molded soles from different rubber mixtures has been described as an example. The layers or blanks, however, may also consist of other materials. The necessary changes in vulcanization times, temperatures and pressure can be easily determined by simple experiments.
For the blanks, one can use, for example, rubber mixtures having a Mooney-scorching (T 5 135°) of approximately 3 to 8, preferably of about 4 to 6.5 can be used. In the case of selection of such rubber mixtures, operating cycles of less than 10 minutes will be achieved.
The mixtures with the selected characteristic Mooney values guarantee a safe processing without problems. Mixtures with smaller Mooney values are not as well suited, since the latter are inclined to automatic branching at ambient temperature.
The layers may be composed of vulcanizable elastic plastics such as, for example, thermoplastic elastomers, butadiene polymerizates, butadiene copolymers with styrene and/or acrylonitrile, isoprene polymerizates, isoprene copolymers with isobutylene, polyolefins, olefin diene terpolymers, chlorosulfonated polyethylene, ethylene vinyl acetate copolymers, polyacrylate, chloroprene polymerizates, rubber elastic polyurethane, silicon rubber and/or chlorohydrin-(co)-polymers.
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A vulcanization mold for producing laminated bodies, particularly shoe soles of different and/or differently colored rubbers or plastics, the interfacial boundary between adjacent plies of the laminate forming non-planar surfaces, is provided. The mold includes several mold cavities, disposed one on top of the other for forming the individual layers of the laminate, the mold cavities being separated by intermediate plates which are removable from the mold following a prevulcanization to allow for uniting of the premolded individual layers into the desired laminated body. A middle plate freely moveable in the direction of opening and closing of the mold together with two intermediate plates disposed on opposite sides thereof form the mold cavity for a central layer of the laminate, the surfaces of the middle plate being non-planar and corresponding to the adjacent surfaces of the intermediate plates. The laminated bodies are produced by inserting blanks into the mold cavities, shaping and prevulcanizing the blanks, opening the mold and removing the intermediate plates and closing the mold and fully curing the pre-vulcanized layers into the finished composite.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
This invention relates to apparatus and processes for measuring physical parameters of sheet material by directing electromagnetic radiation from a source to the material and electronically processing infrared detector responses associated with selected wavelengths of radiation which passes through or otherwise interacts with the material.
2. Description of Prior Art
Measurement of physical parameters of sheet material through the use of infrared absorption phenomena is well-known. Typical procedures employ a source of electromagnetic radiation having a spectral output that includes the infrared region, a collimator or other arrangement for directing the radiation toward the sheet material, a chopper for modulating the directed radiation, filters for passing selected bands of radiation, one or more infrared detectors that produce responses which depend on the intensity of radiation passing through the filters, and electronic processing means for deriving the measurement from the detector responses. The filters may be mounted in a rotating chopper so that radiation transmissions are time-multiplexed to a single detector as in U.S. Pat. Nos. 4,052,615 Cho, or to separate, plural detectors as in 4,300,049 Sturm. Alternatively, the procedure may employ plural sources with two or more detectors as in U.S. Pat. No. 4,306,151 Chase, or a single source with a beam splitter and plural, separate detectors as in U.S. Pat. No. 3,405,268 Brunton.
The physical parameter in question is measured by taking advantage of the selective absorption of certain wavelengths of infrared radiation by certain constituents of the sheet material as taught, for instance, by U.S. Pat. No. 3,228,282 Barker. The typically heterogeneous nature of the sheet material introduces sources of measurement error, some of which can be compensated for by measuring the absorption for two or more different bands of radiation and interrelating the measurements to produce corrected measurements indicative of the physical parameter or parameters in question. This technique is exemplified in U.S. Pat. Nos. 3,405,268 Brunton and 4,577,104 Sturm.
Other sources of measurement error are compensated for by the geometric arrangement of the apparatus, as illustrated in U.S. Pat. Nos. 3,793,524 Howarth and 4,052,615 Cho.
Additional sources of error inhere in the methods by which certain components of such previous apparatus have been used. Specifically, those which use mobile filters to produce sequential detector responses in a time-multiplex arrangement may introduce sources of error as explained in U.S. Pat. No. 4,300,049 Sturm (cols. 3-4). In those which employ plural, separate detectors, the detectors are disposed on separate substrates and may be separately cooled. Either of these conditions may affect the relative thermal stability of the detectors and represent yet another source of error. Moreover, when plural detectors are used in conjunction with a beam splitter, the radiation emitted from the source is divided among the detectors, thereby yielding weaker detector responses. Where stronger responses are desired, the source intensity may be increased--which increases cooling requirements and decreases longevity for the source-- or the weak responses may be further amplified, which yields no improvement in signal-to-noise ratio and heightens electronic filtering requirements in conventional signal processing circuits.
SUMMARY OF THE INVENTION
This invention provides apparatus and associated processes for measuring physical parameters of sheet material by directing electromagnetic radiation from a source to the material and electronically processing infrared detector responses associated with selected bands of infrared radiation which passes through or otherwise interacts with the material, comprising a sensor housing, and an integral filter-detector package (hereinafter "integral package") contained within the sensor housing and containing both a plurality of filters which pass selected bands of radiation, and a corresponding plurality of detectors which detect the radiation passed through the filters.
The detectors may be disposed on a common substrate, and the integral package may further contain a thermoelectric cooler to provide internal temperature control.
The integral package may contain a phase-reference detector which detects radiation emitted from the source that is within a selected band. In that event the integral package will also contain at least two additional detectors which detect infrared radiation within two additional bands that may or may not be included within the band detected by the phase-reference detector. Alternatively, the phase-reference detector may be isolated from the integral package. The phase-reference detector and associated circuitry are used to condition detector responses from the remaining detectors in accordance with the response from the phase-reference detector.
The integral package will typically be displaced from the transmission axis of the source. The phase-reference detector may also be displaced from the transmission axis, although typically to a lesser degree than the integral package, and in a preferred embodiment has a location along the transmission axis.
An object of this invention is to provide apparatus and processes for measuring physical parameters of sheet material via infrared absorption phenomena without the need for plural radiation sources, filter wheels, beam splitters, or similar devices and arrangements.
Another object of the invention is to provide such apparatus and processes that eliminate certain sources of measurement error which inhere in the use of two or more separate detectors.
A further object of the invention is to provide in such apparatus and processes a unique and advantageous method for deriving reliable measurements from relatively weak detector responses.
BRIEF DESRIPTION OF THE DRAWINGS
FIG. 1 is a generally schematic, partially sectional view of an embodiment of the invention.
FIG. 2 is a schematic illustration of a further refinement of the invention as applied to the embodiment of FIG. 1.
FIG. 3 is a generally perspective, partially schematic illustration of an integral filter-detector package that may be used with the invention.
FIG. 4 is a schematic illustration of a modified ratio analyzer circuit that may be used in producing measurements of physical parameters of sheet material in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Although the invention can be incorporated in a variety of sensor designs for measuring properties of sheet material (such as those shown, for example, in U.S. Pat. Nos. 4,306,151 Chase, 3,793,524, Howarth, or 3,405,268 Brunton), it is herein described and illustrated as embodied in a sensor design having a hemispherical detector housing similar to that of U.S. Pat. No. 4,052,615 Cho. The disclosure of the latter patent is hereby incorporated by reference.
The term "sensor housing" as used herein, is intended to encompass both those systems which employ a single-portion housing on one side of the sheet material, and those which employ a two-portion housing with a portion on each side of the sheet material. The context in which the term "filter" (or a form thereof) is used will indicate whether optical or electrical filtering is being described.
Referring to FIG. 1, the numeral 10 designates sheet material that is typically in motion during production thereof, as indicated at 12. The sheet material 10 is shown passing between the source housing 14 and detector housing 16 of a two-portion sensor housing 18. The sensor housing 18 is typically mounted on a conventional sheet-traversing structure (not shown) and in communication with remote means for controlling those physical parameters of the sheet material 10 which the sensor measures.
A source arrangement, indicated generally as 20, is contained within the source housing 14 and includes a conventional lamp 22 and a chopper 24. The lamp 22 provides a source of electromagnetic radiation over a spectral band that includes the infrared region. The chopper 24 may be a motor-driven rotating disc, an electronically-driven tuning fork, or any device suitable for modulating a radiation beam. A tuning fork is preferred for its stability, low cost, and low heat generation. The chopper 24 is driven by a conventional controller 26 at a desired modulation frequency.
The source arrangement 20 preferably includes an elliptical reflector 28 that is secured by conventional means to the source housing 14. An ellipsoidal region is defined by the reflecting surface 29 of the elliptical reflector 28. The foci of the ellipsoidal region define the nominal locations of the lamp 22 and the modulating portion 25 of the chopper 24. Just above the modulating portion 25 is a first window 30 through which radiation is directed to the sheet 10.
The detector housing 16 contains a hemispherical body 32 having a highly-polished, reflecting surface 34 that forms a hemispherical cavity 36. An integral filter-detector package, generally designated as 40, is attached to the hemispherical body 32 and contains means for detecting radiation emitted from the source 20 and passing through, or otherwise interacting with the sheet material 10. The integral package 40 and the reflecting surface 34 are protected by a second window 37 placed between the detector housing 16 and the hemispherical body 32.
The integral package 40 is illustrated in FIGS. 1 and 3 and includes a filter-detector housing 38 with an access window 42. A mounting plate 43 is added to secure the integral package 40 to the hemispherical body 32. The numeral 45 generally designates communication lines for detector responses 62, 64, 66, 68, and the number 47 designates a two-way communication line between the integral package 40 and a cooler control unit 59. Radiation entering through the access window 42 into the filter-detector housing 38 is simultaneously filtered and simultaneously detected in a plurality (four are shown) of radiation channels 44, 46, 48, and 50. Each radiation channel--as, for example, that designated by the numeral 50--comprises a filter 52 selected to pass a desired band of radiation, and a corresponding detector 54. The detectors are preferably disposed on a common substrate 56, and the integral package 40 preferably contains a thermoelectric cooler 58 to control its internal temperature and thereby control the temperature of the filters and detectors. These features are individually and collectively important since the performances of both detectors and filters are affected by physical characteristics which are temperature-dependent. The cooler control unit 59 responds to the internal temperature of the integral package 40 as indicated by a thermistor (not shown) contained therein, and controls operation of the thermoelectric cooler 58. Integral packages of the above description may be obtained from IR Industries, Inc., Waltham, Mass.
The number of radiation channels needed in the integral package 40 will vary with the application. For example, four channels are necessary in applications to which the invention of U.S. Pat. No. 4,577,104 Sturm is directed, wherein it is desired to measure radiation intensity for four narrow bands of radiation centered at about 1.83μ, 1.93μ, 1.89μ, and 2.12μ. In contrast, three channels are necessary in applications to which U.S. Pat. No. 4,582,520 Sturm is directed (corresponding to IR wavelengths of 1.35μ, 1.50μ, and 1.75μ), and only two are necessary to incorporate the integral package 40 in the invention of U.S. Pat. No. 3,228,282 Barker. One-channel packages are known in the field of sheet material property measurement, as exemplified in U.S. Pat. No. 4,052,615 Cho (col. 5, 1. 16-25).
Referring again to FIG. 1, the integral package 40 may be located along the transmission axis 60, or may be displaced from the transmission axis as shown. The degree of displacement may depend on the application or, more particularly, the physical characteristics of the sheet material 10 being examined, as taught in U.S. Pat. Nos. 3,793,524 Howarth and 4,052,615 Cho (col. 5, 1. 36-41).
In the operation of the invention as embodied in FIG. 1, electromagnetic radiation emitted from the source 20 and passed through the sheet material 10 and into the hemispherical cavity 36 is optically filtered within radiation channels 44, 46, 48, 50, to pass four selected bands of radiation to four corresponding detectors. The detectors produce detector responses 62, 64, 66, and 68 that are communicated to a conventional ratio analyzer circuit 70, which in turn produces one or more outputs 72, indicative of the measured physical parameter or parameters of the sheet material 10. These outputs 72 may be further processed and delivered to a visual recorder or a process control device 132 through a computer interface (not shown).
In some applications it may be difficult to produce detector responses with suitably high signal-to-noise ratios. This could occur in a variety of circumstances, one of which is the use of a relatively low-intensity source 20 in conjunction with a relatively small integral package 40 having multiple radiation channels. Another aspect of the invention pertains to the use of what is herein termed a "phase-reference detector" to provide reliable measurements in such applications. A phase-reference detector is 35 herein defined as a detector, the response of which is used in conjunction with a synchronous detector (a conventional circuit) to condition weaker infrared detector responses.
Referring again to FIGS. 1 and 3, one radiation channel 50 of the integral package 40 may contain a detector 54 that serves as a phase-reference detector. The filter 52 corresponding to this detector 54 is selected to pass a given band of radiation . The three filters in the remaining radiation channels 44, 46, and 48 pass narrower bands of infrared radiation, all of which may be included within the radiation band passed by the first filter 52. For example, if one desires to measure both the basis weight and moisture content of paper or other absorbent material in a manner similar to that taught by U.S. Pat. No. 3,405,268 Brunton, the three filters in radiation channels 44, 46, and 48 can be selected to pass relatively narrow bands of radiation centered at about 1.95μ, 1.83μ, and 2.12μ, respectively. The filter 52 corresponding to the phase-reference detector 54 can be selected to pass a relatively broad band of radiation extending from about 0.95μ to about 2.6μ. Since the phase-reference detector 54 receives radiation over a much broader range of wavelengths than any other single detector, it will produce a response 62 with a higher signal-to-noise ratio than the responses 64, 66, and 68 from the detectors in radiation channels 44, 46, and 48 respectively. It is not necessary that the band of radiation passed by the filter 52 corresponding to the phase-reference detector 64 encompass those bands of radiation passed by the filters in the remaining radiation channels 44, 46, and 48. What is important is that the filter 52 is selected so that its corresponding detector 54 will produce a response 62 with a significantly higher signal-to-noise ratio than obtains for the responses 64, 66, and 68 from the remaining detectors. By appropriate modification of the ratio analyzer circuit 70, the stronger response 62 from the phase-reference detector 54 can be used to condition the responses 64, 66, and 68 from the remaining detectors and thereby produce more accurate measurements.
An example of such a circuit is schematically illustrated in FIG. 4 and indicated generally by a rectangularly-shaped box 100 enclosed by dashed lines. Detector responses 64, 66, and 68 are fed into information channels 84, 86, and 88, respectively. In each information channel, as in information channel 84, for example, the detector response 64 is processed through a pre-amp 90 and a filter 92 and fed to a variable-gain amplifier 94. The output of the variable-gain amplifier 94 is an amplified response 96 that is filtered as shown at 98. The response 62 from the phase-reference detector 54 (FIG. 1) is processed through a pre-amp 80 and fed to a bandpass-tuned amplifier 82. The bandpass-tuned amplifier 82 is a conventional amplification and filtering circuit having component specifications that are selected in accordance with the modulation frequency of the chopper 24. The output of the bandpass-tuned amplifier 82 is a reference response 102. The reference response 102 and the amplified response 96 are fed into a synchronous detector 74. The output of the synchronous detector 74 is a conditioned response 104. The conditioned response 104, and a second conditioned response 106 processed from the detector response 66 in another information channel 86, are filtered as indicated at 108 and 110, respectively, and are fed into a log ratio module 112 where they are processed to produce a measurement response 114 indicative of some physical parameter of the sheet material 10. The measurement response 114, and a second measurement response 116 processed from conditioned responses 106 and 118 in information channels 86 and 88, respectively, are inputs to a remote computer 120. An additional input, indicated as 122, is used as part of a feedback loop that includes a gain-setting signal 128 delivered from the computer 120 to all variable-gain amplifiers 94, 124, and 126. The measurement responses 114, 116 may be further processed by the computer 120, which may send an adjustment signal 130 to a process control unit 132. The process control unit 132 may be any of a variety of devices used to effect a change in the measured physical parameter of the sheet material 10.
The synchronous detectors 74, 76, and 78 are conventional circuits in which a relatively strong, low-noise response may be used to condition relatively weak, high-noise responses by way of providing a reference of the general shape and phase of the latter responses in the absence of high noise. The low-noise response is the reference response 102 that is derived from the response 62 of the phase-reference detector 54.
The phase-reference detector 54 need not be incorporated in the integral package 40, but may be used in isolation therefrom as shown in FIG. 2. In an especially-preferred embodiment, the phase-reference detector 54 is separated from the integral package 40 and located along the transmission axis 60. This maximizes the response 62 of the phase-reference detector 54 while simultaneously allowing displacement of the integral package 40 from the transmission axis 60.
The method of conditioning detector responses in accordance with the response 62 from the phase-reference detector 54 is applicable to prior apparatus and processes which employ a single detector or plural, separate detectors. Especially where the conventional detector or detectors are offset from the source (i.e. displaced from the transmission axis) of radiation, this method offers an effective means for processing weak detector responses having correspondingly low signal-to-noise ratios.
While the invention has been described with reference to preferred embodiments, the description is intended as illustrative and not as restrictive. Those skilled in the art of measuring physical parameters of sheet material via infrared absorption phenomena will recognize that numerous modifications can be made without departing from the spirit and scope of the invention.
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An apparatus and process for measuring physical parameters of sheet material via infrared absorption phenomena is disclosed. The invention employs an integral filter-detector package comprising at least two optical filter-detector combinations. The package is contained within a conventional sensor housing which traverses back and forth across the sheet material. The package may comprise an additional filter-detector combination that is selected to produce a detector response having a significantly higher signal-to-noise ratio than the response of remaining detectors. The former response is used in combination with synchronous detectors to provide a reference of the general shape and phase of the latter responses in the absence of high noise.
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FIELD OF THE INVENTION
[0001] The aim of the present invention patent is a wind turbine blade with high-lift devices in the blade's root area, where there are two types of these elements: high-lift devices on the leading edge area and on the trailing edge area, so that said blade is aerodynamically optimized in its whole geometry to increase the wind turbine's energy production.
BACKGROUND OF THE INVENTION
[0002] Traditional wind turbine blades are joined to the hub in a cylindrical area known as the root, with a characteristic length of usually several meters. For most wind turbines, the function of this area is typically structural and does not significantly contribute to the wind turbine's production, as it is not aerodynamically optimized.
[0003] In the current state of the art, detachable elements in the root area, are described to improve the blade's performance. However, they are characterized by having a sharp trailing edge and a very large chord length on the joint with the root.
[0004] Thus for example, we have document WO 2007/131937 that describes a blade for a wind-power generator with a detachable element on the trailing edge detachable from the blade itself.
DESCRIPTION OF THE INVENTION
[0005] To solve the above mentioned problem mentioned, the wind turbine blade with a high-lift device is presented, object of the present patent of invention. Said high-lift devices are of two different types, according to their position and use in the blade:
[0006] (i) High-lift device of the wind turbine trailing edge area;
[0007] (ii) High-lift device of the wind turbine leading edge area;
[0008] The high-lift device of the trailing edge is a fixed part, and not mobile like in other aerodynamic trailing edge devices related in the state of the art. The trailing edge of this element is thicker than known trailing edges, obtaining a bigger lift coefficient, which at the same time allows to make the detachable element with less total length (less chord). In other words, a shorter length or chord is obtained for the same lift, with greater trailing edge relative thickness. The device also allows to make a blade with less torsion, owing to having a greater stall angle in losses at high angles of attack. This high-lift device can be part of a one-piece blade and not only as an additional or detachable element.
[0009] The leading edge's high-lift device is selected amongst:
(i) a first leading edge high-lift device, slightly curved adapted to the blade root without inflection points on its outer surface; (ii) a second leading edge high-lift device, with a smaller contact surface with the blade root and an inflection point on its outer surface, on the bottom, improving its operating performance; (iii) a third leading edge high-lift device, with a pronounced outer profile, without inflection points on the surface and a contact area with the bottom root of the first and second devices' inflection points; (iv) a fourth leading edge high-lift device, with a minimum contact area with the root, which at the same time creates a very pronounced inflection point on the outer surface of this fourth element, increasing the maximum lift coefficient;
[0014] The following technical advantages are obtained with the combined use of the two configurations (trailing edge and leading edge):
[0015] The wind turbine produces more energy, on improving the blades' aerodynamic coefficient.
[0016] Improved performance is obtained at lower ambient wind speeds, as the wind incidence angle has been improved.
[0017] The already installed blades can be used, and their production and transport is also improved and made easier.
BRIEF DESCRIPTION OF THE FIGURES
[0018] A brief description of a series of illustrations is provided below in order to better understand the invention. These illustrations are expressly listed with an embodiment of the present invention and are presented as an illustrative, but not restrictive, example of the same.
[0019] FIG. 1 is a ground plan of a wind turbine blade with incorporated high-lift devices, as described in the present invention.
[0020] FIG. 2 is a transversal section of the wind turbine blade with the first high-lift device of the leading edge installed.
[0021] FIG. 3 is a transversal section of the wind turbine blade with the second high-lift device of the leading edge installed.
[0022] FIG. 4 is a transversal section of the wind turbine blade with the third high-lift device of the leading edge installed.
[0023] FIG. 5 is a transversal section of the wind turbine blade with the fourth high-lift device of the leading edge installed.
[0024] FIG. 6 is a profile view of a wind turbine with installed high-lift devices, according to the present invention.
PREFERRED EMBODIMENT OF THE INVENTION
[0025] As can be observed in the attached figures, the wind turbine blade with high-lift devices comprises, at least, a trailing edge high-lift device ( 1 ) with a blunt end and chord (C) length of 5% to 30% less than a conventional profile for the same lift coefficient; and as the joint area radius is related to the blade's ( 3 ) root ( 4 ) radius, and to the thickness of this trailing edge high-lift device ( 1 ).
[0026] The first trailing edge high-lift device ( 1 ) can be detachable or integrated in a one-piece blade.
[0027] The leading edge's high-lift device ( 2 ) is selected amongst:
(i) a first leading edge high-lift device ( 20 ), slightly curved adapted to the blade ( 3 ) root ( 4 ) without inflection points on its outer surface; (ii) a second leading edge high-lift device ( 21 ), with a smaller contact surface with the blade ( 3 ) root ( 4 ) and an inflection point on its outer surface, on the bottom; (iii) a third leading edge high-lift device ( 22 ), with a pronounced outer profile, that maintains the clearance between it and the root so than a certain amount of air flow can pass between the intrados and extrados of the profile to energize the profile extrados' boundary layer and improve aerodynamic performance, where this third element ( 22 ) can also be mobile (rotary with respect to the center of the cylinder and known in aerodynamics as “slot”) so that it is better adapted to operating conditions set by the ambient flow with the modification of CL and α stall (iv) a fourth leading edge high-lift device ( 23 ), with a minimum contact area with the root ( 4 ), which at the same time favours a very pronounced inflection point in the outer surface of this fourth element ( 23 ), where, additionally, this fourth leading edge high-lift device ( 23 ) or slot, can be mobile (rotary, idem), so that the C L and α STALL ratio is optimized.
[0032] In the design of high-lift devices coupled to the wind turbine blade, both on the leading edge and trailing edge, as well as taking into account optimising the ration between C L lift coefficient and the α STALL angle of attack, a safety distance between the geometrical limits of the detachments and the machine itself should be taken into account.
[0033] FIG. 6 shows the embodiment of a complete wind turbine, with the tower ( 8 ), nacelle ( 9 ) and blade ( 3 ) and where the installation of these high-lift detachments is specifically shown on a wind turbine blade in which the safety distance of the different devices are graphically indicated: safety distance from the hub ( 5 ), safety distance from the nacelle ( 6 ) and safety distance from the tower ( 7 ), for a maximum chord length, so that a safety distance of around 300 mm from the nacelle, around 300 mm from the hub and around 400 mm from the tower is obtained.
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Wind turbine blade with high-lift devices in the leading edge and/or trailing edge (the latter has a relative thickness) in the root area, so that aerodynamic performance is improved and therefore the amount of energy extracted from the wind compared to traditional blades with cylindrical or oval roots.
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FIELD OF THE INVENTION
This invention relates to monitoring systems for multi-axle, heavy vehicles, such as trucks and busses, and specifically to a system which automatically identifies the number of axles and brakes on a vehicle to be monitored.
BACKGROUND OF THE INVENTION
Although the primary intended use of this invention is on large trucks and tractor-trailer combinations, it should be appreciated that the invention is also suitable for use on all vehicles which have independent brakes for each wheel, such as vehicles which generally incorporate an air-brake system. These brakes must be properly adjusted in order properly to function. Various standards have been set by state governments and the Federal Department of Transportation (DOT) to insure that brakes are properly adjusted and are therefore operable to stop these heavy vehicles when the need arises.
One standard that has been set by the DOT is a requirement that the travel of an actuator rod, which extends from a brake air cylinder to an activation arm on the brake mechanism, have a travel distance of two inches or less. A brake is deemed to be out of adjustment if the activation arm travel is two or more inches. Travel distances between 1.75 inches and two inches are considered to be marginally safe, although a travel distance of less than 1.75″ is preferable.
Newer vehicles have self-adjusting brakes. It is estimated that, at this time, approximately fifty percent of the vehicles on the road have such self adjustors. Even with the self-adjusting brakes, the slack adjustors, as they are known in the trade, will sometimes fail to operate or will become inoperative as a result of the build up of petrochemical products, dirt or ice in the slack adjustment mechanism, which allows brakes to be out of adjustment. Older vehicles do not have any self-adjustment mechanism. Regardless of whether the vehicle is equipped with slack adjustors or not, it is a requirement that the driver physically inspect the brakes on the tractor and trailer(s) to insure that they are properly adjusted and are properly operating. As might be expected, this task is not always performed, particularly in inclement weather conditions. If, however, a brake is determined to be out of adjustment, it may be quickly adjusted by the truck operator, with a minimal expenditure of energy and with the use of a few hand tools.
Vehicle brakes are inspected at check points, such as the familiar weigh stations which are found along highways. As in the case of the driver, an inspector must generally crawl under the truck to inspect the travel of the actuator arms to insure that they are in compliance with federal and state regulations. Such inspection must be done for each brake on the vehicle, which generally requires that the driver remain in the truck and operate the brakes while the inspector visually checks each brake mechanism.
A number of monitoring devices have been provided for use on trucks. Some of these monitor air pressure to determine if the brakes are operating safely, others provide a warning only after the brake travel has exceeded legal limits, while still others provide a purely visual indication which still requires the operator to visual check every brake on the truck.
There have been a few attempts to build and market such systems in the industry, however, all known systems suffer from one or more serious defects. Some require extensive and expensive modifications to the vehicle and brake system, others are difficult or inconvenient to use, and still others are not readily adaptable to the wide variety of axle configurations found on modern trucks.
What is needed then is a automatic brake-travel monitoring system that is simple and reliable, easy for the operator to use, is inexpensive to install and maintain, and is readily adaptable to various axle configurations.
U.S. Pat. No. 5,285,190 for Automatic slack adjuster with operation and adjustment monitor, to Humphries, et al., granted Feb. 8, 1994, disclosed an automatic slack adjustor which incorporates a monitoring system alerting the vehicle operator that a brake somewhere on the vehicle is not operating properly, or is out of adjustment, but does not provide any mechanism for identifying the specific brake that is out of adjustment, nor does the system identify any quantitative information about a particular brake.
U.S. Pat. No. 4,937,554 for Electronic brake monitoring system and method, to Herman, granted Jun. 26, 1990, provides a monitoring system which incorporates a push rod oscillator-type sensor to provide an analog output which is related to the push rod extension distance, which output is used along with pressure in the brake system to determine whether or not a brake is operating properly.
U.S. Pat. No. 4,800,991 for Brake maintenances monitor to Miller, granted Jan. 31, 1989, discloses a system which utilizes a mechanical flag to provide an indication that the brake actuator arm has exceeded its safe distance. Additionally, an electronic warning device is provided which will momentarily provide a warning light on the dashboard of the vehicle.
U.S. Pat. No. 5,433,296 for Brake monitoring system, to Webberley, granted Jul. 18, 1995, discloses a system which provides a readout to an operator of a motor vehicle.
SUMMARY OF THE INVENTION
A brake monitoring system for use on a motor vehicle, wherein the vehicle includes plural, powered brakes mounted adjacent a wheel carried on an axle, and wherein each brake include a brake actuator shaft and a mechanism for shifting the brake actuator shaft between a brake-off position and a brake-applied position includes a sensor connected to each brake actuator shaft on the motor vehicle for monitoring the position and travel of the brake actuator shaft and for generating and transmitting a brake condition signal representative of a safety condition of the brake associated with the brake actuator shaft, wherein said brake condition signal includes quantitative information about the length of travel of the brake actuator shaft; a data processor carried in an axle box associated with each axle and connected to sensors associated with brakes for the axle for receiving, interpreting, storing, and upon request, transmitting said brake condition signal, wherein each data processor includes an auto-address mechanism to identify its position on the vehicle; and a master station, wherein said master station includes a display for identifying a particular vehicle brake, a quantitative indication of the travel on the brake actuator shaft associated with the particular brake, and wherein said visual indicating devices include plural indicia which are indicative of said safety condition of a particular brake, including visual and auditory indicating devices connected to said data processor for warning a vehicle operator of said safety condition of the brakes on the vehicle, wherein said visual indicating devices provide both quantitative and qualitative output to the motor vehicle operator for every brake on the vehicle, wherein said master station includes a function selector located in said master station for selecting the various axles on the vehicle for display of brake condition for a selected axle.
It is an object of the invention to provide a brake monitoring system for heavy vehicles which is adaptable to new and old vehicles.
Another object of the invention is to provide a monitoring system which will automatically identify and address all brakes on a vehicle to be monitored.
An object of the invention is to provide an automatic brake-travel monitoring system that is simple and reliable, easy for the operator to use, is inexpensive to install and maintain, and is readily adaptable to various axle configurations.
An object of the instant invention is to provide a brake monitoring and warning system which will provide a continuous check on the safety condition of the brakes on the vehicle.
Another object of the invention is to provide a system which provides a remote visual and auditory warning if a brake is out of adjustment.
A further object of the invention is to provide a system which provides a quantitative display of the travel of any given brake on the vehicle and provides information to the operator as to the overall operating condition of the brake system for the vehicle.
This summary and objectives of the invention are provided to enable quick comprehension of the nature of the invention. A more thorough understanding of the invention may be obtained by reference to the following detailed description of the preferred embodiment of the invention in connection with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a brake monitoring system of the invention.
FIG. 2 depicts a master station of the system of the invention.
FIG. 3 depicts a sensor mounting scheme of the system of the invention.
FIG. 4 depicts a cross-section of a sensor of the invention.
FIG. 5 is a schematic of sensor interface electronics.
FIG. 6 depicts a typical sensor transfer function.
FIG. 7 depicts a basic addressing circuit of the system of the invention.
FIG. 8 depicts a variation of an addressing circuit of the system of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There are three features of the system of the invention described herein. The first is a brake-travel monitoring system, which is applicable to a vehicle having any number of axles. The second is a sensor installed adjacent a wheel to monitor brake travel. The third is an automatic and adaptive addressing system for monitoring individual brakes in a multiple axle vehicle.
Brake Travel Monitoring System
It is desirable to monitor heavy vehicle brakes for safe operation. In large trucks, fairly common and very dangerous situations occur when one or more of the wheel brakes become inoperative. This is usually a result of failure of the automatic brake slack-adjusting mechanism, or failure of a driver to insure proper brake adjustment. When excessive brake travel occurs, eventually the brake shoes no longer properly contact the brake drums, and the brakes become inoperative.
The key symptom of this problem is excessive travel of the brake actuation linkage. For normal bake systems, travel distances of two inches or more indicate failure of the slack-adjusting mechanism.
The system of the invention described here in includes of three major components:
1. a brake-travel sensors—one for each brake actuator, typically two per axle; 2. a brake sensor “axle box”—one per axle; and 3. A “master station”—the control/display for the system, which is normally mounted in the driver's or operator's area.
The system of the invention is a brake monitoring system for use on a motor vehicle, wherein the vehicle includes plural, powered brakes mounted adjacent a wheel carried on an axle, and wherein each brake include a brake actuator shaft and a mechanism for shifting the brake actuator shaft between a brake-off position and a brake-applied position.
The design of the system is modular. A minimum package, in the preferred embodiment, includes a master station and axle boxes and sensors for a 2-axle vehicle. The customer purchases enough additional axle kits (one per axle) to match the requirements of the vehicle and trailers.
FIG. 1 is a schematic diagram of the system of the invention, generally at 10 . The system of the invention includes a master station 12 and a brake pedal sensor 14 , usually located in the vehicle cab, adjacent the driver. Associated with each axle is an axle box, AB 1 , AB 2 , AB 3 , . . . ABn. Each axle box has plural connections, and contains, in the preferred embodiment, auto addressing circuitry and sensor interface circuitry. An “upstream” connector 16 goes to either the master station, if the axle box is for the first axle, or to a “downstream” connector 18 of the next axle box forward. “Downstream” connector 18 goes to the next axle box to the rear, if present. Each axle box also has connectors 20 , 22 , which are connected to brake travel sensors 24 , associated with each brake on an axle. In the case when an axle has more than two brakes thereon, additions connections are provided to the axle boxes. This forms a “daisy-chain” including the master station and the axle boxes. Connections between the tractor and trailers are made by using longer cables with quick-disconnect connectors, similar to that currently used for trailer lights and other monitoring systems found on some trailers.
Each axle box contains a local microcontroller, e.g., a microprocessor or a data processor. This microcontroller automatically and continuously reads the brake actuators position's via sensors 24 , and stores them in an internal memory. The microcontroller also keeps track of the highest and lowest readings since the last initialize. The microcontroller monitors the incoming messages from the “upstream” cable. A feature of the axle boxes is that they can sense their position in the chain of axles boxes downstream from the master station, and assign themselves addresses, i.e., an auto-addressing function. Thus, communications is “daisy-chained” from the master station through however many axle boxes there are, and be written to or read from only the intended device.
The axle boxes and the daisy-chain cables there between are mounted to the bottom of the trailers, above the related axles. Cables from the sensors are routed from the axle to the bottom of the trailer, following the routing of existing brake airlines, and connected to the axle boxes.
Referring now to FIG. 2 , a master station of the system of the invention is depicted generally at 30 . The master station includes, in the preferred embodiment, a power switch 32 , a system check switch 34 , and a graphical display 36 . Graphical display 36 includes a depiction of a tractor 36 a and of the axles and wheels 36 b on attached trailers. An audible warning device 38 may be activated by on/off switch 40 . A numeric display 42 provides an indication of any axle 44 , and the left 46 and right 48 brake actuator travel for that axle, which are selected by right/left selector switch 50 . Graphical display 36 and numeric display 42 are collectively referred to herein as a master station display.
When master station 30 detects that the brake pedal has been pushed upon receipt of a signal from brake pedal sensor 14 , it sends a message to each axle box requesting it to respond with brake travel information. The axle boxes respond by sequentially sending, or transmitting, brake travel information, in the for of a brake condition signal, which is an indication of a safety condition of the brakes associated with the axle box, which brake condition signal includes quantitative information about the travel length of the associated brake actuator shaft, to master station 12 . This reading and sending continues as long as the brakes are actuated. As the information is received by the master station, it is presented on display 36 , wherein each wheel illuminates as an indication of a brake actuator travel, e.g., in the preferred embodiment, each side of each axle is indicated by 3-color LED indicators. These indicators will glow green for normal travel detected, yellow for marginal travel indication, and red for over-the-limit travel. The master station also checks the incoming information against over travel-alarm limits, and indicates any brake which has marginal or excessive travel on the display. Display 36 is automatically updated depending on the number of axles sensed by the master station via the daisy-chain interconnect system. Once the brakes are released, maximum travel information for all axles is retained, so the operator may check the “Axle Readings” display for each wheel, if desired, at a later time. Audible warning device 38 may take the form of a buzzer or other audible indicator, and is set to sound when any wheel has over-limit travel detected, or when a wheel is within e.g., 20% of its over-limit minimum.
Once properly adjusted brakes are released, the LED indicators will go out, however, any wheels with marginal or over-limit indications will continue to be illuminated. Other arrangements for the operators console are possible. In particular, LCD and electro-luminescent displays may be use.
Master station 12 includes a number of microprocessors which provide for operation of the system. At power-up, or whenever system-check button 34 is pressed, a complete system check is performed by the master station. This check determines how many axle boxes are connected, and if reasonable values are returned from all the sensors. Messages with the results are displayed on the panel.
The entire daisy-chain, master station, and all axle boxes operate at low voltage and current, e.g. ˜12V, and draw less than 1 A total for the entire system. Changes in the number of axle boxes present, as when trailers are added or removed, are automatically sensed by master station 12 , which automatically reconfigures display 36 and assigns new addresses to the axle boxes. No setup or other action by the operator is ever required.
Long-term data collection may be stored in an internal memory in master station 12 , for providing driver diagnostics and accident investigation, e.g., a “Black Box” function. A provided black box has sufficient memory for retaining at least thirty days worth of data about the system. The system of the invention is equipped with a wireless, remote reading capability, which allows inspectors and law enforcement officer to interrogate master station 12 to determine the condition of vehicle brakes. Additionally, in vehicles equipped with satellite communication and monitoring systems, the monitoring system of the invention information, including diagnostic information, may also be provided through satellite communications. In most instances, power is applied to master station 12 upon vehicle startup, and interlocks are provided to prevent driver disablement of the system.
Diagnostics are provided to alert a driver of brake timing and sequencing. A variation of the system of the invention incorporates modified communications between the master station and the axle boxes to use emerging “standardized” truck electronics communications protocol. Other variations of the system of the invention include custom versions for vehicles having more than the maximum number of axles, or for vehicles having more than two brake actuators per axle, or for factory built-in options.
Sensor Mounting
Referring now to FIGS. 3 and 4 , sensor 24 of the system of the invention is depicted in detail, in a mounted environment in FIG. 3 , and in cross-section in FIG. 4 . Sensor 24 is specifically designed to be an add-on, to facilitate installing the brake monitoring system on existing vehicles. As shown in FIG. 3 , an air cylinder mount 52 is a conventional and standard part of a tractor/trailer, or other pneumatic-brake equipped heavy vehicle. An air cylinder 54 is conventionally carried on mount 52 and connected by an air hose 55 to the vehicle pneumatic system. Air cylinder has a brake actuator shaft 56 extending therefrom, which is connected through a linkage 57 to a brake shaft 58 . Shaft 58 operates a mechanism which forces brake pads against a brake drum (not shown), which is used to slow or stop the vehicle. The components of the system of the invention are carried on a sensor bracket 60 , which is attached to mount 52 . Sensor 24 has one end thereof fixed to sensor bracket 60 , and the other, movable end, attached to sensor linkage 62 , which is attached to brake actuator shaft 56 . The components of the system of the invention in no way affect the operation of the brakes on a vehicle on which they are mounted. Sensors 24 are physically mounted to brake actuator shafts 56 , so that sensor 24 directly reads the movement of the actuator shafts.
Sensor Construction and Operation
Sensor 24 , and now referring to FIGS. 3 and 4 , includes a sensor housing 64 , which encloses a sensor core, or arm, 66. A sensor attachment 68 is located at one end thereof, and sensor arm, 66 includes a movable attachment point 70 at the other end thereof. Sensor arm 66 moves within a coil form 72 , and is guided by a bushing 74 and a seal 76 . A coil 78 is disposed about coil form 72 , and the coil, coil form and sensor arm are encapsulated 80 within housing 64 . A cable 82 connects each sensor to its associated axle box.
The embodiment of sensor 24 described herein is specifically intended for use in the brake monitoring system of the invention, however, it is applicable to other situations calling for a position sensor with the following characteristics, which are found in the preferred embodiment of sensor 24 : moderate accuracy, e.g., +/−0.010″, (may be fabricated to more precise standards if required); moderate travel distance for sensor arm, e.g., between about 0″ to 6″, and easily adjustable; very inexpensive, e.g., estimated to cost about $10.00 per sensor unit; provides an easy interface with a variety of master control units; can accommodate imprecise mounting and/or non-linear motion; insensitive to temperature, humidity, vibration, light, nearby metal surfaces, etc., and suitable for use in extreme environments.
Known position sensor technologies fail to meet one or more of the forgoing criteria. For example, linear optical encoders are fragile and must be carefully protected and shielded. Linear variable differential transducer (LVDT) sensors meet some of the above requirements but are expensive. Proximity sensors are limited to very short sensing distances and are affected by nearby metallic objects. Ultrasonic sensors cannot easily be used at these shorter distances and are affected by dirt, moisture, or other contaminants on the reflecting surface.
Optical sensors can be obscured by dirt or moisture. Linear or rotary (with linkages) potentiometer are easily damaged by dust or moisture, etc. Hall-effect sensors have limited operating range, and are temperature sensitive, etc.
The sensor of the system of the invention uses variable inductance of an iron-core coil. These iron or ferrite core coils are variable, in order to tune or change the frequency or time-constant of associated electronic equipment; e.g., to tune the frequency of the local oscillator in a radio receiver.
The operation of this sensor is explained in connection with FIGS. 3 and 4 , and in the context of a brake monitoring system for heavy vehicles. Sensor 24 coil 80 is of a length slightly longer than the travel distance to be sensed. Sensor arm 66 is arranged in bushing 74 , or mounted in a bearing, such that it can move into (brake-off position), or out (brake-applied position) of, coil form 72 with the “fully-in” position corresponding to one measurement limit, and the “fully-out” position corresponding to the other measurement limit. The amount of sensor arm 66 which is within the coil determines the inductance of the coil. The associated interface electronics measures this inductance to determine this amount, and thus the distance to be measured.
There are a number of ways to electrically measure the instantaneous inductance of such a coil. One method, which is used in the preferred embodiment, is to apply a voltage across the coil and measure the rise-time of the current. A schematic of such an interface circuit is depicted in FIG. 5 , generally at 90 , which circuit is contained with an axle box, in the preferred embodiment. Circuit 90 includes a control logic portion 92 , likely a separate integrated circuit, or formed on an IC with a microprocessor 94 . A switch transistor 96 opens and closes the circuit, which includes a sensor 24 in parallel with a diode 98 and a resistor 100 combination. A sense resistor 102 and a comparator 104 complete this embodiment of the interface circuit.
Initially “Switch On” signal 106 is inactive. Therefore, switch transistor 96 is off, and no current flows through the sensor or sense resistor 102 . The voltage at the +input of comparator 104 is thus 0V, and the comparator output is low.
At periodic times, set in master station 12 according to how often the sensor is to be read, a “Start” signal 108 pulses high. This causes control logic 92 to set “Switch On” signal 106 high, or true. This turns switch transistor 96 on, and current begins to flow from the +5V supply through sensor 24 and sense resistor 103 . Current starts at zero, and gradually builds according to:
I =5 V/R *(1 −e −(tR/L) ) (1)
where t is the elapsed time since “Start”, R is the combined resistance of sense resistor 102 and sensor 24 , and L is the inductance of sensor 24 .
As the current builds up, a voltage drop results across sense resistor 102 . At some later time, as determined by the value L of sensor 24 , the voltage across sense resistor 102 is equal to V ref , which in this case is +2V. At that instant in time, the comparator output switches high, e.g., signal “Switch Off”, which causes control logic 92 to terminate the “Switch On” pulse. The output of sensor interface circuit 90 is the “Switch On” signal, and it can easily be seen that for every “Start” pulse, there will be a pulse on the “Switch On” signal whose length is proportional to the time it takes the current in sensor 24 to build up to a known value, determined by V ref . This time in turn is proportional to the value of the inductance of sensor 24 , and thus to the position of the arm 66 in sensor 24 . Discharge resistor 100 and diode 98 serve to discharge the current in the inductor (coil 78 ) after the end of the “Switch On” period, preparing circuit 90 for the next “Start” pulse.
As incorporated into the monitoring system of the invention, all of circuit 90 , except sensor 24 , is located in an axle box. The microcontroller in the circuit emits the “Start” pulse, and at the same time starts a digital timer. At the end of the “Switch On” period, the value in the digital timer can be read, and converted to a position measurement by the microcontroller. In other applications for the sensor, this function may be performed by some other microcontroller, microprocessor, or dedicated logic.
There are other methods of reading the variable inductance than interface circuit 90 , which is only one embodiment. For example, the coil may be driven with a sine wave connected to a resistor, wherein the frequency roll-off point is proportional to the inductance. Other shapes of coils, and other types of core materials, such as ferrite, may be used.
A typical sensor transfer function is shown in FIG. 6 , depicting a position vs “Switch On” time (in microseconds) for a sensor having a nominal travel of two inches. As can be seen, the time vs position curve is not a straight line, however, it is a simple curve which may easily be linearized by the microcontroller or system software. The reading system of the system of the invention is simple, robust, and has very low sensitivity to external variables. It is nearly insensitive to temperature changes and has a low sensitivity to power supply fluctuations and noise, because such variations tend to be averaged out by the inductor. The sensor itself connects to the axle box via 2-wire cable 84 , which may be shield cable or non-shielded cable, which is also is insensitive to noise. Accuracy is determined primarily by the uniformity of the sensing coil, the material of the iron core of arm 66 , which, in the preferred embodiment, is formed of 416 stainless steel, the value of the Sense Resistor, and of V ref . All these things are easily controlled, and provide an accuracy better than 0.010 inches. Higher accuracy may be achieved by finer tolerance coil fabrication. Vibration, moisture and dirt, and other environmental issues have little or no effect on sensor 24 , unless they become so severe as to physically inhibit the motion of the arm 66 in coil 78 , which restriction may easily be prevented by seal 76 .
There are no expensive, or difficult-to-fabricate, components in the sensing system. The physical components of the sensor itself are primarily the coil, sensor arm, and housing, all of which are readily adaptable to automated manufacturing. The coil, for example, in the preferred embodiment, is a two-layer winding of 30-gauge wire having 400 turns. The electronic interface components are simple and inexpensive. If other applications require a separate microcontroller to manage the sensor, a very simple one, about one dollar, is more than adequate.
Automatic and Adaptive Addressing System
The problem of addressing variable numbers of axle controllers in a brake-travel monitoring system of the invention is a general one applicable to any system having a single master station and many slave stations in which a “daisy-chain” interconnect system is used.
If a master station is required to communicate with a number of slave stations, there needs to be some means of identifying for which slave station a particular communication is intended. This need applies to the master station and slave stations equally, which need to know when a particular communication is intended for them. Typically, this problem is solved by establishing a unique address, or designator, for each slave station. Thus, when a master station sends a message to, or requests a read from, e.g., slave station #3, only the device with the address of “3” will respond. This problem does not exist if the master station has a unique connection to each slave station. However, such a system is relatively expensive because it requires a number of parallel cables and slave station connections. More common are communications in which either there is a common “party-line,” to which all the slaves stations are connected, e.g., EtherNet®, or systems which are “daisy-chained,” wherein each slave station receives a connection from an “upstream” device and passes a connection to a “downstream” device. The current invention incorporates, in the preferred embodiment, a “daisy-chain” protocol.
Most daisy-chain protocol systems require some explicit action in order to select and assign addresses to each slave station. Typical methods of doing this are via unique EPROM-based serial numbers, as used by most EtherNet® devices, or by “dip-switches,” as used by general purpose interface bus (GPIB) systems.
The system of the invention, as described above for a brake travel monitoring system, has additional constraints. One of the most important is that the daisy-chain interconnect between the master station and first downstream slave station, and between slave stations themselves, use a cable with a minimum number of wires. For the same reason, all cables are identical in the system. The system is self-configuring, so that the addressing of entities in the daisy-chain, such as axle boxes, require no action by the user/operator, and ideally no action by the master station. The system of the invention disclosed herein meets these objectives.
In the preferred embodiment, a protocol wherein a signal is sent from the master station to the first slave station, i.e., AB 1 , is used. The slave station reads the signal and determines that it is the first device in the chain based on the content of this signal. The slave station then modifies this signal and sends it on to the next downstream slave station. The next slave station reads the signal, and based on the signal modification noted above, determines that it is the second device in the chain. The slave station makes an identical modification to the signal and sends it downstream to the third element in the chain, etc. The characteristics of the signal are such that repetitive modifications of an identical nature result in unique and predictable changes. There are a number of ways to do this, but based on the “minimum number of wires” constraint, it is clear that a system that requires only one additional wire to the daisy-chain interconnect is desirable. Systems which are capable of performing this protocol are analog and serial-digital protocols. The preferred embodiment described herein uses an analog protocol, which is the simpler case of the two, and which will be described in greater detail later herein.
The serial-digital protocol is, however, equally feasible, and is readily implemented by one of ordinary skill in the art, e.g., the master station may send, via an RS232-type protocol, or any other serial protocol, a digitally-encoded number, such as “0” to the first slave station. The first slave station adds “1” to the number, and sends it to the next slave station, which in turn adds “1” to the number, and sends it to the third slave station, etc. Once this protocol has been implemented, each slave station will “know” it's address, based on how many slave stations are upstream from it. While this protocol is completely practical, it does require that a digital serial interface be replicated between each slave/master station. This is not particularly simple, and may require a considerable amount of additional software in the microcontroller of each slave station. Also, it may not be used in a system lacking a complicated state machine or microcontroller in each slave station.
The analog protocol embodiment of the system of the invention does not have the complexity of the serial-digital protocol. In the analog protocol, a known voltage is sent down a single “addressing” wire from the master station, e.g., 10.0 VDC. The first slave station reads this voltage, and notes that because the voltage has a value of 10V, the slave station must be the first slave station in the daisy-chain. Each slave station subtracts a fixed voltage from the input, and sends the resulting voltage on to the next slave station. Each slave station may determine, from reading the voltage, how many slave stations are between it and the master station, and thus determine its address. In practice, a simple way to subtract a fixed voltage is to insert a diode and buffer between the “addressing-in” and “addressing-out” ports of the slave station. This results in the voltage on the addressing-out line to the second slave station to be 10.0V-0.65V (typical diode drop), or 9.35V.
The second slave station will look this up, either digitally, after an A/D conversion, or via analog comparators, and determine that it has as an address #2. It will again subtract, via a diode, another 0.65V, resulting in a voltage of 8.7V, and send the signal to the third slave station, etc. A schematic of a basic addressing circuit in a slave station of the system of the invention is shown in FIG. 7 , generally at 110 . Circuit 110 includes a comparator 112 , a diode 114 and a resistor 116 . To function properly, diode drops and/or other subtracted voltages must be predictable. Conventional silicon diodes have forward drops that are approximately constant, and depend primarily on temperature, with a slight variation related to current flow. For systems with a small number, e.g., four, of slave stations, these effects may be ignored. In systems with a higher number of slave stations, it is necessary to keep these forward drops predictable and constant.
A simple modification to the addressing circuit of the system of the invention is depicted in FIG. 8 , generally at 120 , and allows the microcontroller to measure a typical diode drop, and to use this value to correct for actual diode drops. Another part of this embodiment of the system of the invention includes replacing resistor 116 with a current source 122 , and providing a diode 124 between a +5V source and microcontroller 94 . By using current source 122 , all diodes in the daisy chain operate at approximately the same current. Because the axle boxes are on the same vehicle, the diodes are all at approximately the same temperature. Diodes of a similar type, operating at similar currents and temperatures, all have very similar voltage drops. Diode 124 and current source 122 are used as a reference by microcontroller 94 , which measures the voltage drop across diode 124 , and uses the voltage drop and the incoming voltage to calculate the current address. Essentially, the microcontroller subtracts the incoming voltage from +10V, in this example, and divides the difference by the measured diode drop. This tells the microcontroller how many axle boxes are present between it and the master station, and thus allows the microcontroller to know its address.
Additional features may be incorporated into the system of the invention, such as buffering at the output instead of the input of each slave station; some means other than a diode used for subtracting fixed voltages; use of comparators to read the voltage instead of an A/D channel of a microcontroller, and measurement of current versus voltage on the addressing wire.
Thus, a brake monitoring system for heavy vehicles has been disclosed. It will be appreciated that further variations and modifications thereof may be made within the scope of the invention as defined in the appended claims.
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A brake monitoring system for use on a motor vehicle includes a sensor connected to each brake actuator shaft on the motor vehicle for monitoring the position and travel of the brake actuator shaft and for generating and transmitting a brake condition signal; a data processor carried in an axle box associated with each axle and connected to sensors associated with brakes for the axle for receiving, interpreting, storing, and upon request, transmitting the brake condition signal, wherein each data processor includes an auto-address mechanism to identify its position on the vehicle; and a master station, wherein said master station includes a display for identifying a particular vehicle brake, a quantitative indication of the travel on the brake actuator shaft associated with the particular brake, and wherein said visual indicating devices include plural indicia which are indicative of said safety condition of a particular brake.
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[0001] This application is a national stage completion of PCT/EP2006/009903 filed Oct. 13, 2006, which claims priority from German Application Serial No. 10 2005 050 489.2 filed Oct. 21, 2005.
FIELD OF THE INVENTION
[0002] The invention concerns a control valve arrangement for controlling a starting clutch of an automatic transmission of a motor vehicle.
BACKGROUND OF THE INVENTION
[0003] In automatic transmissions with an automated wet starting clutch, in order to activate a mechanical emergency transmission operation function, for example in the event that a transmission control unit has failed, it is usual for the force-flow linkage in the transmission to be eliminated by virtue of the fact that when not energized, the starting clutch is shifted to its disengaged condition. Especially in vehicle conditions typical of flowing traffic, this strategy can lead to critical situations, since the vehicle can only coast forward without any positive propulsion drive.
[0004] For technical reasons related to safety, engaging the wet starting clutch in such a driving situation is also not possible, since the force-flow linkage can only be obtained by way of a hydraulic clutch actuation pressure. Inasmuch as when the speed of the vehicle is reduced with the clutch engaged, the vehicle's engine will stall, there still remains some residual vehicle speed, but some important auxiliary aggregates, such as braking force enhancers or steering assistance pumps normally driven by the engine, can no longer be sufficiently powered.
[0005] In automatic transmissions with a dry starting clutch, when the mechanical emergency operation function is activated, this clutch is engaged so that the vehicle's drive output remains in driving connection with the engine until the vehicle comes to rest. Although no critical driving situations arise because of this, once the vehicle has stopped, it can no longer be moved or pushed out of the way.
[0006] Consequently, there is need for a control device for a starting clutch of an automatic transmission of a motor vehicle which, depending on the engine speed and/or the drive output speed of the transmission, interrupts the force-flow linkage in the drivetrain only when the engine speed or transmission output speed falls below a certain value so that the vehicle's engine does not stall, the auxiliary aggregates remain powered and it is still possible for the driver to drive safely away from any danger area that there may be. In addition, such behavior also allows the vehicle to be moved after coming to rest, since the force flow, between the engine and the transmission, is then interrupted.
[0007] Against this background, a hydraulic emergency control system for a belt-type transmission is known from DE 199 43 939 A1 in which a clutch, associated with the transmission, can be disengaged or engaged, depending on the speed of a vehicle drive engine. In this way, in the event of a failure repeated stalling of the drive engine, when the engine speed falls below a certain limit value, can be avoided and starting when the speed rises above a certain value is made possible. Depending on the design of this emergency control system, the engine-speed-dependent control signal can be produced and used as a hydraulic pressure, a pneumatic pressure or an electric voltage.
[0008] In addition, a method for controlling an emergency shift program for an automatic transmission with a starting clutch is known from DE 102 38 104 A1, which is especially designed to enable emergency running, even when the vehicle is at rest, and to prevent the engine speed from falling below a stalling threshold. In this method, it is provided that the emergency shift program is actuated by a signal that depends on the vehicle's speed and/or its engine speed. The signal is processed by a valve logic system and has the effect that in thrust operation the force linkage to the engine is interrupted in time to prevent stalling of the vehicle's engine.
[0009] Furthermore, a dual-clutch transmission is known from DE 103 38 355 A1, which has a first and a second clutch such that for normal operation to engage/disengage the first clutch, a first hydraulic system and to engage/disengage the second clutch, a second hydraulic system controlled by an electronic system are present. In addition, a status-maintaining hydraulic system is provided to which status signals corresponding to the momentary shift condition of the first and second clutches are passed, via a first and a second hydraulic line, and which is connected by hydraulic control lines to the first and second hydraulic systems. If the electronic system should fail, the status-maintaining hydraulic system controls the first and second hydraulic systems in such a manner that at least in many shift conditions of the two clutches, the shift condition of the clutches that existed immediately before the electronic failure is maintained.
[0010] Finally, from DE10 2004 020 569,8 which was not published before the filing date of the present patent application, a control valve arrangement for controlling a starting clutch of an automatic transmission is known with which, in a simple, inexpensively produced and reliable manner, in an emergency control situation the starting clutch can be disengaged if the engine speed and/or the drive output speed of the transmission or the driving speed of the vehicle fall below a predetermined value.
[0011] This control valve arrangement comprises a clutch control valve for controlling at least one clutch actuation device which, during normal operation of the transmission, converts a supply pressure delivered to it as a function of a pilot pressure or an electric pilot signal, into a clutch actuation pressure to control the clutch actuation device. The control valve arrangement is also characterized in that to realize emergency transmission operation, if the pilot pressure or the electric pilot signal should fail then, as a function of the engine speed and/or the drive output speed, an activation pressure can be delivered to the clutch control valve or directly to the clutch actuation device, where the clutch is kept in the engaged position so long as the speed remains above a predetermined limiting speed value.
[0012] This valve arrangement provides a control device for the emergency driving operation of a vehicle with an automatic transmission that can be produced inexpensively and operated reliably and which is activated, for example when an electronic transmission control unit and/or an electrically actuated clutch control valve fails. The engine-speed-dependent and/or transmission-output-speed-dependent control pressure then ensures that a starting clutch of the automatic transmission remains engaged in order to transmit torque through the transmission so long as the driving speed and thus the speed of the drive engine does not fall below a stalling speed at which the engine's function as a combustion engine would cease.
[0013] During such emergency driving operation, if the driving speed falls so much that there is a risk of stalling if the starting clutch remains engaged, then by way of the speed-coupled control pressure, the known control valve arrangement disengages the starting clutch which was until then transmitting torque. This advantageously avoids stalling of the engine so that important auxiliary vehicle aggregates, such as a braking force enhancer and a steering assistance pump, can still be powered by the engine without problems.
[0014] Although this known control valve arrangement works very well, it has nevertheless been found that in some operating situations its function is disadvantageous and, therefore, requires improvement. For example, an operating situation of a vehicle can arise in which it has first been moved in a forward or reverse gear with an engine speed above the limiting speed value. In this type of operation, a self-holding valve of the control valve arrangement to be improved will have been actuated by the speed-dependent pressure as described.
[0015] Now when starting from this driving operation mode, the vehicle is stopped but the engine speed is still kept above the limiting speed value, the self-holding valve remains in a position such that if the pilot pressure fails, emergency operation with a starting clutch then to be engaged is enabled. However, this system behavior persists when the starting clutch is disengaged by a corresponding selector lever actuation from the forward drive selector lever setting D or from the reverse drive selector lever setting R to the transmission selector lever setting neutral or the parking setting P and in the transmission the most recently used gear remains engaged.
[0016] Inasmuch as in such a situation the pilot pressure is absent, the known control valve arrangement engages the starting clutch and the vehicle starts off with a jerk, because of the comparatively high engine speed, although since the selector lever position is at neutral, the vehicle's driver is not prepared for this. For safety reasons, such behavior of the known control valve arrangement should be prevented.
[0017] Accordingly, the purpose of the invention is to propose a control valve arrangement of the type in question with which unintentional initiation of an emergency operating function can be avoided.
SUMMARY OF THE INVENTION
[0018] According to the claims, the starting point of the invention is a control valve arrangement for controlling the actuation of at least one starting clutch of an automatic transmission of a motor vehicle, in each case having a clutch control valve through which a supply pressure can be passed into a pressure chamber of the respective clutch actuation device, with a pressure regulation valve that produces a controlled pilot pressure, that can be actuated by an electronic control unit and supplies a control valve of the control valve arrangement with the pilot pressure, and with a self-holding hydraulic system with whose help, if the electronic control unit fails and the pilot pressure is therefore absent, the shift condition of the at least one clutch actuation device that existed before the failure of the electronic control unit is maintained in the sense of an emergency operating function, at least in many operating situations.
[0019] To solve the technical problem described, in this control valve arrangement according to the invention, it is first provided that the self-holding hydraulic system for realizing the emergency operating function comprises a self-holding valve and an actuation valve. The self-holding valve is designed to be suitable for passing on to the actuation valve an actuation pressure as a function of an engine-speed-dependent control pressure and the actuation valve is capable of passing the actuation pressure to the at least one clutch control valve. Moreover, the control valve arrangement is provided with means whereby, in certain operating situations, activation of the emergency operating function can be prevented despite the absence of the pilot pressure and the presence of an engine-speed-dependent control pressure sufficiently high to produce the emergency operation function.
[0020] This control valve arrangement according to the invention, therefore, activates an emergency operation mode of the vehicle in the event that an associated electronic control unit fails, or prevents such activation, in a manner appropriate for the vehicle's operating situation at the time.
[0021] A particular operating situation in which, according to the invention, despite a failure of the electronic control unit or absence of the pilot pressure for the valves, and despite a drive engine speed that is above an established limiting value, the at least one starting clutch is not engaged, exists when the motor vehicle is first driven normally forward or in reverse in drive settings D or R with its starting clutch engaged or slipping and the vehicle is then stopped and the starting clutch has been disengaged by moving the transmission selector lever to the neutral or parking position P of the selector lever while a gear is engaged in the automatic transmission. In this way, if a gear is still engaged and the starting clutch is disengaged, the latter is prevented from automatically engaging and taking the driver by surprise.
[0022] According to a further preferred development of the invention, the control valve arrangement is designed such that if the particular operating situation exists, then to prevent activation of the emergency operating function, a hydraulic connection for the actuation pressure, between the self-holding valve and the actuation valve, is engaged.
[0023] In a concrete structural embodiment, it can be provided that the actuation valve, formed in a so-termed valve casing of an electro-hydraulic transmission control unit, can be acted upon by a neutralizing pressure which, in the absence of the pilot pressure, can be passed from the actuation valve to the self-holding valve in such a manner that the self-holding valve blocks the onward passage of the actuation pressure to the actuation valve.
[0024] The neutralizing pressure is provided by an electro-mechanically actuated valve that can be controlled by the electronic control unit. If the electronic control unit has failed, but the aforesaid critical operating situation is not present, activation of the emergency operating function in which the starting clutch is or remains engaged may be desired. Since failure of the electronic control unit also means that the electro-mechanically actuated valve that produces the neutralizing pressure is no longer controlled by it. There is also no neutralizing pressure at the actuation valve. Thus, in the presence of a sufficiently high engine-speed-dependent control pressure, i.e., under the control of the self-holding and the actuation valves, pressure medium can get to the clutch actuation device via the clutch regulation valve and the starting clutch can be engaged.
[0025] In an advantageous design, it can be provided that the neutralizing pressure can be passed into a pressure chamber of the self-holding valve delimited by an axially movable control piston by way of which the onward passage of the actuation pressure, between the self-holding valve and the actuation valve, can be interrupted. In this case, the pressure chamber is preferably that in which a restoring spring of the self-holding valve that acts upon this control piston is located.
[0026] According to another embodiment of the invention, the control valve arrangement comprises a cut-off valve by way of which the pressure medium at the speed-dependent control pressure can be drained into a pressure medium tank when the neutralizing pressure acts on the cut-off valve.
[0027] In a concrete embodiment of this second embodiment of the invention, it is provided that the neutralizing pressure can be passed into the pressure chamber of the cut-off valve that is remote from the restoring spring, where this neutralizing pressure can act upon a servo-piston of the control valve-slide of the cut-off valve. In addition, it is provided that the speed-dependent control pressure is passed, via a line, from the self-holding valve to another pressure chamber of the cut-off valve. Finally, the control valve-slide of the cut-off valve comprises a servo-piston which, when the neutralizing pressure acts on the valve-slide, opens a connection between a pressure chamber of the cut-off valve that can be drained and the pressure chamber of the cut-off valve that is acted upon by the speed-dependent pressure.
[0028] Furthermore, in another embodiment it can be provided that the cut-off valve has a pressure chamber in which a restoring spring that acts on the control valve-slide is arranged, that this pressure chamber is connected, via a line, to the pressure medium tank; that a one-way valve, which blocks in the direction toward the cut-off valve, is arranged in the line and that a hydraulic throttle is arranged in a line whose flow bridges across the one-way valve.
[0029] This structure with a one-way restrictor makes it possible to prolong the time taken to restore the control valve-slide of the cut-off valve to its spring-loaded starting position and to reduce the time to a minimum during which the neutralizing pressure has to be applied to the cut-off valve. Thus, to de-activate the emergency operation function or the hydraulic emergency actuation of the starting clutch, only a short pressure pulse at the neutralizing pressure input of the cut-off valve is needed.
[0030] According to a further embodiment of a control valve arrangement constructed in accordance with the invention, it is provided that the pressure chamber of the self-holding valve, remote from the restoring spring, can be acted upon by a pilot pressure, by way of which the control valve-slide of the self-holding valve, once its self-holding function has been de-activated, can be displaced against the restoring force of the restoring spring of the self-holding valve for enough to allow the speed-dependent pressure to act axially upon a servo-position of the control valve-slide.
[0031] Moreover, it is preferably provided that the pressure chamber of the at least one clutch regulation valve, remote from the restoring spring, can be acted upon by another or by the same pilot pressure. With the help of this pilot pressure, after de-activation of the self-holding function of the self-holding valve, a servo-piston of the clutch regulation valve can be displaced against the restoring force of a restoring spring that acts upon this control valve-slide far enough to allow a supply pressure, delivered to the clutch regulation valve as the clutch actuation pressure, to be passed on to at least one clutch actuation device.
[0032] According to another embodiment of the control valve arrangement, it can be provided that the neutralizing pressure can be delivered to the pressure chamber of the cut-off valve, remote from the restoring spring, and that a pilot pressure P_V 2 can be delivered, via a line, to a central pressure chamber of the cut-off valve and from there, in a manner that can be blocked by the control valve-slide of the cut-off valve, via a line, to the pressure chamber of the self-holding valve on the restoring spring side.
[0033] In addition the control valve arrangement of the invention can be constructed such that the already mentioned pilot pressure P_VST 3 can be delivered to the pressure chamber of the cut-off valve remote from the restoring spring and the pilot pressure P_V 2 can be delivered, via a line, to the control pressure chamber of the cut-off valve and from there, in a manner that can be blocked by the control valve-slide of the cut-off valve, via a line, to the pressure chamber of the self-holding valve on the restoring spring side.
[0034] According to a last embodiment of the control valve arrangement of the invention, it is provided that the neutralizing pressure can be delivered, via a line, to the pressure chamber of the self-holding valve on the restoring spring side and, via another line, to a pressure chamber of the actuation valve. The latter pressure chamber is formed in the area of the end face, remote from the restoring spring, of the central servo-piston of a three-piston control valve-slide of the actuation valve; that the actuation pressure can be passed from the associated pressure chamber of the self-holding valve, via a line, to a pressure chamber of the actuation valve; that close to this latter pressure chamber, a further pressure chamber is formed in the actuation valve, which is connected with an actuation pressure line that leads to the pressure chamber of the clutch regulation valve remote from the spring and that, by way of the central servo-piston of the control valve-slide of the actuation valve, a connection between the two pressure chambers of the actuation valve close to one another can be blocked.
[0035] Let it be said here that with regard to passing on the actuation pressure to the at least one clutch regulation valve, the control valve arrangement can be designed differently with the same effect. As opposed to the embodiments described above, it can also be provided that the actuation pressure is delivered first to the actuation valve, from there to the self-holding valve, and from the latter to the at least one clutch regulation valve.
[0036] Finally, it should be pointed out that the control valve arrangement, according to the invention, can be used to good effect not only for vehicle drivetrains with only one starting clutch, but also advantageously for dual-clutch transmissions. In the case of dual-clutch transmissions, however, it must be ensured that to realize the emergency operation mode described, only one of the two starting clutches need be or remain closed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The invention will now be described, by way of example, with reference to the accompanying drawings in which:
[0038] FIG. 1 is a control valve arrangement with a self-holding hydraulic system and means for the de-activation of a self-holding function;
[0039] FIG. 2 is a control valve arrangement as in FIG. 1 , but with a cut-off valve for de-activating the self-holding function;
[0040] FIG. 3 is a control valve arrangement as in FIG. 2 , but with a ball-type one-way restrictor on the cut-off valve;
[0041] FIG. 4 is another embodiment of the control valve arrangement, similar to that shown in FIG. 2 ;
[0042] FIG. 5 is another control valve arrangement, similar to that of FIG. 4 ;
[0043] FIG. 6 is a diagram of various operating functions of the control valve arrangement shown in FIG. 5 , and
[0044] FIG. 7 is a last embodiment of the control valve arrangement according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The control valve arrangement, shown in FIG. 1 , comprises a self-holding valve 1 , an emergency operation actuation valve 2 (called the actuation valve in what follows), a clutch regulation valve 3 and a clutch actuation device 4 . The clutch actuation device 4 comprises a cylinder 5 in which a piston 6 is surrounded co-axially in the area of its piston rod by a restoring spring 7 that acts in opposition to a clutch actuation pressure P_K and which, when its end face, remote from the spring is acted upon by pressure, can be moved in a closing direction in such a manner that a starting clutch of an automatic transmission is engaged such that torque is transmitted.
[0046] The starting clutch (not shown here), but known to those with knowledge of the field, is part of an automatic transmission which can be made as a variable-speed automatic gearbox based on a planetary transmission, a gearbox that changes its transmission ratio continuously or an automated change-under-load gear shift transmission. When the control valve arrangement is intended for a dual-clutch transmission, two clutch regulation valves and two clutch actuation devices are used.
[0047] The valves 1 , 2 and 3 are arranged in a valve casing (not shown) of an electro-hydraulic control unit for the transmission, each valve having at least one control valve-slide which can be moved axially by hydraulic pressures and/or restoring spring forces to open, connect and/or close pressure chambers.
[0048] The self-holding valve 1 has a control valve-slide 30 arranged to move axially in a valve bore 36 . The control valve-slide 30 has three spaced apart servo-pistons 20 , 21 and 22 . An end face of the servo-piston 20 is acted upon with a restoring force by a restoring spring 31 , which is arranged in a pressure space 71 of the self-holding valve 1 .
[0049] The axially opposite end of the control valve-slide 30 is acted upon, when necessary, by a pilot pressure P_VST 1 which can be delivered, via a pressure line 8 , to a pressure chamber 38 of the self-holding valve 1 . The pilot pressure P_VST 1 is also delivered by a line 10 to a pressure chamber 74 of the clutch regulation valve 3 , which serves to exert pressure on the free end faces of two control valve-slides 19 , 34 of the clutch regulation valve 3 , whose function will be described below in due course.
[0050] The pilot pressure P_VST 1 is provided by a pressure regulation valve 168 from the main pressure of the pressure medium generated by an oil pump (not shown). For this purpose the pressure regulation valve 168 can be controlled by an electronic control unit not shown here, preferably a transmission control unit.
[0051] Another pilot pressure P_VST 3 is provided from the main pressure by a pressure regulation valve 166 , which can also be controlled by the electronic control unit. This pilot pressure P_VST 3 is delivered to a pressure chamber 78 of the actuation valve 2 remote from the restoring spring, wherein it can act on the end face of a servo-piston 23 of a control valve-slide 29 of the actuation valve 2 .
[0052] In addition, via a line 11 , a control pressure P_D is delivered to a pressure chamber 39 of the self-holding valve 1 , between the servo-pistons 21 and 22 . The level of this pressure depends on the speed of the vehicle's drive engine.
[0053] Furthermore, via a line 12 , an actuation pressure P_A is delivered to a pressure chamber 70 of the self-holding valve 1 , located between the servo-pistons 20 and 21 which, during emergency operation of the transmission after a failure of the electronic control unit, ensures that a torque-transmitting clutch of the transmission remains engaged in a speed-dependent manner.
[0054] With regard to the structure of the actuation valve 2 , it should be mentioned that its control valve-slide 29 has three spaced apart servo-pistons 23 , 148 and 24 that are arranged to move axially in a bore 63 of the valve casing. An end face of the servo-piston 24 is acted upon by the force of a restoring spring 32 .
[0055] The pilot pressure P_VST 3 already mentioned can be delivered by a line 9 to a pressure chamber 78 at the axially opposite end of the control valve-slide 29 . Also, a line 14 connects the pressure chamber 70 or 143 of the self-holding valve 1 to a pressure chamber 72 of the actuation valve 2 , so that this pressure chamber 72 can be closed by way of the servo-piston 23 remote from the restoring spring or, if the pilot pressure P_VST 3 is absent, connected hydraulically to a pressure chamber 73 of the actuation valve 2 .
[0056] By way of the central servo-piston 148 , a pressure chamber 149 of the actuation valve 2 , connected to a line 150 , can be engaged or, when the pilot pressure P_VST 3 is absent, connected to a pressure chamber 147 of the actuation valve. In certain critical operating situations of the motor vehicle or its automatic transmission, the line 150 carries a hydraulic neutralizing pressure P_Lösch, which is provided by a switching valve 167 that can be actuated by the electronic control unit. The pressure chamber 147 is connected by a line 151 to the pressure chamber 71 of the already mentioned self-holding valve 1 .
[0057] The clutch regulation valve 3 comprises an axially longer control valve-slide 19 with three servo-pistons 26 , 27 and 28 and the axially shorter control valve-slide 34 , which are held and able to move axially in bores 64 and 65 of the valve casing. At one end of the servo-piston 28 , the axially longer control valve-slide 19 is acted upon by a restoring force of a restoring spring 33 .
[0058] The axially shorter control valve-slide 34 comprises a servo-piston 25 whose end facing toward the other control valve-slide 19 can be acted upon by the already mentioned pilot pressure P_VST 1 . For this, the pressure chamber 74 of the clutch regulation valve 3 is connected, via lines 10 and 152 , to a pressure regulation valve 168 that produces the pilot pressure P_VST 1 . The actuation pressure P_A can be delivered, via a line 15 , to the opposite end face of the piston 25 in a pressure chamber 80 , which is connected to a pressure chamber 73 of the actuation valve 2 .
[0059] The axially longer control valve-slide 19 of the clutch regulation valve 3 has three servo-pistons 26 , 27 and 28 . The two pistons 26 and 27 are arranged axially directly adjacent to one another. The free end of the servo-piston 26 , opposite the axially shorter control valve-slide 34 , can also be acted upon, via the pressure chamber 74 , by the pilot pressure P_VST 1 , while the end of the servo-piston 28 , remote from the restoring spring, is associated with a pressure chamber 75 to which a system or supply pressure P_V 1 can be delivered.
[0060] During normal operation, this pressure chamber 75 can be connected with an adjacent pressure chamber 76 by actuating the clutch control valve 3 by way of the pilot pressure P_VST 1 so that a controlled clutch actuation pressure P_K, produced by the servo-piston 28 , can act in the pressure chamber 76 . In addition, the pressure chamber 76 is connected by a line 16 to the cylinder 5 of the clutch actuation device 4 and to a pressure chamber 77 of the clutch regulation valve 3 that also accommodates its restoring spring 33 .
[0061] The mode of operation of the control valve arrangement shown in FIG. 1 , is now as follows:
[0062] During normal driving operation the pilot pressure P_VST 1 is set such that the control valve-slide 30 of the self-holding valve 1 is pushed axially against the force of the spring 31 such that the servo-piston 20 is axially displaced far enough to open a path for the supply pressure P_A from the pressure chamber 70 , via a pressure chamber 143 and a line 14 , to a pressure chamber 72 of the actuation valve 2 .
[0063] In addition, during normal driving operation, the pilot pressure P_VST 3 acts within the pressure chamber 78 of the actuation valve 2 in such a manner that the latter's control valve-slide 29 is pushed axially within the bore 63 against the force of the restoring spring 32 far enough for the pressure chamber 73 to be separated from the pressure chamber 72 by the servo-piston 23 . This prevents the passage of the actuation pressure P_A from the actuation valve 2 , via a line 15 , to the clutch regulation valve 3 .
[0064] Furthermore, via line 10 , the axially longer control valve-slide 19 of the clutch regulation valve 3 is acted upon by the pilot pressure P_VST 1 in such a manner that a control edge of the servo-piston 28 opens up the pressure chamber 75 of the clutch regulation valve 3 to a greater or lesser extent. In this way, as a function of the pilot pressure P_VST 1 , the supply pressure P_V 1 can be adjusted to the clutch actuation pressure P_K such that the clutch actuation device 4 can ultimately be brought to a position that disengages or engages the clutch. Of course, intermediate positions can also be set in which the clutch is operated in a slipping mode.
[0065] In FIG. 1 , it can also be seen that the end of the servo-piston 28 of the clutch regulation valve 3 facing the restoring spring 33 can also be acted upon by the controlled clutch actuation pressure P_K or by the actuation pressure P_A, via the pressure chamber 76 and lines 16 and 17 .
[0066] For example, if a fault or failure of the transmission control unit results in an absence, or at least a large decrease of the pilot pressure P_VST 1 and P_VST 3 , the speed-dependent pressure P_D in the pressure chamber 39 of the self-holding valve 1 becomes effective for actuation. If the speed of the vehicle's drive engine is high enough such that stalling of the engine is not to be feared, this control pressure P_D will also be high enough to be able to keep the control valve-slide 30 of the self-holding valve 1 positioned such that the supply pressure P_A is delivered, via the pressure chambers 70 and 143 and via line 14 , to the pressure chamber 72 of the actuation valve 2 .
[0067] The self-holding function of the self-holding valve 1 ceases when the speed-dependent control pressure P_D falls below a predetermined value. This limiting pressure value characterizes the stalling speed of the engine. In such a case, the control valve-slide 30 is pushed axially by the force of the restoring spring 31 in the direction toward the pressure chamber 38 so that the actuation pressure supply P_A of the actuation valve 2 is cut off. The starting clutch is therefore disengaged.
[0068] In an emergency operating situation, the pilot pressure P_VST 3 is also absent or greatly reduced in the pressure chamber 78 of the actuation valve 2 , so that its control valve-slide 29 is pushed axially by the force of the restoring spring 32 in the direction toward the pressure chamber 78 in such a manner that the pressure chambers 72 and 73 are connected to one another. Consequently, the actuation pressure P_A is also delivered, via line 15 , to the pressure chamber 80 of the clutch regulation valve 3 , where it acts upon the axially shorter control valve-slide 34 . As a result, the control valve-slide 34 pushes against the free end of the piston 26 of the axially longer control valve-slide 19 , so that the latter is pushed axially against the force of the restoring spring 33 . Thereby, despite the absence of the pilot pressure P_VST 1 , the connection between the pressure chambers 75 and 76 is kept disengaged.
[0069] Thanks to this mode of action, even if the pilot pressure P_VST 1 or P_VST 3 is absent, a clutch actuation pressure P_K can be delivered via a line 18 , the pressure chambers 75 , 76 and line 16 to the clutch actuation device 4 to hold it in its disengaging position.
[0070] If the engine speed falls so much that there is a risk of stalling, then the speed-dependent pressure P_D will also have a correspondingly low value. This ultimately leads to an interruption of the emergency operation of the transmission, since the force of the restoring spring 31 in the self-holding valve 1 will then be sufficient to push its control valve-slide 30 axially far enough to cut off the actuation pressure connection between the pressure chamber 70 of the self-holding valve 1 and the pressure line 14 .
[0071] As a result of this, the short control valve-slide 34 of the clutch regulation valve 3 will also no longer be acted upon by the actuation pressure P_A so that the longer control valve-slide 19 , driven by the force of the restoring spring 33 , is moved to a position such that the connection, between the pressure chambers 75 and 76 , is cut off. Consequently, the clutch actuation pressure in the cylinder 5 of the clutch actuation device 4 also falls so that its piston 6 , driven by the force of the restoring spring 7 , is pushed to its disengaged position.
[0072] As FIG. 1 makes clear, if the speed-dependent control pressure P_D again increases after an emergency operation phase, the clutch actuation device 4 at first can not be restored to its engaging position, giving the advantage from a standpoint of safety that the engine speed can be run up in a repair workshop for test purposes without the resultant increase of the speed-dependent pressure P_D then automatically establishing a force flow in the automatic transmission.
[0073] With the control valve arrangement described, according to the invention, a further operating mode is possible in which, in certain critical operating situations of the motor vehicle or the automatic transmission, triggering of the emergency operation function described, i.e., when the starting clutch is engaged or kept disengaged in an engine-speed-dependent manner in the event of the electronic control unit failure, is prevented.
[0074] For example, an operating situation of a motor vehicle is possible, in which it has first been moving in a forward or a reverse gear with an engine speed above the limiting speed value. During such operation, the self-holding valve 1 of the control valve arrangement has, as described, been activated by the speed-dependent pressure P_D and the control valve-slide 30 has, therefore, been pushed against the force of the restoring spring 31 , far enough for pressure medium at the pressure P_D to reach the pressure chamber 39 of the self-holding valve 1 .
[0075] Starting from such driving operation, when the vehicle is stopped, but the engine speed remains above the limiting speed value, the self-holding valve 1 remains in the position described which enables emergency operation with the starting clutch to be engaged in the absence of the pilot pressure P_VST 1 , P_VST 3 . This system behavior persists even when the starting clutch is disengaged by actuation of the selector lever to the transmission selector positions neutral or parking P.
[0076] Now prevent the possibility that in such a situation with a gear engaged, the starting clutch disengaged, the transmission selector lever at neutral or parking P and an engine speed above the limiting value, the starting clutch is then automatically engaged by virtue of a failure of the electronic control unit and thus an absence of the pilot pressure P_VST 1 , P_VST 3 , such autonomous engaging of the starting clutch can be prevented by the prompt application of the neutralizing pressure.
[0077] To do this, the electro-hydraulic valve 167 , shown in FIG. 1 , is actuated so that a hydraulic neutralizing pressure P_Lösch is present in line 150 , leading to the pressure chamber 149 of the actuation valve 2 . Inasmuch as the pilot pressure P_VST 3 is present in line 9 , this acts via the pressure chamber 78 of the actuation valve 2 on the free end of the servo-piston 23 of the control valve-slide 29 in the actuation valve 2 so that the control valve-slide 29 is pushed against the force of the restoring spring 32 . Thereby, when the electronic control unit is functional the pressure chamber 149 is closed by the servo-piston 148 and the connection, between the pressure chambers 72 and 73 , is cut off.
[0078] Now, if the pilot pressures P_VST 1 and P_VST 3 cease to act, then as already explained, and if the speed-dependent pressure P_D were high enough, the control valve-slide 30 of the self-holding valve 1 would remain in its position, shown in FIG. 1 , while the control valve-slide 29 of the actuation valve 2 , driven by the restoring spring 32 , would be moved in the direction toward the pressure chamber 78 so that the pressure chambers 73 and 74 would be connected. This would enable the actuation pressure P_A to reach the clutch regulation valve 3 and there push the smaller control valve-slide 34 in such a manner that, by virtue of the large control valve-slide 19 , pressure medium at the supply pressure P_V 1 could be delivered to the clutch actuation device 4 for engaging the starting clutch.
[0079] However, thanks to the delivery of the neutralizing pressure P_Lösch to the actuation valve 2 , according to the invention, if the pilot pressure P_VST 3 is absent then pressure medium at the neutralizing pressure P_Lösch passes from the pressure chamber 149 into the pressure chamber 147 and from there, via line 151 , to the pressure chamber 71 at the foot of the self-holding valve 1 . Here, the neutralizing pressure P_Lösch pushes from below and assists the restoring spring 31 in biasing the servo-piston 20 so that the control valve-slide 30 moves against the speed-dependent pressure P_D in the direction toward the pressure chamber 38 . This blocks the delivery of actuation pressure P_A to the pressure chamber 70 byway of the servo-piston 20 , with the consequence that the actuation valve 2 and the clutch regulation valve 3 are not supplied with this actuation pressure P_A and the starting clutch is disengaged or remains disengaged due to the force of the restoring spring 7 in the clutch actuation device 4 .
[0080] The neutralizing pressure P_Lösch is delivered by actuation of the electro-hydraulic valve 167 when the electronic control unit is functioning and the critical operating situation of the vehicle occurs (described above). If the electronic control unit then fails, the emergency operation function of the hydraulic control arrangement could not be activated. When the critical operating situation is no longer present and the electronic control unit is still working correctly, the latter switches off the neutralizing pressure P_Lösch by de-energizing the valve 167 so that the control valve-slide 30 of the self-holding valve 1 , under the action of the pilot pressure P_VST 1 applied there, is displaced against the force of the restoring spring 31 for the speed-dependent pressure P_D to fill the pressure chamber 39 at the end of the servo-piston 21 remote from the restoring spring.
[0081] Although the control valve arrangement according to FIG. 1 as such, has a very advantageous structure, in order to initiate its neutralizing function, i.e., to prevent activation of the emergency operation function, the hydraulic emergency operating function has to be activated by briefly cutting off the pilot pressure P_VST 3 . Because of this a perceptible though short engaging of the starting clutch cannot be completely excluded. The following embodiments of the control valve arrangement, according to the invention, avoid the possible occurrence of this disadvantage.
[0082] The control valve arrangement, according to the invention shown in FIG. 2 , differs from the example embodiment just explained mainly in that it comprises a separate cut-off valve 153 , while the actuation valve 2 has only two servo-pistons 23 and 148 . The cut-off valve 153 has a control valve-slide 159 with two servo-pistons 154 and 155 a distance apart, which can be pushed to its starting position by the restoring spring 166 a pressure chamber 156 is formed. At the end of the cut-off valve 153 , remote from the restoring spring, can be pressurized, via line 150 , with the neutralizing pressure P_Lösch. Between the two servo-pistons 154 , 155 is formed a pressure chamber 157 that can be drained into a pressure medium tank. This pressure chamber 157 can be connected by axial displacement of the servo-piston 155 against the force of a restoring spring 142 to a pressure chamber 158 , which is connected via a line 146 to line 11 that carries the engine-speed-dependent control pressure P_D in the area of the pressure chamber 39 of the self-holding valve 1 .
[0083] To suppress the emergency operation function of the control valve arrangement, according to FIG. 2 , in the critical vehicle operation situation outlined above, the pressure chamber 156 of the cut-off valve 153 is pressurized with the neutralizing pressure P_Lösch so that its control valve-slide 159 is moved against the force of the restoring spring 142 . This causes the servo-piston 155 , with its control edge, to open the pressure chamber 158 so that pressure medium at the speed-dependent pressure P_D passes from line 11 or the pressure chamber 39 of the self-holding valve 1 , via a line 146 , and the pressure chamber 158 into the pressure chamber 157 . From there, the pressure medium passes into a pressure medium tank 165 so the pressure in the pressure chamber 39 of the self-holding valve 1 falls until its control valve-slide 30 is moved by the force of the restoring spring 31 . The servo-piston 20 of the control valve-slide 30 then cuts off the pressure chamber 70 from the pressure chamber 143 so that the actuation pressure P_A can no longer pass from the self-holding valve 1 to the actuation valve 2 . Thus, the self-holding function for emergency operation of the drivetrain, if an electronic control unit failure occurs, cannot at first be activated.
[0084] As soon as the critical vehicle operation situation outlined has disappeared, the neutralizing pressure P_Lösch is received by the pressure chamber 156 of the cut-off valve 153 so that the drainable pressure chamber 157 is no longer acted upon by pressure medium at the pressure P_D which, instead, again passes into the pressure chamber 39 of the self-holding valve 1 . Since the pilot pressure P_VST 1 is acting in the pressure chamber 38 of the self-holding valve 1 , the control valve-slide 30 of the self-holding valve 1 is again pushed against the force of the restoring spring 31 so that, even if the pilot pressure P_VST 1 should subsequently disappear, pressure medium at the pressure P_A can still pass from the self-holding valve 1 to the actuation valve 2 when the speed-dependent pressure P_D is high enough.
[0085] In the two embodiments of the control valve arrangement described so far, it is necessarily the case that the discharge of the pressure medium at the speed-dependent pressure P_D into a pressure medium tank 165 and the return of the control valve-slide 30 of the self-holding valve 1 to its starting position take up a certain time. Furthermore, during this the neutralizing pressure P_Lösch must be applied continually. To design this working behavior in a different way, the control valve arrangement, according to FIG. 3 , is equipped with a one-way restrictor ball in the cut-off valve, which prolongs the restoration duration of the return of the control valve-slide 30 of the self-holding valve 1 and shortens the time during which the neutralizing pressure P_Lösch must be applied to the cut-off valve 153 to the point where, to de-activate the emergency operation property of the control valve arrangement, only a short pressure pulse P_Lösch is needed.
[0086] As can be seen in FIG. 3 , the control valve arrangement is largely identical to that of FIG. 2 . As a supplement thereto, a pressure chamber 160 in which the restoring spring 142 of the cut-off valve 153 is located, is connected to a line 164 which disengages into the pressure medium tank 165 . Integrated in this line is a spring-loaded one-way ball valve 163 which blocks in the direction toward the cut-off valve 153 , which can be bridged across by a line 161 that has a hydraulic throttle 162 .
[0087] With regard to its structure and mode of operation, the embodiment of the control valve arrangement, according to FIG. 4 , corresponds largely to the embodiment shown in FIG. 2 , so that in what follows essentially only the differences will be explained. Whereas the neutralizing pressure P_Lösch can be delivered by line 150 to the pressure chamber 156 of the cut-off valve 153 , its pressure chamber 158 can be acted upon, via a line 81 , by a control pressure P_V 2 . For example, the two pressures P_Lösch and P_V 2 can be the main pressure of the hydraulic system produced by the pressure medium pump or a reduced pressure of the hydraulic system, which can preferably be switched on by way of electromagnetically actuated valves 90 or 167 respectively. In addition, a line 82 runs from the pressure chamber 158 of the cut-off valve 153 to the pressure chamber 71 of the self-holding valve 1 .
[0088] During normal operation of the vehicle, the restoring spring 142 pushes the control valve-slide 159 of the cut-off valve 153 to its home position, so that the pressure chamber 158 is closed by the servo-piston 155 . In the critical operating situation already mentioned, the pilot pressure P_VST 1 is no longer applied at the level required in the pressure chamber 38 of the self-holding valve 1 , but the speed-dependent pressure P_D is high enough to move the servo-piston 21 of the self-holding valve 1 against the force of the restoring spring 31 far enough for pressure medium at the actuation pressure P_A to be delivered to the clutch regulation valve 3 in order to realize an emergency operation function.
[0089] Now, to prevent the activation of the hydraulic emergency operation, the neutralizing pressure P_Lösch is delivered to the pressure chamber 156 . This moves the control valve-slide 159 against the force of the restoring spring 142 so that pressure medium at the pilot pressure P_V 2 passes into the pressure chamber 71 of the self-holding valve 1 on the spring side, via line 81 , the pressure chamber 158 and line 82 . The pilot pressure P_V 2 , supported by the force of the restoring spring 31 , then pushes the control valve-slide 30 to its home position so that, although the speed-dependent control pressure P_D is high enough for emergency operation, no actuation pressure can get from the self-holding valve 1 to the actuation valve 2 .
[0090] A further embodiment, similar to the control valve arrangement according to FIG. 4 , is shown in FIG. 5 . Advantageously, in this case the delivery of the separate neutralizing pressure P_Lösch is dispensed with. Rather, the pilot pressure P_VST 3 is not only passed to the actuation valve 2 , via line 9 , but also via a line 83 , to the pressure chamber 156 of the cut-off valve 153 . By a different switching point design of the cut-off valve 153 and the actuation valve 2 , this pilot pressure P_VSR 3 can be used to actuate both valves 2 , 153 , as will be explained below with reference to FIGS. 5 and 6 .
[0091] During normal operation of the vehicle, the pilot pressure P_VST 3 acts both in the pressure chamber 78 of the actuation valve 2 and in the pressure chamber 156 of the cut-off valve 153 . Accordingly, the servo-piston 23 of the actuation valve 2 blocks the delivery of the actuation pressure P_A to the clutch regulation valve 3 , so that the emergency operation function is de-activated. By designing the switching points of the actuation valve 2 and the cut-off valve 153 differently, in normal operation the pilot pressure P_VST 3 can be set between the two switching points S 1 and S 2 in FIG. 6 so that the piston 155 of the cut-off valve 153 remains in its home position, the pressure chamber 71 of the self-holding valve 1 on the spring side is drained into the pressure medium tank, and when the pilot pressure P_VST 1 in the pressure chamber 38 and/or the speed-dependent pressure P_D in the pressure chamber 39 is high enough, the valve piston 21 of the self-holding valve 1 is held in its pushed-over position against the force of the restoring spring and the emergency operation function can therefore be activated. The emergency operation function is de-activated by increasing the pilot pressure P_VST 3 above the switching threshold S 2 in FIG. 6 , where the valve piston 155 of the cut-off valve 153 is pushed away from its rest position against the restoring spring force and the pilot pressure P_V 2 in the pressure chamber 158 is passed via pressure line 82 into the pressure chamber 71 of the self-holding valve 1 on the spring side so that the valve piston 21 of the self-holding valve 1 is pushed back with spring support to its home position against the pilot pressure P_VST 1 that may be present in the pressure chamber 38 and the speed-dependent pressure P_D that may be present in the pressure chamber 39 so that the connection, between the actuation pressure P_A in the pressure chamber 70 and pressure line 14 leading to the actuation valve 2 , is interrupted.
[0092] Finally, FIG. 7 shows a control valve arrangement, according to the invention, in which described activation of the emergency operation function can be prevented by pushing the self-holding valve 1 on the spring chamber side to its home position by the action of the neutralizing pressure P_Lösch and, at the same time, bringing the actuation valve 2 , against the force of its restoring spring, to a position in which a servo-piston of the actuation valve 2 prevents the further transmission of the actuation pressure P_A.
[0093] For this, according to FIG. 7 a control valve arrangement is provided, which is largely the same as that shown in FIG. 1 , since the actuation valve 2 is made with three servo-pistons 23 , 24 and 148 . In addition, the neutralizing pressure P_Lösch can be delivered, via a line 83 , to the pressure chamber 71 of the self-holding valve 1 on the restoring spring side and to a pressure chamber 86 of the actuation valve 2 , via a line 85 , which is arranged axially between the two servo-pistons 23 and 148 remote from the restoring spring. The actuation pressure P_A can be delivered by the self-holding valve 1 , via a line 84 , to a pressure chamber 87 which can be blocked off by the servo-piston 148 of the actuation valve 2 . Between the servo-pistons 148 and 24 , a pressure chamber 88 in the actuation valve 2 is formed, which can be connected to the pressure chamber 87 when the control valve-slide 29 is appropriately positioned and thus enables the actuation pressure P_A to be passed on via a line 84 to the pressure chamber 80 of the clutch regulation valve 3 .
[0094] With this control valve arrangement according to FIG. 7 , in order to prevent activation of the emergency operation function, if the pilot pressure P_VST 3 disappears, the neutralizing pressure P_Lösch is passed both to the pressure chamber 71 of the self-holding valve 1 on the spring side and also to the pressure chamber 86 of the actuation valve 2 . Thereby, the control valve-slide 30 of the self-holding valve 1 is pushed to its non-spring-loaded home position against a possibly sufficiently high speed-dependent control pressure P_D. In addition, this neutralizing pressure P_Lösch in the pressure chamber 86 of the actuation valve 2 pushes its control valve-slide 29 against the force of the restoring spring 32 far enough for the middle servo-piston 148 to prevent the further transmission of the actuation pressure P_A via the pressure chambers 87 and 88 .
REFERENCE NUMERALS
[0000]
1 self-holding valve
2 actuation valve
3 clutch regulation valve
4 clutch actuation device
5 cylinder
6 clutch piston
7 restoring spring
8 line carrying the pilot pressure P_VST 1
9 line carrying the pilot pressure P_VST 3
10 line carrying the pilot pressure P_VST 1
11 line carrying the speed-dependent pressure P_D
12 line carrying the actuation pressure P_A to the self-holding valve
14 connection line self-holding valve to actuation valve
15 connection line actuation valve to clutch regulation valve
16 connection line clutch regulation valve to clutch actuation device
17 connection line clutch regulation valve to clutch actuation device
19 line carrying the supply pressure
19 control valve-slide in the clutch regulation valve
20 servo-piston on the control valve-slide in the self-holding valve
21 servo-piston on the control valve-slide in the self-holding valve
22 servo piston on the control valve-slide in the self-holding valve
23 servo-piston on the control valve-slide in the actuation valve
24 servo-piston on the control valve-slide in the actuation valve
25 servo-piston on the control valve-slide in the clutch regulation valve
26 servo-piston on the control valve-slide in the clutch regulation valve
27 servo-piston on the control valve-slide in the clutch regulation valve
28 servo-piston on the control valve-slide in the clutch regulation valve
29 control valve-slide in the actuation valve
30 control valve-slide in the self-holding valve
31 restoring spring in the self-holding valve
32 restoring spring in the actuation valve
33 restoring spring in the clutch regulation valve
34 short control valve-slide in the clutch regulation valve
36 valve bore in the self-holding valve
38 pressure chamber in the self-holding valve
39 pressure chamber in the self-holding valve
63 bore for the control valve-slide in the actuation valve
64 bore for the long control valve-slide in the clutch regulation valve
65 bore for the short control valve-slide in the clutch regulation valve
70 pressure chamber in the self-holding valve
71 pressure chamber in the self-holding valve
72 pressure chamber in the actuation valve
73 pressure chamber in the actuation valve
74 pressure chamber in the clutch regulation valve
75 pressure chamber in the clutch regulation valve
76 pressure chamber in the clutch regulation valve
77 pressure chamber in the clutch regulation valve
78 pressure chamber in the actuation valve
80 pressure chamber in the clutch regulation valve
81 line
82 line
83 line
84 line
85 line
86 pressure chamber
87 pressure chamber
88 pressure chamber
90 electromagnetically actuated valve
142 restoring spring of the cut-off valve
143 pressure chamber in the self-holding valve
146 line
147 drainable pressure chamber in the self-holding valve
148 servo-piston in the self-holding valve
149 pressure chamber carrying the neutralizing pressure
150 line carrying the neutralizing pressure
151 line
152 line carrying P_VST 1
153 cut-off valve
154 servo-piston
155 servo-piston
156 pressure chamber
157 pressure chamber that can be drained
158 pressure chamber
159 control valve-slide of the actuation valve
160 pressure chamber of the actuation valve
161 line
162 throttle
163 one-way valve
164 line
165 pressure medium tank
166 electromagnetically actuated valve
167 electromagnetically actuated valve
168 electromagnetically actuated valve
I_VST 3 control current for valve 166
P_A actuation pressure
P_D speed-dependent control pressure
P_K clutch actuation pressure
P_Lösch neutralizing pressure
P_V 1 supply pressure
P_V 2 pilot pressure
P_VST 1 pilot pressure
P_VST 3 pilot pressure
S 1 switching point of actuation valve
S 2 switching point of cut-off valve
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A control valve arrangement having a clutch regulation valve ( 3 ), which pressurizes a device to actuate the clutch, and a valve that produces a controlled pilot pressure (P_VST 3 ). An electronic control unit (ECU) controls a valve to supply a control valve with the pressure (P_VST 3 ). The arrangement further having a hydraulic system which, if the ECU fails and the pressure (P_VST 3 ) ceases, the last shift condition of the clutch actuation device, prior to the ECU failure, can be maintained in an emergency. The arrangement includes a valve, which delivers an activation pressure (P_A), depending on an engine-speed-dependent control pressure (P_D), to an actuation valve ( 2 ), which then delivers the pressure (P_A) to the valve ( 3 ) to prevent the emergency function initiation despite a lack of pressure (P_VST 3 ) and existance of the pressure (P_D) sufficiently high to initiate the emergency function.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2014-169042 filed on Aug. 22, 2014, the entire contents of which are incorporated herein by reference.
FIELD
The embodiments discussed herein are related to a debugging circuit, a debugger device, and a debugging method.
BACKGROUND
In a logic analyzer technique which is an actual debugging tool adapted to confirm whether a hardware is normally operated, a debugging circuit is inserted when a debugging target circuit is implemented.
Related technologies are disclosed in, for example, Japanese Laid-Open Patent Publication No. 2005-317023 and International Publication Pamphlet No. WO 2008/020513.
SUMMARY
According to one aspect of the embodiments, a debugging circuit including: a storage configured to store a first code value which is calculated by an encoding method in which a value is changed according to a sequence of a signal in a debugging target circuit, and indicates a stop condition of the debugging target circuit; a code value calculator configured to calculate a second code value by the encoding method based on the signal each time when the signal is changed; and an operation stopper configured to stop an operation of the debugging target circuit when the first code value and the second code value are identical to each other.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagram illustrating an example of a semiconductor device, a debugging circuit, and a debugger device;
FIG. 2 is a diagram illustrating an exemplary debugging system;
FIG. 3 is a diagram illustrating an exemplary semiconductor device;
FIG. 4 is a diagram illustrating an example of hardware of a debugger device;
FIG. 5 is a diagram illustrating an example of a debugging method;
FIG. 6 is a diagram illustrating an example of a debugging target;
FIG. 7 is a diagram illustrating an example of a functional block of a circuit model;
FIG. 8 is a diagram illustrating an example of a stop condition;
FIG. 9 is a diagram illustrating another exemplary semiconductor device; and
FIG. 10 is a diagram illustrating still another exemplary semiconductor device.
DESCRIPTION OF EMBODIMENTS
A debugging circuit, for example, monitors a temporal change in a signal of a debugging target circuit designated by a user. When a value of the signal becomes identical to a stop condition, the debugging circuit stops an operation of the debugging target circuit and outputs the monitored temporal change of the signal stored in a trace memory to, for example, a display device.
In debugging of software, a breakpoint is used and thus a program is stopped under various conditions. However, in debugging of hardware, hardware may not be stopped under a condition or at a timing intended by the user due to the hardware constraints such as a capacity of a trace memory or the number of signal lines capable of being used in debugging.
FIG. 1 illustrates an example of a semiconductor device, a debugging circuit, and a debugger device.
A semiconductor device 1 includes a debugging circuit 2 and a debugging target circuit 3 which is hardware. The debugging circuit 2 is a circuit which stops an operation of the debugging target circuit 3 under a stop condition and includes storage units 2 a and 2 b , a code value calculation unit 2 c , and an operation stopping unit 2 d.
The storage unit 2 a stores a code value (hereinafter, referred to as a code value “A”) which indicates a stop condition of the debugging target circuit 3 . The code value “A” may be calculated by an encoding method in which a value varies according to a sequence of signals related to the debugging target circuit 3 . In a case where the debugging circuit 2 stops the operation of the debugging target circuit 3 at a certain sequence of signals, the certain sequence may be indicated by the code value “A” as a stop condition.
As the encoding method (encoding algorithm) in which a value varies according to a sequence of signals, for example, a Cyclic Redundancy Check (CRC), a hamming code, an Message Digest Algorithm (MD) 5, or an Secure Hash Algorithm (SHA)-1 may be used. The code value “A” is calculated by the debugger device 4 .
The storage unit 2 b stores a code value (hereinafter, referred to as a code value “B”) calculated in the code value calculation unit 2 c within the debugging circuit 2 . The code value calculation unit 2 c calculates the code value “B” by the same encoding method as that used for calculating the code value “A” based on a signal related to the debugging target circuit 3 each time when the signal is changed.
When the code value “A” and the code value “B” are identical to each other, the operation stopping unit 2 d stops the operation of the debugging target circuit 3 . When the code values “A” and “B” are identical to each other, for example, the operation stopping unit 2 d stops the operation of the debugging target circuit 3 in such a way that the supply of a clock signal to the debugging target circuit 3 is stopped by the circuit stop signal. The operation stopping unit 2 d blocks the data input to the debugging target circuit 3 and the data output from the debugging target circuit 3 such that the debugging target circuit 3 may be handled as if being stopped.
The debugger device 4 communicates with the semiconductor device 1 to perform debugging. The debugger device 4 calculates the code value “A” based on a circuit model formed by modeling the debugging target circuit 3 and data D 1 containing information of the sequence of signals which stops the operation of the debugging target circuit 3 (Operation S 1 ). The debugger device 4 updates the code value by the encoding method each time when the signal is changed in a specific sequence included in the data D 1 using, for example, a circuit simulation, and sets a code value obtained when the sequence is ended as the code value “A”. The debugger device 4 outputs (transmits) the code value “A” to the semiconductor device 1 (Operation S 2 ).
When an input data “x” and an output data “y” are changed in a sequence of, for example, (x 1 , y 1 ), (x 2 , y 2 ), . . . , (xi, yi) in the debugging target circuit 3 , the operation of the debugging target circuit 3 may be stopped.
The debugger device 4 performs a circuit simulation on the circuit model of the debugging target circuit 3 and computes the code value “A” at the time when the signal is changed in the above sequence. For example, a variable “ci” is calculated as the code value “A”. The debugger device 4 transmits the “ci” as the code value “A”. The debugging circuit 2 of the semiconductor device 1 receives and stores the “ci” in the storage unit 2 a.
The debugging circuit 2 detects the change in signal of the debugging target circuit 3 . The code value calculation unit 2 c updates the code value “B” each time when the input data “x” or the output data “y” is changed in FIG. 1 .
For example, as illustrated in FIG. 1 , when the input data “x” or the output data “y” of the debugging target circuit 3 is changed in the sequence of (x 1 , y 1 ), (x 2 , y 2 ), . . . , (xi, yi) and the code value “B” is changed in the sequence of “c 1 ”, “c 2 ”, . . . , “ci”, the code value “B” is identical to the code value “A”.
In this case, the operation stopping unit 2 d stops the operation of the debugging target circuit 3 . Thereafter, for example, a debugging operation such as checking the signal of each unit of the debugging target circuit 3 may be performed by the debugger device 4 .
In the semiconductor device 1 , the debugging circuit 2 , and the debugger device 4 , the stop condition is obtained in advance by a code value which varies according to the signal sequence of the debugging target circuit 3 , and stored in the storage unit 2 a . The debugging circuit 2 stops the debugging target circuit 3 when the stored code value is identical to the obtained code value each time when the signal is changed. The code values described above may be used to make the debugging target circuit 3 to stop easily regardless of hardware constraints, such that work efficiency may be improved.
Even when a complicated sequence is set as the stop condition, since a stop condition is represented by the code value, the capacity of the storage units 2 a and 2 b may be small. Accordingly, the circuit area of each of the debugging circuit 2 and the semiconductor device 1 may be reduced.
When it is intended to change the stop condition, the debugger device 4 may have only to calculate a code value indicating a new stop condition and the storage unit 2 a may have only to store the calculated code value. Therefore, re-implementation of a circuit may not be performed.
FIG. 2 is a diagram illustrating an exemplary debugging system.
The debugging system illustrated in FIG. 2 includes a semiconductor device 10 and a debugger device 20 that are coupled with each other via a communication cable 30 . The semiconductor device 10 and the debugger device 20 may communicate with each other wirelessly.
The semiconductor device 10 may be, for example, SoC (System on Chip) and includes a debugging circuit 11 and a user circuit 12 which corresponds to a debugging target. The debugger device 20 may be, for example, a computer, and is manipulated by an operator 40 and communicated with the semiconductor device 10 through the communication cable 30 to perform debugging.
FIG. 3 is a diagram illustrating an exemplary semiconductor device. In addition to the debugging circuit 11 and the user circuit 12 , the semiconductor device 10 includes a reception unit 13 which receives data transmitted through the communication cable 30 from the debugger device 20 .
The debugging circuit 11 includes registers 11 a and 11 b , a code value calculation unit 11 c , and an operation stopping unit 11 d . The register 11 a stores the code value which indicates the stop condition transmitted from the debugger device 20 and received in the reception unit 13 .
The register 11 b stores the code value calculated by the code value calculation unit 11 c . Further, the register 11 b stores an initial value of the code value transmitted from the debugger device 20 and received in the reception unit 13 . Each time when the signal related to the user circuit 12 is changed, the code value calculation unit 11 c calculates the code value which is changed according to the sequence of the signal by using the same encoding method as the encoding method used for calculating the code value by the debugger device 20 . For example, the CRC, the hamming code, the MD5, or the SHA-1 may be used as the encoding method.
When both of the code values stored in the register 11 a and register 11 b are identical to each other, the operation stopping unit 11 d stops the operation of the user circuit 12 which corresponds to the debugging target. FIG. 4 is a diagram illustrating an example of hardware of a debugger device.
The debugger device 20 may be a computer and is controlled by a processor 21 in its entirety. A RAM 22 and a plurality of peripheral equipments are coupled to the processor 21 through a bus 29 . The processor 21 may be a multiprocessor. The processor 21 may be, for example, a CPU, a Micro Processing Unit (MPU), a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), or a Programmable Logic Device (PLD). The processor 21 may be a combination of two or more of the CPU, the MPU, the DSP, the ASIC, and the PLD.
The RAM 22 is used as a primary storage device of the debugger device 20 . In the RAM 22 , at least a portion of an OS (Operating System) program or an application program executed by the processor 21 is temporarily stored. Further, various data used for a process to be executed by the processor 21 are stored in the RAM 22 .
The peripheral equipment connected to the bus 29 may include a Hard Disk Drive (HDD) 23 , a graphic processing device 24 , an input interface 25 , an optical drive device 26 , an equipment connection interface 27 , or a network interface 28 .
The HDD 23 performs writing and reading data into and from a built-in disk magnetically. The HDD 23 may be used as an auxiliary storage device of the debugger device 20 . The OS program, the application program such as circuit simulation software, and various data are stored in the HDD 23 . A semiconductor storage device such as a flash memory may be used as the auxiliary storage device.
The graphic processing device 24 is coupled with a monitor 24 a . The graphic processing device 24 displays an image such as a debugging result on a screen of the monitor 24 a according to an instruction from the processor 21 . The monitor 24 a may include, for example, a display device using a CRT (Cathode Ray Tube) or a liquid crystal display device (LCD).
The input interface 25 is coupled with a keyboard 25 a and a mouse 105 b . The input interface 25 transmits the signal sent from the keyboard 25 a or the mouse 25 b to the processor 21 . The mouse 25 b may be an example of a pointing device and different types of the pointing devices may be used instead. The different types of the pointing devices may include, for example, a touch panel, a tablet, a touch pad and a track ball.
The optical drive device 26 performs reading-out of data recorded in the optical disk 26 a using, for example, laser light. The optical disk 26 a is a portable recording medium in which data is recorded to allow data to be read out by reflection of light. The optical disk 26 a may include, for example, a DVD (Digital Versatile Disc), a DVD-RAM, a CD-ROM (Compact Disc Read Only Memory) or a CD-R (Recordable)/RW (ReWritable).
The equipment connection interface 27 may be a communication interface for coupling the peripheral equipment to the debugger device 20 . For example, a memory device 27 a or a memory reader/writer 27 b may be coupled to the equipment connection interface 27 . The memory device 27 a may be a recording medium equipped with a function for communicating with the equipment connection interface 27 . The memory reader/writer 27 b writes data into a memory card 27 c or reads data from the memory card 27 c . The memory card 27 c is, for example, a card type recording medium.
The equipment connection interface 27 is coupled with the semiconductor device 10 through the communication cable 30 . The network interface 28 is coupled with a network 28 a . The network interface 28 transmits and receives data to and from other computer or communication equipment through the network 28 a.
The debugger device 4 illustrated in FIG. 1 may also include a hardware similar to the hardware of the debugger device 20 illustrated in FIG. 4 .
The debugger device 20 executes a program recorded in, for example, the computer-readable recording medium. The program in which processing contents to be executed by the debugger device 20 are described may be recorded into various recording media. For example, the program to be executed by the debugger device 20 may be stored in the HDD 23 . The processor 21 loads at least a portion of the program stored in the HDD 23 onto the RAM 22 and executes the program. Further, the program to be executed by the debugger device 20 may be recorded in the portable recording medium such as the optical disk 26 a , the memory device 27 a , or the memory card 27 c . The program stored in the portable recording medium may be executed after being installed on the HDD 23 by, for example, a control from the processor 21 . The processor 21 may directly read the program from the portable recording medium to be executed.
FIG. 5 illustrates an example of a debugging method.
The debugger device 4 performs a circuit simulation on a circuit model, which is formed by modeling, for example, a user circuit 12 that performs an operation similar to the operation of the user circuit 12 which is a debugging target, by software, and calculates a code value indicating a stop condition of the user circuit 12 (Operation S 10 ).
FIG. 6 is a diagram illustrating an example of a debugging target. In FIG. 6 , descriptions on a circuit model of a user circuit are illustrated. In FIG. 6 , an example of the circuit model described in a Verilog HDL (Hardware Description Language) is illustrated. FIG. 6 illustrates a clock signal “ck” and a 16-bit input data “x” that are input to the circuit model, a 16-bit output data “y” output from the circuit model, and 1-bit signal “s” as the signal which indicates an internal state of the circuit model.
The output data “y” becomes 0 (zero) when a value of the signal “s” is 0, and becomes a value obtained by multiplying the input data “x” by 2 (two) when the value of the signal “s” is 1 (one) (see, e.g., the fourth line in the description of FIG. 6 ). The processing from the sixth line to the tenth line is performed synchronously with the rising of the clock signal “ck”. Descriptions of the sixth line to the tenth line indicates that in a case where the value of the signal “s” is 0 (zero), the signal “s” transits from 0 to 1 (one) when the input data “x” is “16′h0010” and in a case where the value of the signal “s” is 1 (one), the signal “s” transits from 1 to 0 (one) when the input data “x” is “16′h0030”.
In FIG. 6 , a breakpoint is set in the timing at which the signal “s” transits to 0. The breakpoint may be set by, for example, an operator 40 . FIG. 7 illustrates an example of a functional block of a circuit model. A circuit model illustrated in FIG. 7 may be the circuit model illustrated in FIG. 6 .
A circuit model 12 a includes a state machine 12 a 1 and a function unit 12 a 2 . The state machine 12 a 1 makes the transition of the signal “s” from 0 to 1 or vice versa based on the input data “x” and the value of the signal “s” which indicates the internal state of the circuit model 12 a.
The function unit 12 a 2 sets the output data “y” as 0 (zero) when the value of signal “s” is 0 and sets the output data “y” as a value obtained by multiplying the input data “x” by 2 when the value of signal “s” is 1, based on the value of signal “s”.
A processor 21 of the debugger device 20 executes the circuit model 12 a by the circuit simulation, for example, the Register Transfer Level (RTL) simulation. The circuit simulation is set to be stopped at the breakpoint illustrated in FIG. 6 . The processor 21 performs a code value computation processing T 1 based on the input data “x” and the output data “y” at the time of performing the circuit simulation.
For example, a sequence of the input data “x” of the circuit model 12 a may be “16′h0010”, “16′h0020”, “16′h0030”, and “16′h0040” as described in this order. For example, the processor 21 of the debugger device 20 may compute a code value (CRC value) by performing the CRC32 stipulated at the IEEE (Institute of Electrical and Electronics Engineers) 802.3 as the code value computation processing T 1 .
FIG. 8 illustrates an example of a stop condition. In FIG. 8 , execution results of the circuit model, examples of the calculated CRC values, and determination results of whether the stop condition is satisfied or not are listed. In an initial state, the value of signal “s” is 0, and a CRC value based on the input data “x” and the output data “y” is “32′h00000000”. Since this timing does not correspond to the breakpoint, the stop condition is not satisfied.
When the value of signal “s” is in a state of 0 (zero) and the input data “x” becomes “16′h0010”, the output data “y” becomes “16′h0000” by the processing performed in the function unit 12 a 2 . In this case, the CRC value is updated and becomes “32′h715d8883” as illustrated in FIG. 8 . Also, in this case, the stop condition is not satisfied.
When the input data “x” becomes “16′h0010” and the clock signal “ck” rises, the value of the signal “s” becomes 1 (one) by the processing performed in the state machine 12 a 1 . When the value of signal “s” is in a state of 1 and the input data “x” becomes “16′h0020”, the output data “y” becomes twice the input data “x”, for example, “16′h0040” by the processing performed in the function unit 12 a 2 . In this case, the CRC value is updated and becomes a value of “32′h49d20e79”. Also, in this case, the stop condition is not satisfied.
When the value of the signal “s” is in a state of 1 (one) and the input data “x” becomes “16′h0030”, the output data “y” becomes twice the input data “x”, for example, “16′h0060” by the processing performed in the function unit 12 a 2 . In this case, the CRC value is updated and becomes a value of “32′h1435d0af”. Since this state corresponds to a timing at which the breakpoint, where the value of signal “s” is 1 and the input data “x” is “16′h0030”, is set, the stop condition is satisfied, as illustrated in FIG. 6 .
In this case, when the clock signal “ck” rises, the value of signal “s” becomes 0 (zero) by the processing performed in the state machine 12 a 1 . When the value of signal “s” is in a state of 0 (zero) and the input data “x” becomes “16′h0040”, the output data “y” becomes “16′h0000” by the processing performed in the function unit 12 a 2 . In this case, the CRC value is updated and becomes a value of “32′h9a3aad89”. Further, in this case, the stop condition is not satisfied.
As described above, the code value calculation processing at Operation S 10 is performed. The debugger device 20 transmits the CRC value of “32′h1435d0af” calculated at the time when the stop condition is satisfied to the semiconductor device 10 .
The semiconductor device 10 receives the code value transmitted from the debugger device 20 in the reception unit 13 and sets (stores) the code value in the register 11 a of the debugging circuit 11 (Operation S 11 ). The debugger device 20 transmits the initial value of “32′h00000000” to be set in the register 11 b to the semiconductor device 10 .
The semiconductor device 10 receives the initial value transmitted from the debugger device 20 in the reception unit 13 and sets (stores) the initial value in the register 11 b of the debugging circuit 11 (Operation S 12 ). Thereafter, the operation stopping unit 11 d of the debugging circuit 11 causes the user circuit 12 of the debugging target to start an operation (Operation S 13 ). For example, the operation stopping unit 11 d turns the supply of the clock signal to the user circuit 12 ON such that the user circuit 12 starts the operation.
After the operation of the user circuit 12 is started, the code value calculation unit 11 c of the debugging circuit 11 calculates the code value each time when the input data “x” or the output data “y” of the user circuit 12 is changed and updates the code value stored in the register 11 b (Operation S 14 ).
The code value calculated by the processing at Operation S 14 is calculated by an encoding method which is substantially the same encoding method used for the code value calculated by the debugger device 20 . When the debugger device 20 computes the code value by the CRC 32 , the code value is similarly computed by the CRC 32 also in the code value calculation unit 11 c of the debugging circuit 11 .
When the code value stored in the register 11 b is updated, the operation stopping unit 11 d determines whether both code values stored in the registers 11 a and 11 b are identical to each other (Operation S 15 ). When it is determined that both code values differ from each other, the processing starting from Operation S 14 is repeated.
When both code values are identical to each other, the operation stopping unit 11 d stops the operation of the user circuit 12 which corresponds to the debugging target (Operation S 16 ). For example, the CRC value of “32′h1435d0af” calculated by the debugger device 20 at the time when the input data “x” and the output data “y” of the circuit model 12 a have transited in the sequence illustrated in FIG. 8 may be stored in the register 11 a.
When the input data “x” and the output data “y” of the circuit model 12 a have transited in the sequence illustrated in FIG. 8 in the user circuit 12 of the semiconductor device 10 as well, the CRC value calculated in the code value calculation unit 11 c becomes a value of “32′h1435d0af” to be identical to the CRC value stored in the register 11 a . In this case, the operation stopping unit 11 d sets the circuit stop signal to be supplied to the user circuit 12 to “1” and stops the operation of the user circuit 12 by, for example, turning the supply of the clock signal to the user circuit 12 OFF.
Thereafter, reading of the state of the user circuit 12 which is the debugging target of the semiconductor device 10 is performed by manipulation of the operator 40 for the debugger device 20 (Operation S 17 ). In the processing at Operation S 17 , for example, a boundary scan circuit within the semiconductor device 10 may be utilized to perform an operation such as reading the state of the user circuit 12 such as, for example, the input data “x”, the output data “y”, or the signal “s” indicating the internal state.
Next, the debugger device 20 determines whether the stop condition is actually satisfied from the read state of the user circuit 12 (Operation S 18 ). For example, the debugger device 20 determines whether the values of the input data “x”, the signal “s”, and the output data “y” that satisfy the stop condition illustrated in FIG. 8 are identical to the signals read from the semiconductor device 10 . When it is determined that the values and the signal are identical to each other, the debugger device 20 determines that the stop condition is satisfied. Accordingly, the debugging process is ended. When it is determined that the values and the signals are not identical to each other, the debugger device 20 causes the debugging circuit 11 of the semiconductor device 10 to resume the operation of the user circuit 12 . The processing starting from Operation S 13 is repeated.
After the processing at Operation S 18 , the operator 40 causes the debugger device 20 to change the signal of the user circuit 12 within the semiconductor device 10 and causes the debugger device 20 and the semiconductor device 10 to repeat the processing starting from Operation S 10 again.
The sequence of the processing described above are not limited thereto and the processing such as setting of the initial value to the register 11 b may be performed before the processing at Operation S 10 . The same effect as in the semiconductor device 1 , the debugging circuit 2 , and the debugger device 4 illustrated in FIG. 1 may be obtained in the semiconductor device 10 , the debugging circuit 11 , and the debugger device 20 .
The determination at Operation S 18 is performed such that a situation where the code values are identical to each other even though the stop condition is not actually satisfied and the signal at the time when the user circuit 12 is stopped at erroneous timing is presented to the operator 40 is reduced.
The operation stopping unit 11 d of the debugging circuit 11 may stop the operation of the user circuit 12 by, for example, turning the supply of the clock signal to the user circuit 12 OFF.
FIG. 9 is a diagram illustrating another exemplary semiconductor device. In FIG. 9 , the same reference numerals may be given to constitutional elements similar to the constitutional elements of the semiconductor device 10 illustrated in FIG. 3 and descriptions thereof may be omitted or reduced.
A semiconductor device 10 a illustrated in FIG. 9 includes an input blocking unit 14 coupled to an input side of the user circuit 12 and an output blocking unit 15 coupled to an output side of the user circuit 12 . When a signal to stop the operation of the user circuit 12 , for example, a circuit stop signal of “1” (one) is received from the operation stopping unit 11 d , the input blocking unit 14 outputs a fixed value, for example, 0 (zero) regardless of the value of the input data “x”.
When a signal to stop the operation of the user circuit 12 , for example, a circuit stop signal of “1” (one) is received from the operation stopping unit 11 d , the output blocking unit 15 outputs a fixed value, for example, 0 (zero) regardless of the value of the output data “y”.
When the user circuit 12 is a circuit which operates in a handshake fashion, the operation of the user circuit 12 is stopped by blocking the input or output. Therefore, the input and output is blocked by the input blocking unit 14 illustrated in FIG. 9 and the output blocking unit 15 illustrated in FIG. 9 , respectively, to stop the operation of the user circuit 12 such that the increase of the amount of a circuit may be reduced. The effect similar to the effect of the semiconductor device 10 and the debugging circuit 11 illustrated in FIG. 3 may be obtained.
FIG. 10 is a diagram illustrating another exemplary semiconductor device. In FIG. 10 , the same reference numerals may be given to constitutional elements similar to the constitutional elements of the semiconductor device 10 illustrated in FIG. 3 and descriptions thereof may be omitted or reduced.
In a semiconductor device 10 b , a debugging circuit 50 includes registers 11 a 1 and 11 a 2 that store the code values corresponding to a plurality of stop conditions. The code values stored in the registers 11 a 1 and 11 a 2 may be code values calculated by, for example, the processing at Operation S 10 illustrated in FIG. 5 performed by the debugger device 20 . For example, a plurality of code values are calculated for a plurality of sequences of signals of the circuit model 12 a until the sequences of signals reach a plurality of breakpoints, and the plurality of calculated code values are transmitted to the semiconductor device 10 b and stored in the registers 11 a 1 and 11 a 2 .
The debugging circuit 50 includes operation stopping units 11 d 1 and 11 d 2 , and an OR circuit 51 . The operation stopping unit 11 d 1 compares the code value stored in the register 11 a 1 and the code value stored in the register 11 b , and stops the operation of the user circuit 12 when both code values are identical to each other. In the semiconductor device 10 b illustrated in FIG. 10 , the operation stopping unit 11 d 1 may output the circuit stop signal of which value becomes 1 (one) when both code values are identical to each other.
The operation stopping unit 11 d 2 compares the code value stored in the register 11 a 2 and the code value stored in the register 11 b , and stops the operation of the user circuit 12 when both code values are identical to each other. The operation stopping unit 11 d 2 may output the circuit stop signal of which value becomes 1 (one) when both code values are identical to each other.
The OR circuit 51 receives the circuit stop signal outputted from the operation stopping units 11 d 1 and 11 d 2 as inputs, performs a logical OR operation on the inputs, and outputs the result of the logical OR operation to the user circuit 12 . When the value of any one of the circuit stop signals output from the operation stopping units 11 d 1 and 11 d 2 is 1 (one), the OR circuit 51 outputs 1 . Therefore, the operation of the user circuit 12 is stopped.
The effect similar to the effect of the semiconductor device 10 and the debugging circuit 11 illustrated in FIG. 3 may be obtained in the semiconductor device 10 b and the debugging circuit 50 illustrated in FIG. 10 . The user circuit 12 may be stopped under the complicated condition. Since the stop condition is indicated not by a plurality of input data “x” or a plurality of output data “y” but by the code value, the increase of the amount of a circuit may be reduced even when a plurality of stop conditions are set.
The number of code values indicating the stop conditions received from the debugger device 20 may be two, or three or more. In this case, the registers and the operation stopping units may be prepared to be corresponded to the number of code values.
The number of operation stopping units may be two or one with respect to two code values indicating the stop conditions. In this case, two code values indicating two stop conditions are sequentially compared with the code value stored in the register 11 b and the circuit stop signal may be output at the time when the code value indicating the stop condition is identical to the code value stored in the register 11 b in any one comparison for the code values.
The semiconductor device 10 b may be combined with the semiconductor device 10 a illustrated in FIG. 9 . In this case, the output terminal of the OR circuit 51 may be coupled with the input blocking unit 14 and the output blocking unit 15 .
The code value may be calculated based on, for example, either both input data and output data or any one of the input data and the output data of the debugging target circuit. The code value may be calculated based on the sequence of the internal signals of the debugging target circuit.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to an illustrating of the superiority and inferiority of the invention. Although the embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
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A debugging circuit including: a storage configured to store a first code value which is calculated by an encoding method in which a value is changed according to a sequence of a signal in a debugging target circuit, and indicates a stop condition of the debugging target circuit; a code value calculator configured to calculate a second code value by the encoding method based on the signal each time when the signal is changed; and an operation stopper configured to stop an operation of the debugging target circuit when the first code value and the second code value are identical to each other.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a brake disc in a disc brake used in a vehicle such as a motorcycle.
[0003] 2. Description of the Related Art
[0004] As the conventional brake disc used in motorcycles, a brake disc 50 shown in FIG. 5 has been well known (See the Japanese Design Registration No. 1151976.). The brake disc 50 has a circular outer periphery and also has an inner peripheral portion adapted to be coupled with an outer peripheral portion of a disc hub 52 by a plurality of rivet-like pins 51 arranged in a circumferential direction. When the disc hub 52 is bolted to a hub (not shown) of the wheel, the brake disc 50 is supported by the wheel through the disc hub 52 . A braking force is applied to the wheel when opposite braking surfaces of the brake disc 50 are sandwiched by a pair of frictional pads in a caliper fitted to a vehicle frame structure.
[0005] In the meantime, the brake disk 50 is required to reduce its outer diameter and plate thickness in view of the demand for reduction in weight. However, if the outer diameter and the plate thickness are reduced, the heat capacity and the amount of heat dissipation decrease, so that during braking the temperature of the brake disc 50 may increase to result in thermal deformation of the brake disc 50 . Also, since the radial width of the braking surfaces of the disc 50 is fixed in the circumferential direction, brake squeal or noises tend to occur during braking as a result of resonance taking place between the brake disc 50 and the frictional pads.
[0006] In view of the above, there is known a brake disc having an outer peripheral surface formed with a circumferentially extending groove in order to secure the amount of heat dissipation, but the effectiveness of the groove is still insufficient. According to a series of experiments conducted by the inventor of the present invention, it was found that the effectiveness of the groove was something within the range of a measurement error. Also, since the radial width of the braking surfaces of the brake disc is fixed in the circumferential direction, the brake noises cannot be prevented.
[0007] In addition, as a brake disc for use in automotive vehicles that is designed to reduce the weight and increase the amount of heat dissipation, the brake disc disclosed in U.S. Pat. No. 6,386,340 is known in which the outer peripheral face and the inner peripheral face are formed in a sinusoidal waveform. However, the radial width of the braking surfaces of the brake disc remains fixed in the circumferential direction and, accordingly, the brake noises cannot be avoided.
SUMMARY OF THE INVENTION
[0008] The present invention has been devised in view of the foregoing situations and is intended to provide a brake disc in a disc brake for a vehicle, which can be manufactured lightweight, suppress the thermal deformation and is effective to prevent brake noises.
[0009] In order to accomplish the foregoing object, a brake disc for a vehicle according to a first construction of the present invention is a brake disc that is supported by a wheel at an inner peripheral portion thereof through a plurality of support members and is operable to exert a braking force when sandwiched by frictional pads and which includes a plurality of outer recesses defined in an outer peripheral face so as to deploy in a circumferential direction, and braking surfaces engageable with the frictional pads and having a radial width that varies in a direction circumferentially thereof.
[0010] With the brake disc of the structure described above, not only can the weight be reduced in a quantity corresponding to the outer recesses, but also an outer peripheral portion of the brake disc, which has a greater thermal deformation than the inner peripheral portion because of the diameter greater than that of the inner peripheral portion, can expand along the outer recesses in the circumferential direction and, therefore, the thermal expansion of the outer peripheral portion can be sufficiently allowed not only in the circumferential direction, but also in the radial direction. In other words, the thermal deformation of the outer peripheral portion can easily be accommodated and an undesirable deformation of the brake disc in a direction across the thickness thereof (i.e., the axial direction) can be suppressed. Also, since the radial width of the braking surfaces changes in the circumferential direction of the brake disc, the surface area of each of the braking surfaces in contact with the frictional pads varies as the brake disc rotates and, therefore, resonance which would occur between the brake disc and the frictional pads can advantageously be prevented to thereby minimize the phenomenon of brake noises resulting from the resonance during braking.
[0011] The number of the outer recesses is preferably equal to or greater than that of the support members. According to this structural feature, because the number of the outer recesses in a number equal to or greater than that of locations at which the brake disc are fastened by the support members, the thermal deformation of the outer peripheral portion can easily be accommodated in the outer recesses.
[0012] In one preferred embodiment of the present invention, each of the outer recesses has a bottom having an arcuate shape. Accordingly, since the bottom of each of the outer recesses forms a convex surface or a surface smoothly curved to bulge in a direction radially outwardly, dirt and grits would hardly be accumulated in the outer recesses.
[0013] Preferably, each of the outer recesses has a depth that is set to a value within the range of 0.15 to 0.25 times a maximum width of the braking surface delimited between outermost and innermost peripheral edges of the braking surface. If the depth of each outer recess is smaller than the value 0.15 times the maximum width of the braking surface, the degree of change of the radial width of the braking surface in the circumferential direction becomes too small and, therefore, respective effects of the present invention to reduce the weight, suppress the thermal deformation and prevent the brake noises would be minimal. On the other hand, if the depth of each outer recess is more than the value 0.25 times the maximum width of the braking surface, the radial width of the braking surface becomes too small at an area where the outer recesses exist and, therefore, the braking force will decrease.
[0014] The brake disc may have an inner peripheral face formed with a plurality of inner recesses. According to this structural feature, additional formation of the inner recesses makes it possible to further reduce the weight of the brake disc and also to further facilitate change of the radial width of the braking surface, preventing the phenomenon of the brake noises which would occur during braking.
[0015] Each of the inner recesses may be formed in the inner peripheral face of the braking surface at a location between the neighboring support members.
[0016] Also, the inner recesses may be formed at respective locations of the inner peripheral face that confront with some of the plural outer recesses in a direction radially inwardly thereof. According to this feature, change of the radial width of the braking surface can be increased at such locations of the brake disc where the inner recesses exist.
[0017] Each of the inner recesses has a bottom which may be of, for example, an arcuate shape.
[0018] Preferably, each of the inner recesses has a depth that is set to a value within the range of 0.15 to 0.25 times a maximum width of the braking surface delimited between outermost and innermost peripheral edges of the braking surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a side view showing a motorcycle front wheel provided with a brake disc for an automotive disc brake assembly according to a first preferred embodiment of the present invention;
[0020] FIG. 2 is a transverse sectional view of the brake disc showing the manner in which the brake disc is fitted to the motorcycle front wheel;
[0021] FIG. 3A is a side view of the brake disc shown as coupled with a disc hub;
[0022] FIG. 3B is a fragmentary side view, on enlarged scale, showing the brake disc shown in FIG. 3B ;
[0023] FIG. 4A is a side view of the brake disc shown as coupled with the disc hub according to a second preferred embodiment of the present invention;
[0024] FIG. 4B is a fragmentary side view, on enlarged scale, showing the brake disc shown in FIG. 4A ; and
[0025] FIG. 5 is a side view of the conventional brake disc.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0026] Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. Referring first to FIG. 1 illustrating, in a side view, a motorcycle front wheel provided with a brake disc for a vehicle according to a first preferred embodiment of the present invention, the brake disc identified by 2 forms a part of and is operatively associated with a disc brake assembly 1 that is mounted on a motorcycle. This brake disc 2 is fixedly mounted on a wheel 4 for rotation together therewith and has braking surfaces 9 and 9 opposite to each other. The disc brake assembly 1 also includes a caliper 6 mounted on a motorcycle body structure, for example, a front fork 5 . As shown in FIG. 2 , the brake disc 2 is fixedly mounted on the wheel 4 through a disc hub 3 rigidly secured to a wheel hub 4 a of the wheel 4 by a plurality of bolts 7 . The caliper 6 includes left and right frictional pads 8 and 8 that can be driven through caliper pistons (not shown) by a hydraulic pressure, generated in a master cylinder (not shown), so as to move close towards and away from each other. As will be described later, the caliper 6 includes two pairs of frictional pads 8 and 8 . The left and right frictional pads 8 and 8 sandwich the braking surfaces 9 and 9 of the brake disc 2 to apply a braking force to the wheel 4 .
[0027] FIG. 3A illustrates a side view of the brake disc 2 coupled with the disc hub 3 . The brake disc 2 has inner and outer peripheral faces 2 a and 2 b opposite to each other and also has a plurality of, for example, seven, support limbs 22 protruding radially inwardly from the inner peripheral face 2 a and spaced an equal distance from each other in a circumferential direction. This brake disc 2 is connected with the disc hub 3 in coaxial relation through the support limbs 22 by the use of a corresponding number of support members 10 that are positioned spaced an equal distance from each other in the circumferential direction of the disc hub 3 . The disc hub 3 has an inner peripheral portion formed with a circular row of bolt insertion holes 16 spaced equally in the circumferential direction and is mounted on the wheel 4 by threading bolts 7 , which have been inserted in the bolt insertion holes 16 , into screw holes 17 that are formed in the wheel hub 4 a as shown in FIG. 2 . The support members 10 shown in FIG. 3A may be a rivet-like pin and connection of the disc hub 3 with the brake disc 2 can be accomplished by upsetting those support members 10 . Thus, it will readily be seen that the brake disc 2 is supported by the wheel 4 ( FIG. 2 ) through the disc hub 3 by way of the support members 10 .
[0028] More specifically, as shown in FIG. 3B , each of the support members 10 is loosely accommodated within semi-circular mounting grooves 20 and 30 defined respectively in the brake disc 2 and the disc hub 3 , with a slight gap formed between the support member 10 and the corresponding mounting grooves 20 , 30 , so that vibrations of the brake disc 2 during braking can be prevented from being directly transmitted to the wheel 4 ( FIG. 2 ). It is to be noted that each support member 10 may be a bolt.
[0029] Referring again to FIG. 3A , the outer peripheral face 2 b of the brake disc 2 is formed with a plurality of circumferentially equidistantly spaced outer recesses 11 , leaving protrusions 21 between the neighboring outer recesses 11 . Thus, the outer peripheral face 2 b of the brake disc 2 has the outer recesses 11 and the protrusions 21 that alternate with each other in a direction circumferentially thereof. The fourteen outer recesses 11 are employed herein. On the other hand, the inner peripheral face 2 a of the brake disc 2 is formed with a plurality of circumferentially equidistantly spaced inner recesses 12 defined therein so as to extend radially inwardly of the brake disc 2 and positioned generally in alignment with the outer recesses 11 . In the illustrated embodiment, each support limb 22 or each support member 10 is employed and arranged every other outer recess 11 in the outer periphery of the brake disc 2 while each inner recess 12 in the inner periphery of the brake disc 2 is employed and arranged every other outer recess 11 and generally in alignment with one of the outer recesses 11 which is out of alignment with the corresponding support limb 22 or the corresponding support member 10 , i.e., between the neighboring support limbs 22 or the support members 10 . Accordingly, it will readily be seen that the opposite braking surfaces 9 and 9 engageable with the frictional pads 8 and 8 has a width as measured in a direction radially thereof, which varies discretely in a direction circumferentially of the brake disc 2 . It is also to be noted that although the two pairs of circumferentially spaced frictional pads 8 and 8 have been described as employed in the illustrated embodiment, only one pair of the frictional pads 8 and 8 may be employed.
[0030] To reduce the weight of the brake disc 2 to a value as small as possible, the brake disc 2 has a multiplicity of perforations 13 and 14 defined therein so as to extend completely across the thickness of the brake disc 2 . As shown by the double-dotted phantom line in FIG. 3A , the frictional pads 8 and 8 have a width as measured in a direction radially with respect to the brake disc 2 and are engageable with the corresponding braking surface 9 of the brake disc 2 over the entire width thereof. Accordingly, as shown in FIG. 3B , each of the braking surfaces 9 of the brake disc 2 is represented by a surface region bound within an annular area S of a radial width W delimited between an innermost peripheral edge 9 b and an outermost peripheral edges 9 a of the respective braking surface 9 shown by the double-dotted lines extending in areas where no outer recesses 11 is formed.
[0031] Also, each outer recess 11 has a depth e defined between the bottom 11 a thereof and the imaginary line extending in touch with respective radially outermost edges of the neighboring radially outward protrusions 21 as shown in FIG. 3B , which depth e is preferably chosen to be within the range of 0.15 to 0.25 times and, more preferably, within the range of 0.17 to 0.23 times the maximum radial width f of each braking surface 9 , that is, the radial distance fm between the outermost peripheral edge 9 a and the innermost peripheral edge 9 b . It is to be noted that in the illustrated embodiment the radial distance fm referred to above is shown to be equal to the maximum radial width W and, in such case, the depth e of each outer recess 11 is chosen to be 0.20 times the radial distance fm.
[0032] Each outer recess 11 also has an effective circumferential length L as measured between the neighboring radially outward protrusions 21 on respective sides of such outer recess 11 and along the imaginary circle depicted so as to pass through points each intermediate between the hill, represented by the radially outermost edge of the respective radially outward protrusion 21 , and the dale represented by the bottom 11 a of the respective outer recess 11 . This effective circumferential length L of each of the outer recesses 11 is of a value preferably within the range of 0.30 to 1.40 times and, more preferably, within the range of 0.60 to 1.30 times the maximum radial width fm between the outermost peripheral edge 9 a and the innermost peripheral edge 9 b . In the illustrated embodiment, however, the effective circumferential length L is chosen to be 1.0 times the maximum radial width fin, i.e., of a value equal to the maximum radial width fm. Thus, the bottom 11 a of each outer recess 11 is of an arcuate shape occupying a portion of the circle concentric with the axis of rotation of the brake disc 2 and is positioned radially inwardly from the outermost peripheral edge 9 a.
[0033] Similarly, each inner recess 12 has a depth h defined between the bottom 12 a thereof and the innermost peripheral edge 9 b , which depth h is chosen to be preferably within the range of 0.15 to 0.25 times and, more preferably, within the range of 0.17 to 0.23 times the maximum radial width fm of each braking surface 9 as is the case with the depth e of each outer recesses 11 . In the illustrated embodiment, however, the depth h of each of the inner recesses 12 is chosen to be 0.20 times the maximum radial width fin. It is accordingly clear that the bottom 12 a of each of the inner recesses 12 is positioned radially outwardly from the innermost peripheral edge 9 b.
[0034] In the brake disc 2 so constructed as hereinabove described, since the outer peripheral face 2 b of the brake disc 2 of FIG. 3A is formed with the plural outer recesses 11 deployed in a direction circumferentially thereof, the weight of the brake disc 2 can advantageously be reduced. Also, the formation of the plural outer recesses 11 in the brake disc 2 permits the outer peripheral portion, which has a greater thermal deformation than the inner peripheral portion because of the diameter greater than that of the inner peripheral portion, to expand along the outer recesses 11 in the circumferential direction and, therefore, thermal expansion of the outer peripheral portion can be sufficiently allowed not only in the circumferential direction, but also in the radial direction. In other words, thermal deformation of the outer peripheral portion can easily be accommodated. As a result thereof, an undesirable deformation of the brake disc 2 in a direction across the thickness thereof can advantageously be suppressed. Also, since the presence of the outer recesses 11 allows the radial width f of the braking surfaces 9 , with which the frictional pads 8 are engageable, to vary in the circumferential direction of the brake disc 2 , the surface area of each of the braking surfaces 9 , with which the frictional pads 8 are engageable, varies as the brake disc 2 rotates and, therefore, resonance which would occur between the brake disc 2 and the frictional pads 8 if such surface area does not vary can advantageously be prevented to thereby minimize the phenomenon of brake noises resulting from the resonance during braking.
[0035] In addition, since respective portions of the inner peripheral face 2 a of the brake disc 2 which confront the outer recesses 11 in the radial direction thereof are formed with the inner recesses 12 , the weight of the brake disc 2 can advantageously be further reduced. Also, the formation of the plural inner recesses 12 in the brake disc 2 permits the radial width f of the braking surfaces 9 , with which the frictional pads 8 are engageable respectively, to vary considerably in the circumferential direction of the brake disc 2 , resulting in increase of the effect of preventing the resonance between the brake disc 2 and the frictional pads 8 during braking and, therefore, the phenomenon of brake noises resulting from the resonance during braking can advantageously be minimized.
[0036] Considering that the number of the outer recesses 11 is chosen to be equal to or greater than that of the support members 10 (although in the illustrated embodiment the outer recesses 11 are employed in a number twice that of the support member 10 ), the number of the outer recesses 11 which serve to accommodate thermal deformation comes to be equal to or greater than that of the support limbs 22 that are fastened by the respective support members 10 and, therefore, the thermal deformation can easily be accommodated.
[0037] FIG. 4A illustrates a side view of the brake disc according to a second preferred embodiment of the present invention, which disc is shown as coupled with the disc hub. The brake disc now identified by 2 A is similar to the brake disc 2 shown in and described with particular reference to FIGS. 3A and 3B , except that the outer peripheral face 2 b ( FIG. 4B ) of the brake disc 2 A is so corrugated as to leave circumferentially alternating recesses and protrusions 15 a and 15 b that are arranged spaced an equidistant from each other in the circumferential direction thereof. On the other hand, the inner peripheral face 2 a of the brake disc 2 A is formed with the inner recesses 12 each positioned between the neighboring support members 10 and 10 in a manner similar to those described in connection with the previously described embodiment and, thus, it is clear that the radial width f of the braking surfaces 9 , with which the frictional pads 8 are engageable, varies discretely in the circumferential direction of the brake disc 2 A.
[0038] Even in the embodiment now under discussion, as shown in FIG. 4B showing a portion of the brake disc 2 A on an enlarged scale, each of the outer recesses 15 a has the depth e which is chosen to be of a value preferably within the range of 0.15 to 0.25 times the maximum radial width fm of the braking surfaces 9 , although in the illustrated embodiment the depth e is chosen to be of a value 0.20 times the maximum radial width fin. Similarly, each of the outer recesses 15 a has the effective circumferential length L that is chosen to be of a value 0.33 times the maximum radial width fin of the braking surface 9 . Unlike the outer recesses 11 of which bottoms 11 a represent the arcuate shape occupying a portion of the circle concentric with the axis of rotation of the brake disc 2 in the previously described embodiment, the outer recesses 15 a shown in FIGS. 4A and 4B have their bottoms representing not the arcuate shape, but a generally sinusoidal waveform. Also, in the embodiment of FIGS. 4A and 4B , the inner recesses 12 has the depth h which is chosen to be of a value preferably within the range of 0.15 to 0.25 times the maximum radial width fm of the braking surfaces 9 , although so far shown therein the depth h is chosen to be 0.20 times the maximum radial width fin.
[0039] As described above, in the brake disc 2 A so constructed, since the outer peripheral face 2 b of the brake disc 2 is formed with the circumferentially alternating outer recesses and protrusions 15 a and 15 b deployed in a direction circumferentially thereof, the weight of the brake disc 2 A can advantageously be reduced. Also, the formation of the circumferentially alternating outer recesses and protrusions 15 a and 15 b in the brake disc 2 permits the outer peripheral portion, which has a greater thermal deformation than the inner peripheral portion because of the diameter greater than that of the inner peripheral portion, to expand along the outer recesses in the circumferential direction and, therefore, thermal expansion of the outer peripheral portion can be sufficiently tolerated not only in the circumferential direction, but also in the radial direction. As a result thereof, an undesirable deformation of the brake disc 2 A in a direction across the thickness thereof (i.e., the axial direction) can advantageously be suppressed. Also, since the presence of the outer recesses and protrusions 15 a and 15 b allows the radial width f of the braking surfaces 9 , with which the frictional pads 8 are engageable, to vary in the circumferential direction of the brake disc 2 A, the surface area of each of the braking surfaces 9 , with which the frictional pads 8 are engageable, varies as the brake disc 2 A rotates and, therefore, resonance which would occur between the brake disc 2 A and the frictional pads 8 can advantageously be prevented to thereby minimize the phenomenon of brake noises resulting from the resonance during braking. It is to be noted that in the second embodiment of the present invention shown in and described with reference to FIGS. 4A and 4B , the width of each of the protrusions 15 b as measured in a direction circumferentially of the brake disc 2 A is smaller than that of each protrusion 21 shown in FIGS. 3A and 3B and, therefore, the amount of thermal deformation of each protrusion 15 b is correspondingly smaller than that occurring in the protrusion 21 . Accordingly, even though the circumferential width of each of the recesses 15 a is small, thermal deformation of the protrusions 15 b both in the radial direction and in the circumferential direction can be tolerated.
[0040] In addition, since respective portions of the inner peripheral face 2 a of the brake disc 2 A which are each encompassed between the neighboring support members 10 and 10 are formed with the inner recesses 12 , not only can the weight of the brake disc 2 A be further reduced advantageously, but also the phenomenon of brake noises resulting from the resonance between the brake disc 2 A and the frictional pads 8 during braking can also be further minimized.
[0041] Yet, since the number of the outer recesses 15 a is chosen to be equal to or greater than that of the support members 10 , it is effective to facilitate accommodation of the thermal deformation of the outer recesses 15 a in a manner similar to that described in connection with the previously described embodiment.
[0042] A series of experiments were conducted to determine the amount of thermal deformation occurring in the brake disc 2 and 2 A and the conventional brake disc 50 shown in FIG. 5 . Results of those experiments are shown in Table 1 below. The amount of thermal deformation of the brake discs 2 , 2 A and 50 in thickness (i.e., the axial thickness) was determined in terms of millimeter by heating to 500° C. one of the opposite braking surfaces of each of the brake discs 2 , 2 A and 50 while the other of the opposite braking surfaces was left at room temperature.
TABLE 1 First Second Type of Disc Embodiment Embodiment Conventional Amt. of Thermal 1.06 1.18 1.21 Deformation (mm)
[0043] From the results of measurement shown in Table 1, it is clear that the amount of thermal deformation (1.18 mm) in the brake disc 2 A according to the second embodiment of the present invention shown in and described with reference to FIGS. 4A and 4B is smaller than the amount of thermal deformation (1.21 mm) in the conventional brake disc 50 shown in FIG. 5 and that the amount of thermal deformation (1.06 mm) in the brake disc 2 according to the first embodiment of the present invention shown in and described with reference to FIGS. 3A and 3B is much smaller than that in the conventional brake disc 50 shown in FIG. 5 .
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There is provided a brake disc in a disc brake for a vehicle, which can be manufactured lightweight, suppress the thermal deformation and is effective to prevent the brake noises. This brake disc ( 2 ) is supported by a wheel 4 through a plurality of support members ( 10 ) and is operable to exert a braking force when sandwiched by frictional pads ( 8, 8 ). The brake disc ( 2 ) has an outer peripheral face ( 2 b ) formed with a plurality of outer recesses ( 11 ) deploying in a circumferential direction. Accordingly, the radial width (f) of the braking surfaces ( 9 ), with which the frictional pads ( 8 ) is engageable, varies in a direction circumferentially thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefits of provisional patent application Ser. No. US 62/276,929, filed 2016 Jan. 10 by the present inventor.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)
[0004] Not applicable.
STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR
[0005] Not applicable.
BACKGROUND
[0006] Field of Invention
[0007] This invention relates to the field of cover assemblies for pickup trucks. More particularly, this invention relates to an aerodynamic cover assembly for pickup truck beds that is easily transformable between open and closed configurations. Known prior art relevant to this invention can be found in U.S. Patent Class 296, subclasses 100 and 165.
[0008] Description of Related Art
[0009] Pickup trucks are popular vehicles in part because of their ability to haul cargo in the open bed located behind the pickup truck's cab. One of the disadvantages of a pickup truck's open bed is that it creates aerodynamic drag which, in turn, decreases the fuel efficiency of the pickup truck. Many pickup truck owners desire to cover the open bed of their pickup truck to protect their cargo from exposure to the elements and theft. For years, a popular method of covering a pickup truck bed has been to install a raised pickup truck bed cover, which is typically rectangular in shape. The rectangular shape of these raised bed covers offer little, if any, reduction in aerodynamic drag and in some cases can increase aerodynamic drag, which can decrease the fuel efficiency of the pickup truck. Currently known rectangular raised bed covers are either rigid shells, or comprised of a flexible outer covering over a rigid frame.
[0010] To reduce aerodynamic drag and increase fuel efficiency, some pickup truck owners elect to install an aerodynamic cover over the pickup truck bed. The currently known aerodynamic covers are either made of rigid materials or a flexible material over a frame that does not fold. These aerodynamic covers have a roof which begins at a height in approximation with the roof of the pickup truck cab and then tapers downwards towards the pickup trucks tailgate. These aerodynamic covers also have sides that may taper inwards towards the centerline of the pickup truck. This tapered shape provides less aerodynamic drag than a traditional rectangular pickup truck cover. The greatest benefit of an aerodynamic pickup truck cover is an increase in the fuel efficiency of the pickup truck. However, there are several disadvantages. Because of the tapered shape and the non-foldability of the current known aerodynamic pickup truck covers, there is a loss of interior volume that can only be remedied by fully removing the cover. Additionally, the rigid aerodynamic pickup truck cover is fairly heavy which can reduce the fuel efficiency of the host pickup truck and also makes the cover difficult to install and remove. While the currently know aerodynamic covers made of flexible materials weigh less, they are not foldable and, thus, the cover must be manually and fully disassembled to allow large cargo to be loaded into the pickup truck bed.
[0011] U.S. Pat. No. 4,964,669A to Geier (1989) and U.S. Pat. No. 7,147,265,B1 to Schmeichel (2005) both show foldable pickup truck covers which have a rigid foldable frame with a flexible outer covering. Both of these designs have a traditional rectangular shape, rather than a tapered aerodynamic shape. In most cases, this rectangular shape will not reduce the aerodynamic drag of a vehicle they are mounted on and in some cases they will increase the aerodynamic drag of the host vehicle. These two covers lack the design which would allow an aerodynamic shape to be created and easily folded. Furthermore, these two pickup truck covers lack the linkages to bring the top of crossbar close to the truck cab when the cover is closed. This creates a large gap between the pickup truck cover and pickup truck cab, which further decreases aerodynamic efficiency. Additionally, because these covers lack a split front frame/rear frame design, the outer covering must be detached from the side bed frame before the frame can be folded into an open positon.
[0012] Several types of rigid aerodynamic pickup truck covers have been proposed—for example U.S. Pat. No. US20100045069A1 to Koba (2008) and U.S. Pat. No. US20090256382A1 to Stum (2008) and U.S. Pat. No. 8,282,020B2 to Herndon (2007) show tapered, aerodynamic pickup truck covers. Since these covers are made out of rigid materials, they are known to suffer from a number of disadvantages:
[0013] a) A truck cover fabricated from rigid materials is heavy and difficult to mount and remove from a pickup truck bed.
[0014] b) It is generally more expensive to fabricate a truck cover from rigid materials.
[0015] c) A truck cover fabricated from rigid materials is heavy and the weight will negatively impact the fuel efficiency of the vehicle it is mounted upon.
[0016] d) Since the rigid truck cover cannot be broken down it is expensive to ship.
[0017] e) A truck cover fabricated from rigid material limits the height of cargo that can be placed in the pickup truck bed without completely removing the cover from the truck.
[0018] U.S. Pat. No. 5,335,960A to Benignu (1992) and U.S. Pat. No. 4,496,184A to Byrd (1983) both show tapered truck covers consisting of a rigid frame with a flexible outer covering. Neither of these two covers are able to quickly and easily fold into an open position, which limits access to the pickup truck bed. If large cargo needs to be loaded into the bed of the pickup truck, these covers need to be disassembled.
BRIEF SUMMARY OF THE INVENTION
[0019] In accordance with one embodiment, a foldable aerodynamic cover for pickup truck bed comprising an outer covering and a means for creating a folding frame, which supports said outer covering into an aerodynamic shape. The foldable aerodynamic cover for a pickup truck bed preferably has a tapered shape that minimizes wind resistance. Using such a shape for a pickup truck bed cover reduces aerodynamic drag and improves fuel efficiency. The reduction in aerodynamic drag comes due to improved pattern of airflow and elimination of complex vortices forming behind the pickup truck cab.
[0020] Additional benefits include:
[0021] a) Allowing a cross bar to be closer to the pickup truck cab in the closed position to minimize the gap between the cross bar and the pickup truck cab to further reduce aerodynamic drag;
[0022] b) Allowing folding from the closed position to the open position without having to disconnect the sides of outer cover from front and rear frames;
[0023] c) Lighter weight and less expensive to manufacture and ship than other prior art references;
[0024] d) Easily folds into an open position which allows full access to the pickup truck bed to allow for loading large cargo without having to fully remove or disassemble the aerodynamic cover;
[0025] e) Allows fast and easy removal from host pickup truck; and,
[0026] f) Protecting cargo from theft and the elements.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0027] Figures
[0028] FIG. 1 shows a perspective view of a foldable, aerodynamic cover installed and in the full closed position.
[0029] FIG. 2 shows a side view of a foldable, aerodynamic cover installed and in the full closed position.
[0030] FIG. 3 shows a perspective view of a framework of a foldable, aerodynamic cover installed and in the full closed position.
[0031] FIG. 4 shows a perspective view of a framework of a foldable, aerodynamic cover installed and in a partially open position.
[0032] FIG. 5 shows a side view of a framework of a foldable, aerodynamic cover installed and in a partially open position.
[0033] FIG. 6 shows a perspective view of a framework of a foldable, aerodynamic cover installed and in the full open position.
[0034] FIG. 7 shows a perspective view of a framework of a foldable, aerodynamic cover installed and in the full closed position in accordance with another embodiment.
[0035] FIG. 8 shows a perspective view of a framework of a foldable, aerodynamic cover installed and in the full closed position in accordance with another embodiment.
[0036] FIG. 9 shows a perspective view of a framework of a foldable, aerodynamic cover installed and in the full closed position in accordance with another embodiment.
[0037] FIG. 10 shows a side view of a framework of a foldable, aerodynamic cover shown in FIG. 9 . The cover is installed and in the full closed position.
[0038] FIG. 11 shows a side view of a framework of a foldable, aerodynamic cover in the full closed position in accordance with another embodiment.
[0039] FIG. 12 shows a side view of a framework of a foldable, aerodynamic cover in the full closed position in accordance with another embodiment.
[0040] FIG. 13 shows detail view of the rear frame to front support bar swinging pivot point in accordance with another embodiment.
[0041] FIG. 14 shows an isometric view of the rear frame in accordance with another embodiment.
REFERENCE NUMERALS
[0042] 1 Foldable, Aerodynamic Cover
[0043] 2 Framework
[0044] 3 Outer Covering
[0045] 4 Outer Covering Window
[0046] 5 Rear Frame Window
[0047] 6 Front Support Bar
[0048] 7 Cross Bar
[0049] 8 Rear Frame
[0050] 9 Central Pivot Point
[0051] 10 Lift Bar
[0052] 11 Front Frame
[0053] 12 Front Connecting Bar
[0054] 13 Rear Frame To Front Support Bar Swinging Pivot Point
[0055] 14 Front Frame To Lift Bar Pivot Point
[0056] 15 Lift Bar To Front Support Bar Pivot Point
[0057] 16 Means To Hold Rear Frame To Bed Of Pickup Truck
[0058] 17 Means To Clamp Front Frame To Bed Of Pickup Truck
[0059] 18 Means To Connect Outer Covering
[0060] 19 Support Cable
[0061] 20 Front Support Arm
[0062] 21 Rear Support Arm
[0063] 22 Front Support Arm to Crossbar Pivot Point
[0064] 23 Front Support Arm to Rear Support Arm Pivot Point
[0065] 24 Rear Support Arm to Rear Frame Pivot Point
[0066] 25 Front Secondary Support Bar
[0067] 26 Rear Secondary Support Bar
[0068] 27 Front Secondary Cross Bar
[0069] 28 Rear Secondary Cross Bar
[0070] 29 Secondary Support Bar Central Pivot Point
[0071] 30 Secondary Support Bar to Front Support Bar Pivot Point
[0072] 31 Secondary Support Bar to Rear Frame Pivot Point
[0073] 32 Pull Cable
[0074] 33 Outer Covering Attachment
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 , 2 , 3 —First Embodiment
[0075] One embodiment of a foldable, aerodynamic cover 1 can be illustrated in FIG. 1 (perspective view) and FIG. 2 (side view). As shown in FIG. 1 , the foldable, aerodynamic cover 1 can be installed on a pickup truck and can be in a full closed position. Said foldable, aerodynamic cover 1 can include, but is not limited to, a framework 2 and an outer covering 3 . These views show said foldable, aerodynamic cover 1 which can include an outer covering 3 which is preferably made of a durable and flexible material, which can included one or more outer covering windows 4 which can be made of transparent material, such as vinyl. Said outer covering 3 can be supported by a framework 2 show in subsequent Figs.
[0076] Said outer covering 3 from FIG. 1 & FIG. 2 can be connected to a rear frame 8 , a front frame 11 and a front connecting bar 12 (shown in FIG. 3 ) by a means to connect outer covering 18 . Said means to connecting outer covering 18 could include, without limitation, various prior art including snaps, buttons, Velcro or screws.
[0077] FIG. 3 shows said framework 2 for said foldable, aerodynamic cover 1 which can be installed on a pickup truck and can be in a full closed position. In this Fig, said foldable, aerodynamic cover 1 is shown without said outer covering 3 and only said framework 2 is shown. Said framework 2 can include, but is not limited to, a rear frame 8 , a central pivot point 9 , a rear frame to front support bar swinging pivot point 13 , a plurality of front support bars 6 and at least one cross bar 7 . Said cross bar 7 can be connected to said front support bars 6 . Said front support bars 6 can be pivotally connected to said rear frame 8 at the rear frame to front support bar swinging pivot point 13 . When said foldable, aerodynamic cover 1 is in the full closed position, said rear frame 8 can be held against the bed rails of the pickup truck by a means to hold rear frame to bed of pickup truck 16 , which can include a clamp or u-shaped hooks that hook under the lip of the pickup truck bed rails. The height of the vertical portion of said rear frame 8 can be dictated by the pickup truck cab height, pickup truck bed length and the optimal aerodynamic angle of said foldable, aerodynamic cover 1 . Said rear frame 8 may include a rear frame window 5 . In some cases, said rear frame 8 may not have a vertical portion at the back. Said rear frame 8 may be pivotally connected to said front frame 11 at a central pivot point 9 . Said front frame 11 can be mounted on the bed rails of the pickup truck and can held down by a means to clamp front frame to the bed of pickup truck 17 , which can include known prior art including, without limitation, c-clamps, screws or nuts and bolts. Lift bars 10 can be pivotally mounted to said front frame 11 at the front frame to lift bar pivot point 14 . The other end of said lift bars 10 can be pivotally mounted to said front support bars 6 at the lift bar to front support bar pivot point 15 . Said front frames 11 can be connected together by a front connecting bar 12 .
FIGS. 3 , 4 , 5 , and 6 —Operation
[0078] FIG. 3 shows said framework 2 of said foldable, aerodynamic cover 1 , which can be in a full closed position. In this position said foldable, aerodynamic cover 1 can reduce the aerodynamic drag of the pickup truck that it is mounted on. To transform said foldable, aerodynamic cover 1 into an open position, said means to hold rear frame to bed of pickup truck 16 can be released. As shown in FIG. 4 & FIG. 5 , said rear frame 8 may rotate around said central pivot point 9 towards the cab of the pickup truck. Said rear frame to front support bar swinging pivot point 13 can rotate around said central pivot point 9 and said front support bars 6 can move down and back. As said front support bars 6 moves down and back, said lift bars 10 can rotate towards the back of the pickup truck, around said front frame to lift bar pivot point 14 . FIG. 6 shows said framework 2 of said foldable, aerodynamic cover 1 , which can be in a full open position which may allow large cargo to be placed in the bed of the pickup truck.
FIGS. 7 , 8 , 9 , 10 , 11 , 12 , 13 , and 14 —Alternative Embodiments
[0079] There are various possibilities with regards to the method of supporting said outer covering 3 . FIG. 7 shows said framework 2 of said foldable, aerodynamic cover 1 , which can have an addition of a plurality of support cables 19 that may be connected to said front connecting bar 12 , may go over or through said cross bar 7 and may be connected to said rear frame 8 .
[0080] FIG. 8 shows said framework 2 for said foldable, aerodynamic cover 1 , which can have a plurality of front support arms 20 and rear support arms 21 as a method of supporting the outer covering 3 . Said front support arms 20 can be pivotally connected to said cross bar 7 at a front support arm to crossbar pivot point 22 . Said rear support arms 21 can be pivotally connected to said rear frame 8 at a rear support arm to rear frame pivot point 24 . Said front support arms 20 and rear support arms 21 can be pivotally connected to each other at a front support arm to rear support arm pivot point 23 .
[0081] Another possibility for supporting the outer covering would be the addition of a plurality of secondary support bars and cross bars. FIG. 9 & FIG. 10 shows said framework 2 for said foldable, aerodynamic cover 1 , which can include a plurality of front secondary support bars 25 , rear secondary support bars 26 , front secondary cross bar 27 and rear secondary cross bar 28 . Said front secondary support bar 25 can be connected to said front secondary cross bar 27 and pivotally connected to said rear frame 8 at a secondary support bar to rear frame pivot point 31 . Said rear secondary support bar 26 can be connected to said rear secondary cross bar 28 and pivotally connected to said front support bar 6 at a secondary support bar to front support bar pivot point 30 . Said front secondary support bar 25 and said rear secondary support bar 26 can be pivotally connected to each other at a secondary support bar central pivot point 29 .
[0082] FIGS. 11, 12 & 13 show possible embodiments where said front support bars 6 can be pulled into position without the need for said lift bars 10 shown in previous embodiments.
[0083] The embodiment in FIG. 11 shows the addition of a pull cable 32 . One end of said pull cable 33 can be connected to said cross bar 7 and the other end can be connected to said rear frame 8 . As said foldable, aerodynamic 1 cover goes from an open to a closed position and said rear frame 8 may rotate around said central pivot point 9 , said rear fame 8 may pull said pull cable 32 , which may then pull said cross bar 7 , which may cause said front support bar 6 to rotate around said rear frame to front support bar swinging pivot point 13 , which may bring said front support bars 6 into position.
[0084] The embodiment in FIG. 12 shows the possible addition of an outer covering attachment 33 . Said outer covering attachment 33 may be a sleeve sewn into said outer covering 3 , which may wraparound said cross bar 7 . As said foldable, aerodynamic cover 1 goes from an open to a closed position and said rear frame 8 may rotate around said central pivot point 9 , said rear frame 8 may pull said outer covering 3 which may allow said outer covering attachment 33 to pull said cross bar 7 , which may cause said front support bar 6 to rotate around said rear frame to front support bar swinging pivot point 13 , which may bring said front support bars 6 into position.
[0085] The embodiment in FIG. 13 shows a possible reconfiguration of said rear frame 8 , said front support bar 6 and said rear frame to front support bar swinging pivot point 13 . As the foldable, aerodynamic cover 1 goes from an open to a closed position and said rear frame 8 may rotate around said central pivot point 9 , said front support bar 6 may rotate around said rear frame to front support bar swinging pivot point 13 until the bottom of said front support bar 6 may rest on top of said back frame 8 , which can then push said front support bar 6 into position.
[0086] The embodiment in FIG. 14 shows a possible reconfiguration of said rear frame 8 , which may have no vertical portion at the back and said means to connect outer covering 18 , which may be attached to the sides and the back of said rear frame 8 .
CONCLUSION, RAMIFICATIONS AND SCOPE
[0087] Accordingly, the reader will see that the foldable aerodynamic cover of the various embodiments create an aerodynamic shape over the bed of a pickup truck, is lightweight and inexpensive to manufacture and folds easily between an open and closed position. Additionally, the various embodiments show that the foldable aerodynamic cover allows full access to the pickup truck bed to load large cargo when the cover is in the open position.
[0088] Although the description above contains many specificities, these should not be construed as limiting the scope of the embodiments but rather as merely providing illustrations of some of several embodiments. For example, the front frame and central pivot point can be incorporated into the bed of the pickup truck; the lift bars could mount directly to the sides of the pickup truck bed; the outer covering could attach directly to the cross bar; the front support bars can have other shapes such as square, oval, etc.; the rear frame could be flat with no vertical section to house the rear frame window; when in the open position, the cross bar could be in front of the rear frame; etc. Additionally, the foldable aerodynamic cover can be designed to fit on any pickup truck with any bed length or width and pickup trucks various cab configurations including single cab, double cab, extra cab, etc.
[0089] Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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A foldable, aerodynamic cover assembly for pickup truck beds which is user switchable between a closed aerodynamic configuration and a folded open configuration which allows the user access to the pickup truck bed. The aerodynamic configuration reduces vehicle wind resistance and drag, which increases fuel efficiency. The foldable, aerodynamic cover is comprised of a rigid folding frame with an outer cover. The outer cover is disposed over the frame and detachably connected to the base portion of said frame.
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[0001] The present invention relates to a device which is intended for a waste stripping unit. The invention also relates to a waste stripping cassette which is intended for a waste stripping unit which is provided with a device. The invention relates to a waste stripping unit which comprises a waste stripping cassette. The invention relates to a waste stripping unit which comprises a device. The invention relates to a packaging production machine which successively comprises a cutting unit and a waste stripping unit.
[0002] A packaging production machine is intended for the production of boxes, which form packagings, after folding and gluing. In this machine, an initial plane support, such as a continuous cardboard web, is unwound and is printed by a printing unit which is itself constituted by sub-units in the form of printing groups. The web is then transferred to a cutting unit. The cutting operation allows plate elements to be produced, in this instance blanks which are constituted by a plurality of boxes which are joined together.
[0003] The blanks obtained have waste zones which form cardboard discards which are removed by means of ejection. These zones are separated from the rest of the blank by a waste stripping unit. The blanks are then conveyed to a separator in order to be separated from each other, in order to obtain individual boxes.
[0004] The waste stripping unit is mounted after the cutting unit. The stripping unit ensures precise and rapid stripping of the waste. The operation precision of the ejection unit also prevents the waste and the blank from bringing about jams.
[0005] The stripping unit comprises two tools, in the form of two rotary cylinders, which are most often positioned parallel with each other, and one above the other, so as to cooperate with each other. The blanks run between the two cylinders following a substantially horizontal path.
PRIOR ART
[0006] Documents US-2004/0,053,761 and U.S. Pat. No. 3,643,553 give examples of stripping systems for cut waste.
[0007] One of the cylinders, the lower cylinder, comprises radial needles which are pressed into each waste. The needles separate the waste from the blank by carrying them with the rotation of this lower needle cylinder. The needles are positioned on the cylinder in accordance with a layout. The waste is then disengaged from these radial needles during the rotation of the cylinders. To this end, ejectors in the form of fixed combs are arranged parallel with the cylinders. The radial needles are thus released from the waste and become pressed into other waste of the following blank during the next revolution of the cylinder.
[0008] The other of the cylinders, the upper cylinder, may have at the surface thereof a flexible coating of the vulcanized rubber type. Holes are made at various locations in the cylinder or in the rubber coating, depending on the version. The position of the holes corresponds to the layout and therefore to that of the needles of the lower cylinder. The needles are received in the holes during the rotation of the two cylinders, in order to readily perforate the waste. The upper and lower cylinders ensure the transport and maintain of the blanks during the perforation of the waste.
[0009] Document U.S. Pat. No. 3,435,737 describes a method and device for stripping waste from a sheet. A stripping needle which is carried by a lower stripping cylinder is introduced into the waste and removes it from the sheet. The waste is then removed from the stripping needle. The sheet passes into the pinching zone between the lower cylinder and the upper cylinder, being supported by an assembly of spaced-apart support fingers or bars. The needle extends between the support fingers. The waste which has to be separated from the sheet can pass between the fingers which are mutually spaced apart.
[0010] However, the waste is attached to the boxes and to the blanks by means of nicks. The nicks connect two edges of a cutting line between a waste and a box and constitute bridges of the same material as the waste, the boxes and the blanks. In this manner, in such stripping systems, if the nicks are not broken, the needles which are nailed in the waste also carry the blanks and the boxes during the rotation of the needle cylinder. This waste which is poorly separated from the blanks and the boxes leads to jam of the waste stripping unit, and to stoppage of the entire packaging production machine.
[0011] Waste surrounds zones of the box which are more fragile, such as glue tabs or lugs or folded flaps. The perforation of this waste thus causes the tabs and the flaps to be carried with the waste itself. The tabs and the flaps become torn and/or folded in an untimely manner, in particular in the case of cardboard having a low basis weight. Jams are generated further downstream in the machine if the adhesive gluing tabs are folded down.
STATEMENT OF INVENTION
[0012] A main objective of the present invention involves developing a device for a waste stripping unit. A second objective is to provide a device which facilitates the separation between waste and the cut plate elements. A third objective is to facilitate the transfer of blanks of plate elements through the waste stripping unit. A fourth objective is to optimize the precision of the stripping of the waste. A fifth objective is to prevent the phenomena of jam in a waste stripping unit and to limit the machine downtime. A sixth objective is to prevent the disadvantages of the units and the arrangements of the prior art. Another objective is to provide a packaging production machine with a waste stripping unit which is integrated after an upstream cutting unit and which has a high degree of flexibility of use.
[0013] According to an aspect of the present invention, a device is provided for a waste stripping unit fitted with two rotating tools which are arranged so as to cooperate with each other and to strip at least one item of waste. The waste originates from a blank of a plate element. The blank of the plate element passes through the waste stripping unit, passing between the two rotating tools. The device comprises at least one part, which is capable of being inserted between the two rotating tools. The part or parts form a support for the blank of the plate element and a passage for the stripping of the item of waste.
[0014] The device is characterized in that the part or parts are shaped and positioned in accordance with the layout of the blank of the plate element.
[0015] That is to say, the blank of the plate element is sandwiched with the device and the two tools. The device acts as a bridge between an inlet and an outlet of the stripping unit. The device stabilizes the blank during the stripping of the waste. The blank remains towed by the two tools which are mutually synchronized. When the waste is stripped, the blank is advanced and maintained between the two rotating tools. The waste is stripped and the blank keeps an optimum trajectory between the inlet and the outlet.
[0016] The systems of the prior art release the blank through the stripping. The device with the constituent part or parts thereof according to the invention is provided in accordance with the layout, i.e. the template, design or marking of the blank.
[0017] The device provides a constant support for the blank. With the shape and the arrangement thereof, the device ensures the stability of the transfer of the blank, whilst permanently providing a support plane for the zones of the blank which have no waste. With the shape and the arrangement thereof, the device prevents the same zones with no waste from following the waste at the time of their removal. With such a device, the stripping is facilitated and promotes the production of plate elements having more complex cut shapes, with numerous waste zones and numerous zones outside the waste and around the waste.
[0018] Owing to the direct passage of the blank through the stripping owing to the device, there are no other elements to be adjusted in the immediate vicinity of the tools with a very high degree of precision, in order to ensure the transfer and prevent any risk of jam. The device is simply placed at the unit, without requiring adjustments.
[0019] The upstream and downstream directions are defined with reference to the movement direction of the plate elements, in the longitudinal direction in the waste stripping unit and in the whole of the packaging production machine. The longitudinal direction is defined with reference to the movement direction of the plate elements in the waste stripping unit and in the machine, in accordance with the longitudinal center axis thereof. The transverse direction is defined as being the direction perpendicular relative to the movement direction of the plate elements. The front and rear positions are defined relative to the transverse direction as being the operator's side or side of the driver, respectively, and the opposite operator's side or opposite side of the driver, respectively.
[0020] In another aspect of the invention, a waste stripping cassette, which is for a waste stripping unit and which is positioned downstream of a cutting unit for cutting a plane support into plate elements, comprises a frame which is provided with bearings, carrying two rotating tools which cooperate with each other, is capable of being introduced, attached and removed from the waste stripping unit, and is characterized in that it comprises a device which has one or more of the technical features described below and claimed.
[0021] In another aspect of the invention, a waste stripping unit for in a packaging production machine which is positioned downstream of a cutting unit for cutting a plane support into plate elements, comprising a frame and two rotating tools which cooperate with each other, is characterized in that it comprises a stripping cassette which has one or more of the technical features described below and claimed.
[0022] In another aspect of the invention, a waste stripping unit in a packaging production machine, which is positioned downstream of a cutting unit for cutting a plane support into plate elements, comprising a frame and two rotating tools which cooperate with each other, is characterized in that it comprises a device which has one or more of the technical features described below and claimed.
[0023] According to yet another aspect of the invention, a packaging production machine, is characterized in that it comprises the unit which has one or more of the technical features described below and claimed and which is positioned downstream of a cutting unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will be readily understood and the various advantages and different features will be better appreciated from the following description of the non-limiting embodiment, with reference to the appended schematic drawings, in which:
[0025] FIG. 1 is a synoptic side view of a packaging production machine with a waste stripping unit;
[0026] FIG. 2 is a perspective view of a waste stripping cassette, with a sleeve of one of the two tools in a withdrawn position, comprising a device according to the invention; and
[0027] FIG. 3 is a perspective view of the device which can be seen in FIG. 2 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] As illustrated in FIG. 1 , a packaging production machine 1 processes a support or a material in the form of a continuous web 2 , which in this instance is flat cardboard. The machine 1 comprises a conversion unit, for example a cutting press with platen 3 . Upstream of the press 3 , the machine 1 may have units such as printing groups, means for checking the quality and the register, embossing groups, etc. (not illustrated).
[0029] The web 2 enters into the press 3 in the horizontal state via the upstream transverse side thereof. The press 3 cuts the web 2 and releases the support in the form of plate element blanks, i.e. blanks 4 of flat cardboard. The blanks 4 are going out from the press 3 via the downstream transverse side thereof. The advance or running direction (arrows F) of the web 2 and blanks 4 in the longitudinal direction indicates the upstream direction and the downstream direction.
[0030] The machine 1 comprises a drive arrangement 6 , which is arranged downstream of the press 3 . This arrangement 6 first comprises a lower drive roller 7 which is rotatably driven by a motor. The arrangement 6 then comprises a single or a series of pressing rollers 8 which are arranged above in abutment against the roller 7 . The blanks 4 are engaged, maintained and driven between the roller 7 and the roller or rollers 8 . The arrangement 6 ensures active transfer of the blanks 4 , so as to release the blanks 4 , successively one after the other, from the press 3 , in the longitudinal direction F along the downstream direction.
[0031] The machine 1 comprises a transfer device 9 for the blanks 4 . The device 9 is intended to transfer the blanks 4 to the downstream direction successively one after the other, starting from the arrangement 6 , along the longitudinal direction F.
[0032] The machine 1 then comprises a first transport assembly which is more specifically a first vacuum transport 11 and which is arranged downstream of the transfer device 9 . This first vacuum transport 11 comprises a conveyor with one or more endless belts 12 with holes. A vacuum casing 13 , which is connected to a vacuum source, presses the blanks 4 against the belt 12 .
[0033] The blanks 4 are disposed on the upper face of the belt 12 , one after the other, with a short gap between them. The first vacuum transport 11 ensures active transfer of the blanks 4 . The belt 12 carries the blanks 4 along the longitudinal direction F, from the upstream to the downstream direction.
[0034] The machine 1 then comprises a waste stripping unit 14 , which is placed downstream of the press 3 and after the first vacuum transport 11 . This unit 14 allows the cardboard waste which is precut from the blanks 4 to be removed in a controlled manner.
[0035] The waste stripping unit 14 comprises a carrier structure or frame 16 . The operational portion of the unit 14 comprises a first cylindrical lower rotating tool 17 which cooperates with a second cylindrical upper rotating tool 18 . The two tools 17 and 18 are mounted, parallel with each other, one above the other, and transversely relative to the frame 16 and thus the unit 14 . The blanks 4 pass through the unit 14 , passing between the two tools 17 and 18 .
[0036] The lower tool 17 is provided with radial needles (not visible) which protrude radially in the direction of the upper tool 18 . These needles are positioned in an appropriate manner on the surface of the lower tool 17 at the locations where the cutting of the web 2 produces waste. In this manner, these needles penetrate into each of the waste. The waste is torn from the blanks and carried by the rotation of the lower tool 17 , and is removed using combs which are mounted close to the lower tool 17 .
[0037] The upper tool 18 may be a cylinder which is coated with a layer of flexible vulcanized rubber (not visible). Holes 19 may be provided in the upper tool 18 in the rubber layer. The end of each of the needles of the lower tool 17 is received in a hole 19 of the upper tool 18 .
[0038] The machine 1 comprises a second transport assembly which is more specifically a second vacuum transport 21 , and which is arranged downstream of the waste stripping unit 14 . The second transport assembly 21 is substantially similar to the first transport assembly 11 , with endless belts 12 having holes and a vacuum casing 13 .
[0039] The transfer device 9 , the first vacuum transport 11 and the second vacuum transport 21 are mounted in the frame 16 . The removal of the waste outside the waste stripping unit 14 is carried out by means of suction.
[0040] The machine 1 then comprises a separator (not illustrated) which is arranged downstream of the waste stripping unit 14 , after the second transport assembly 21 . The nicks present on the blanks 4 and between the boxes are broken owing to the separator and the blanks 4 are thus converted into boxes.
[0041] In a particularly favorable embodiment (see FIGS. 1 and 2 ), the waste stripping unit 14 may comprise a removable cassette 22 . The removable cassette 22 is capable of being introduced into the frame 16 , of being attached to the frame 16 and, conversely, of being disjoined and removed from this frame 16 .
[0042] The removable cassette 22 comprises a carrier structure or frame 23 . As can be seen in FIG. 2 , the frame 23 is provided with a lower front bearing 24 and a lower rear bearing 26 which carries the first tool, i.e. the lower tool 17 . The frame 23 is provided with an upper front bearing 27 and an upper rear bearing 28 which carries the second tool, i.e. the upper tool 18 .
[0043] The unit 14 comprises a transverse housing which is arranged in the frame 16 between the first transport assembly 11 and the second transport assembly 21 . The cassette 22 may be introduced into this transverse housing transversely relative to the frame 16 . Conversely, the cassette 22 may be removed from this transverse housing transversely relative to the frame 16 .
[0044] The cassette 22 comprises transverse movement means, which also serve to adjust the transverse position thereof in the unit 14 . These means are in the form of a rack 29 which protrudes at the front face 31 of the frame 23 . The rack 29 is capable of cooperating with a pinion which is driven by an electric motor which is present at the frame 16 . Means for locking the longitudinal position of the cassette 22 relative to the frame 16 are provided.
[0045] The cassette 22 comprises drive means which are intended to rotatably drive the two tools 17 and 18 . These means are in the form of a first pinion 32 for the first tool 17 . This first pinion 32 meshes with a second pinion 33 for the second tool 18 . The introduction of the cassette 22 into the frame 16 causes the teeth of the first pinion 32 to engage with those of a cooperating pinion of a motor of the unit 14 .
[0046] The two tools 17 and 18 are formed with a mandrel 34 and a removable cylindrical sleeve 36 . Only the second tool 18 has been illustrated in FIG. 2 . The sleeve 36 is inserted (arrow I), is locked and is driven in rotation by the mandrel 34 of the tool 18 . The sleeve 36 is unlocked and is then withdrawn (arrow R). The sleeve of the lower tool 17 is a hollow cylinder with a wall in which the waste stripping needles which protrude radially and outwards are engaged. The sleeve 36 of the upper tool 18 is a hollow cylinder with a wall in which the series of holes 19 is provided.
[0047] In order to allow the insertion I or the removal R and to change the sleeve 36 during a job change of job and tools 17 and 18 , the lower front bearing 24 of the lower tool 17 is inserted into a lower arm 37 which can be moved by means of transverse sliding, then pivoting in a longitudinal plane. The upper front bearing 27 of the upper tool 18 is inserted into an upper arm 38 which can be moved by means of transverse sliding, then pivoting in a longitudinal plane.
[0048] In order to facilitate the stripping of the waste and in accordance with the invention, the stripping unit 14 and/or the cassette 22 comprise a device for stabilizing the blanks 4 . The device comprises at least one bridge-like part 39 between the first vacuum transport 11 and the second vacuum transport 21 . The part 39 forms a support for the blanks 4 during the stripping of the waste. Owing to the part 39 , the blanks 4 are not carried downwards by the lower tool 17 which pierces the waste with the needles thereof. The blanks 4 which are carried in a downstream direction by the first vacuum transport 11 then pass over the part 39 and are carried by the second vacuum transport 21 .
[0049] The part 39 is capable of being inserted between the two tools 17 and 18 . The part 39 preferably extends through all or part of a space located between the two tools 17 and 18 between an upstream inlet and a downstream outlet of the unit 14 , and more particularly between an upstream inlet and a downstream outlet of the cassette 22 . The part 39 is mounted substantially tangentially relative to the two tools 17 and 18 . The part 39 is sized so as to be accommodated substantially in the horizontal in a radial gap located between the two tools 17 and 18 . The part 39 , which is fixed, and the blanks 4 , which are moving, pass via this gap.
[0050] The part 39 advantageously has an upper plane which extends just below the outer surface of the first lower rotating tool 17 . The fact that the part 39 is located below the surface of the lower tool 17 does not interfere with the advance of the web 4 which will be carried out by the vacuum transports 11 and 21 . The speed of the two stripping cylinders 17 and 18 is synchronized with the speed of the two vacuum transports 11 and 21 .
[0051] The part 39 is shaped so as to form a passage for the waste which is stripped by the first tool 17 . In a favorably manner, the part 39 is a plate. One or more openings 41 to allow the waste to pass are provided in the plate. The number, shape, dimensions and position of the openings 41 are dependent on the number, shape, dimensions and position of the waste. The number, shape, dimensions and position of the openings 41 are dependent on the layout provided for the plate element, and therefore the complexity and the solidity of the cut blank 4 . A plurality of waste may pass through a single opening 41 .
[0052] The openings 41 have flat edges, being delimited by longitudinal rods 42 . The rods 42 form the support for the blanks 4 acting as a support. The openings 41 are also delimited by an upstream transverse metal sheet 43 , a downstream transverse metal sheet 44 and two lateral longitudinal metal sheets 46 . The openings 41 and thus the rods 42 have shapes and widths which vary in accordance with the layout resulting in the blank 4 , between the upstream transverse metal sheet 43 and the downstream transverse metal sheet 44 .
[0053] The part 39 is attached to the frame 23 of the cassette 22 , at the inlet by the upstream metal sheet 43 and at the outlet by the downstream metal sheet 44 . For reasons of efficiency of maintaining the blanks 4 , the part 39 is positioned as close as possible to the first tool 17 .
[0054] However, collisions between the needles which protrude radially outwards from the outer surface of the first tool 17 and the part 39 must be avoided. To this end, the part 39 preferably comprises at least one longitudinal recess or notch 47 .
[0055] This notch or these notches 47 are located at the inlet of the unit 14 and/or the cassette 22 . The notches 47 are cut longitudinally in the upstream metal sheet 43 and open out in the downstream direction in the passage for the waste, i.e. in the openings 41 . The notches 47 are sized in order to allow at least one stripping needle to pass through.
[0056] When the waste is pierced by the first tool 17 , the glue tabs and/or flaps of the blanks 4 , which are more flexible and more fragile zones, have a tendency to follow the same path as that of the waste which surrounds them. The flaps and the tabs are folded by following the rotation of the first tool 17 . In order to prevent jams, the part 39 advantageously comprises at least one longitudinal slant 48 .
[0057] This slant or these slants 48 are located at the outlet of the unit 14 and/or the cassette 22 . The slants 48 originate from longitudinal notches in the downstream metal sheet 44 in the extension of the openings 41 and on either side of the rods 42 . The slants 48 leave the tangential plane between the two tools 17 and 18 . The slants 48 are folded downwards and are orientated in the direction of the first tool 17 . A free edge of each slant 48 is located in the passage for the waste, i.e. in the openings 41 . The slants 48 are sized to catch the flaps and the tabs and to return them to the transport plane of the web 4 .
[0058] The present invention is not limited to the embodiments described and illustrated. Numerous modifications can be carried out, without for all that departing from the scope defined by the extent of the set of claims.
[0059] The waste stripping unit 14 may or may not have a waste stripping cassette 22 . The two tools 17 and 18 may or may not have a mandrel 34 and sleeve 36 .
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A device for a waste stripping unit fitted with two rotating tools which cooperate to strip at least one item of waste which originates from a blank of a plate element ( 4 ) which passes through the unit and between the two tools. At least one tool has pins that remove the waste items. At least one part ( 39 ) is inserted between the two tools and which forms a support for the blank and also opens a passage for the stripped off waste. The part is shaped and positioned in accordance with the layout of the blank
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CLAIM TO PRIORITY
This application claims the benefit of U.S. Provisional Application 61/606,294, entitled “Reversible Wing Plow and Methods of Rotation” filed Mar. 2, 2012, which is hereby incorporated by reference.
TECHNICAL FIELD
The present invention relates generally to snow moving equipment. More particularly, the present invention relates to a wing plow for connection to the rear of a vehicle, wherein the wing plow includes a reversible moldboard that is configurable into a variety of positions.
BACKGROUND OF THE INVENTION
In the snow removal industry it is common practice to use a plow mounted to the front of a snow removal vehicle. The plow mounted to the front of the vehicle may be raised or lowered in relation to the traveled surface. When the plow is in the lowered position it is driven along by the vehicle; thereby pushing snow to one side or the other, depending on the operators' manipulation of the angle of the plow relative to the travel direction.
Side mounted wing plows to supplement the front plow are also well known to the snow removal industry. A side wing plow is generally used when extra width of the plowing swath is desired and the perceived risks involved in the employment of a side wing plow do not exceed the benefits. Typically the side wing is mounted to the side of a moving vehicle (tractor, truck, loader or grader). Side wing plows typically include a portion referred to as a side wing plow moldboard, which is a curved metal blade used for pushing snow.
With a typical side wing plow, an operator can manipulate the side wing plow moldboard up or down relative to the surface to be plowed, as well as angle the side wing plow moldboard relative to the direction of travel. When an operator configures the side wing plow to its plowing position, and the vehicle to which the side wing plow is attached is generally moving forward, snow is discharged down the length of, and past the end of the side wing plow moldboard, thereby creating a cleared path parallel to the direction of travel of the vehicle. Accordingly, by utilizing the side wing plow, the operator can increase the width of cleared snow (i.e., the swath width) beyond that which a front plow is capable of clearing alone. This extra swath width is beneficial because it increases the amount of cleared snow and pavement in a given pass, thereby increasing productivity and reducing the overall cost of the snow removal process.
U.S. Pat. No. 4,096,652, and entitled “Retractable Snowplow Wing and Mounting Therefor” discloses a side wing plow mounted to one side of a vehicle. However, side wing plows such as this are limited to use on only one side of the vehicle, thereby limiting the operator efficiency. To accommodate for special circumstances where a side wing plow mounted to the opposite side of the vehicle is needed, oftentimes there is a one vehicle with an opposite mounted wing plow within the fleet of plows. Furthermore, when this type of side wing is in a transport, or upright position, the side wing plow greatly increases the overall width of the vehicle, thereby increasing the risk of accident.
Another demonstration of prior art can be seen in U.S. Pat. No. 3,241,254, entitled “Snow Wing for Motor Graders”. This again shows a side wing plow mounted to the side of a vehicle. Neither of these inventions allow for the immediate change of discharge of snow from one side of the vehicle to the other.
In accordance with the prior art, to accomplish snow discharge on either side of the vehicle, one would currently need to mount a large and cumbersome plowing apparatus on the rear of a vehicle; such a device is taught in U.S. Pat. No. 3,908,289, entitled “Swing-Over Snow Wing”. This device, however, is extremely large and complex, and requires a great deal of thought and manipulation by the operator to function properly. This device further causes a significant decrease in operator visibility when the wing plow is in the transport position, thereby adding an unnecessary safety risk.
Another possible solution is taught in U.S. Pat. No. 7,367,407, entitled “Towed Snowplow and Method of Plowing.” This device however, requires the plow to be trailered, thereby greatly reducing maneuverability. Accordingly, this device is not meant for use within cities where frequent backing up, or travel in reverse, may be necessary.
Collectively the prior art devices add immense weight, expense and complication to the efforts of snow removal. Moreover, because of their complexity and bulk, they decrease the operators' focus, comfort and, most importantly, public safety.
Accordingly, there is a need in the snow removal industry for a wing plow that has a moldboard that can easily be moved from one side of the vehicle to the other, thereby allowing an increased swath width on either side of the vehicle without significantly adding to the weight, expense and complication of snow removal.
Additionally, there is a need in the snow removal industry for a wing plow with a moldboard that can be transported while maximizing the visibility of the operator to improve safety.
SUMMARY OF THE INVENTION
The present invention provides embodiments of a reversible wing plow with a prime mover. The reversible wing plow is comprised of a hitch, a moldboard and a moldboard shifting mechanism. The hitch is coupleable to the prime mover at a rear of the prime mover. The moldboard has an inboard end and an outboard end. The moldboard is operably coupled to the hitch proximate the inboard end and rotatable about a first horizontal axis that extends outwardly from the hitch generally parallel to a direction of forward movement of the prime mover.
The mold board shifting mechanism includes a first linear actuator and a second linear actuator. The first linear actuator has a first fixed end coupled to the hitch and a second moving end. The second linear actuator has a second fixed end coupled to the hitch and a second movable end. The first movable end of the first linear actuator and the second movable end of the second linear actuator are coupled to a rotation crank plate on opposing sides of the rotation crank plate. The crank plate is further operably coupled to the moldboard proximate the inboard end of the moldboard via a rotation member whereby the moldboard is rotatably shiftable between a first position extending outwardly on a first side of the prime mover to a second position extending outwardly on a second side of the prior mover and to a vertically oriented transport position between the first position and the second position by coordinated extension and retraction of the first linear actuator and the second linear actuator.
The above summary of the invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description that follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be more completely understood in consideration of the following detailed description of various embodiments of the invention, in connection with the accompanying drawings, in which:
FIG. 1 depicts a side view of a prime mover with reversible wing plow deployed to the driver side plowing position mounted to the rear of the prime mover by means of a three point hitch in accordance with an example embodiment of the invention;
FIG. 2 depicts a rear view a prime mover with reversible wing plow deployed to the driver side plowing position in accordance with an example embodiment of the invention;
FIG. 3 depicts a rear view a prime mover with reversible wing plow deployed to the passenger side plowing position in accordance with an example embodiment of the invention;
FIG. 4 depicts a side view of a prime mover with reversible wing plow positioned substantially vertically in accordance with an example embodiment of the invention;
FIGS. 5A through 5C depict close-up rear view of the horizontal rotation of the wing plow moldboard as it hydraulically rotates relative to the prime mover in accordance with an example embodiment of the invention;
FIG. 6 depicts an isometric view of the operable coupling of the inboard end of the moldboard to the crank plate via a rotation member in accordance with an example embodiment of the invention;
FIG. 7A depicts an isometric view of reversible wing plow with the moldboard folded in transport mode in accordance with an example embodiment of the invention;
FIG. 7B depicts a close up isometric view of the automatic safety locking mechanism in transport mode in accordance with an example embodiment of the invention;
FIG. 8 depicts an isometric view of a prime mover with reversible wing plow including the operator-manipulated joystick and smart controller in accordance with an example embodiment of the invention; and
FIG. 9 depicts a schematic of the hydraulic control system in accordance with an example embodiment of the invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have by shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
Referring now to the drawings and illustrative embodiments depicted therein, a reversible wing plow 10 for use with a prime mover 12 generally includes a hitch assembly 14 , a moldboard assembly 16 , a moldboard rotation assembly 18 , and an electro hydraulic control system 20 .
As best seen in FIGS. 7A and 8 , hitch assembly 14 includes an L-shaped hitch plate 22 , a vertical member 24 , a horizontal member 26 , and a rotational shaft 28 . In an example embodiment of the invention, L-shaped hitch plate 22 can be positioned between the rear of prime mover 12 and moldboard assembly 16 . L-shaped hitch plate 22 can be integrated with, or coupled to, vertical member 24 and horizontal member 26 .
Vertical member 24 has a front surface 30 , a back surface 32 and an inboard shaft support 34 . Front surface 30 includes at least one vehicle mount coupler 36 for removable connection to prime mover 12 . Prime mover 12 can be a tractor, grader, loader, truck, or other suitable piece of motorized equipment having ground engaging wheels or tracks. In an example embodiment of the invention, vehicle mount coupler 36 can be a three-point hitch. The vehicle mount coupler 36 can allow for vertical ground clearance adjustment of reversible wing plow 10 separate from prime mover 12 . Back surface 32 includes hydraulic ram supports 38 and 39 , turning cylinders 40 and 41 and locking pin receiver 42 . Hydraulic ram supports 38 and 39 provide connection points for coupling one end of turning cylinders 40 and 41 to vertical member 24 . Turning cylinders 40 and 41 include a first double acting hydraulic lift cylinder 40 and a second double acting hydraulic lift cylinder 41 . Vertical member 24 further includes locking pin receiver 42 . Inboard shaft support 34 provides a rotational coupling point to, and support for, the inboard end of rotational shaft 28 .
Horizontal member 26 includes outboard shaft support 44 and reinforcements 46 . Outboard shaft support 44 provides a rotational coupling point to, and support for, the outboard end of rotational shaft 28 . Reinforcements 46 provide ample structural support for maintaining rotational shaft 28 substantially fixed in position relative to L-shaped hitch plate 22 , particularly when subjected to external forces in operation.
Rotational shaft 28 is oriented substantially horizontal and substantially parallel to the direction of travel of prime mover 12 . Rotational shaft 28 is supported at by inboard shaft support 34 and outboard shaft support 44 . Rotational shaft 28 can be laterally secured in place relative to the L-shaped hitch plate 22 , for example by a large nut or other common retainer.
As best seen in FIGS. 2 , 4 and 7 A, moldboard assembly 16 , generally includes moldboard 48 and moldboard hinge knuckle 50 . In the depicted embodiment, moldboard 48 includes cutting edges 52 and 53 , bracing 54 , inboard portion 56 , outboard portion 58 , and folding linkage assembly 60 .
Cutting edges 52 and 53 include a first cutting edge 52 and a second cutting edge 53 . Cutting edges 52 and 53 are positioned opposite one another on the lateral edges of moldboard 48 . Cutting edges 52 and 53 can be coupled to moldboard 48 in a manner that allows ease in periodic replacement, for example with a series of bolts or other suitable fasteners.
In an example embodiment of the invention, bracing 54 provides ample structural support for substantially maintaining the shape of moldboard 48 , particularly when subjected to external forces in operation. Bracing can be coupled both horizontally and vertically along a surface of moldboard 48 .
Inboard portion 56 of moldboard 48 includes folding cylinder mount 64 , link arm mount 66 , angle cylinder mount 67 , and a portion of folding hinge 68 . Folding cylinder mount 64 provides a connection point for pivotably coupling one end of double acting folding cylinder 76 to inboard portion 56 . Link arm mount 66 provides a connection point for pivotably coupling one end of link arm 72 to inboard portion 56 . In an example embodiment of the invention, angle cylinder mount 67 , can be coupled to the side of moldboard opposite folding cylinder mount 64 and link arm mount 66 , as show in FIG. 6 . Angle cylinder mount 67 provides a connection point for pivotably coupling one end of angle cylinder 88 to moldboard assembly 16 .
In the depicted embodiment, outboard portion 58 of moldboard 48 includes pushrod mount 70 and a portion of folding hinge 68 . Pushrod mount 70 provides a connection point for pivotably coupling one end of push rod 74 to outboard portion 58 . Corresponding portions of folding hinge 68 are respectively coupled to inboard portion 56 and outboard portion 58 of moldboard 48 . These portions can be joined, for example by a pin, thereby hingedly coupling inboard portion 56 to outboard portion 58 .
Inboard portion 56 and outboard portion 58 of moldboard 48 can have a curved shape, thereby forming a channel to accommodate the flow of snow along the length of moldboard 48 when plowing.
In an example embodiment, folding linkage assembly 60 includes link arm 72 , pushrod 74 and double acting folding cylinder 76 . In an example embodiment of the invention, pushrod 74 , is pivotably coupled to outboard portion 58 at one end, and pivotably coupled to an end of link arm 72 on its other end. Link arm 72 is pivotably coupled to an end of pushrod 74 at one end and pivotably coupled to inboard portion 56 on the other end. Folding cylinder 76 is a double acting cylinder and is pivotably coupled to inboard portion 56 at one end, and pivotably coupled to an intermediate location on link arm 72 at its 76 the other end.
Moldboard hinge knuckle 50 is coupled to the inboard portion 56 of moldboard 48 , proximate the end opposite folding hinge 68 . Moldboard hinge knuckle 50 can be joined, for example, by hinge pin 94 to rotation member knuckle 92 , thereby hingedly coupling moldboard assembly 16 to moldboard rotation assembly 18 . Hinge pin 94 can be secured in place by a nut or other common retainer.
As best seen in FIGS. 5 , 6 , 7 B, and 8 , moldboard rotation assembly 18 includes box channel 80 , hinge plate 82 , rotation crank plate 84 , angle cylinder support plate 86 , angle cylinder 88 , and locking cylinder 90 .
Box channel 80 is supported by, and rotationally coupled to, rotation shaft 28 . Hinge plate 82 is coupled to the end of box channel 80 distal to hitch assembly 14 . Hinge plate 82 includes rotational member knuckle 92 and hinge pin 94 .
Rotation crank plate 84 is coupled to the end of box channel 80 opposite hinge plate 82 , proximate to hitch assembly 14 . As best seen in FIGS. 5 , in an example embodiment of the invention, rotation crank plate 84 includes two similar plates 96 , a first cylinder pin 98 and a second cylinder pin 100 . The two similar plates 96 can have apertures appropriately sized to accommodate first and second cylinder pins 98 and 100 . First cylinder pin 98 pivotably couples the end of first turning cylinder 40 to two similar plates 96 . Second cylinder pin 100 pivotably couples the end of second lift cylinder 41 to two rotation crank plates 96 .
As best seen in FIGS. 6 , angle cylinder support plate 86 is coupled to box channel 80 . Angle cylinder support plate 86 pivotably couples to one end of angle cylinder 88 . The opposite end of angle cylinder 88 pivotably couples to angle cylinder support 67 of the moldboard assembly 16 .
As best seen in FIG. 7B , locking cylinder 90 includes locking pin 91 , and is coupled to, and can be positioned substantially parallel to, the length of box channel 80 such that locking pin 91 can selectively extend through an aperture in two similar plates 96 and into locking pin receiver 42 of hitch assembly 14 .
As best seen in FIGS. 8 and 9 , according to an example embodiment, electro hydraulic control system 20 includes hydraulic controls 102 and electronic control 104 .
Hydraulic controls 102 generally include angle cylinder valve 108 , accumulator 109 , lock cylinder valve 110 , folding cylinder valve 112 , turning cylinder valves 114 , float valves 116 , pressure sensor 117 , directional control valve 118 , and vehicle auxiliary 119 . Hydraulic controls 102 receive hydraulic pressure from a vehicle auxiliary 119 .
Electronic control 104 includes controller 120 , joystick 122 and button 124 . Controller 120 is a computer device that senses various electrical inputs and executes preset programs based on the sensed various electrical inputs. Controller 120 is in communication with hydraulic controls 102 . Joystick 122 and button 124 can be manipulated by an operator to provide various electrical inputs to controller 120 .
In operation, moldboard assembly 16 can rotate about the rotational shaft 28 of hitch assembly 14 more than 180 degrees, allowing the change of plowing positions from one side of prime mover 12 to the other side of prime mover 12 . In an example embodiment of the invention, rotation of moldboard assembly 16 is caused by turning cylinders 40 and 41 . Other methods of rotation, such as chains, cable, gears and motor are also contemplated.
To rotate moldboard assembly 16 from the driver side plowing position (as shown in FIG. 5A ) to the passenger side plowing position (as shown in FIG. 5C ) the operator can manipulate joystick 122 towards the passenger side of prime mover 12 until rotation is complete. Manipulation of joystick 122 will activate controller 120 , which in this case, executes a preset program to activate the lift mode of hydraulic controls 102 . Upon activating the lift mode of hydraulic controls 102 , individual valves 114 , 116 and 118 are activated and fluid pressure is directed to turning cylinders 40 and 41 , thereby retracting turning cylinders 40 and 41 until they reach their equalized point (as shown in FIG. 5B ). Once this equalized point is reached, and no further hydraulic fluid can be displaced, a pressure spike occurs in hydraulic controls 102 . This pressure spike causes pressure sensor 117 to send a signal to controller 120 . This input from pressure sensor 117 causes controller 120 to execute a preset program to activate the drop mode of hydraulic controls 102 . Once the drop mode is activated controller 120 will take into consideration the direction in which the operator has manipulated joystick 122 . Based on a preset program, then controller 120 activates valves 114 to reverse the flow of hydraulic fluid to one of the turning cylinders 40 and 41 . The reversed turning cylinder 40 or 41 then extends, thereby overpowering the other turning cylinder 40 or 41 to continue rotation of moldboard assembly 16 in the direction that the operator has manipulated joystick 122 .
If the operator continues to hold joystick 122 in the same position after rotation of moldboard assembly 16 has subsided, controller 120 executes a preset program to activate the float mode of hydraulic controls 102 . The float mode removes retraction or extension pressure to turning cylinders 40 and 41 and allows free movement of hydraulic fluid through the turning cylinders 40 and 41 , thereby allowing gravity to keep cutting edge 52 or 53 of moldboard 48 against the plowing surface, particularly in uneven terrain. Float mode is activated by deactivating individual valves 114 and 118 , but allowing valves 116 to remain active. After float mode is activated, the operator can release joystick 122 .
Moldboard assembly 16 is pivotable about moldboard hinge knuckle 50 , so as to angle moldboard 48 in relation to the direction of travel of prime mover 12 by manipulation of joystick 122 forward or backward in relation to prime mover 12 . Manipulation of joystick 122 forward or backward sends an input signal to controller 120 . Controller 120 then directs hydraulic pressure to angle cylinder 88 via hydraulic controls 102 . Accordingly, when an operator manipulates joystick 122 forward, Moldboard assembly 16 pivots forward about moldboard hinge knuckle 50 until moldboard 48 is substantially perpendicular to the direction of travel of prime mover 12 . When an operator manipulates joystick 122 backward, moldboard assembly 16 pivots aft about moldboard hinge knuckle 50 until the discharge angle of moldboard 48 is at a maximum relative to the direction of travel of prime mover 12 . Accordingly, by adjusting the angle of moldboard 48 , the operator can change the discharge angle of the reversible wing plow 10 , thereby varying the effective swath width.
In addition to varying the swath width, there can be a safety function to allow moldboard 48 to automatically rotate about moldboard hinge knuckle 50 or angle back when encountering an obstacle. This is accomplished via accumulator 109 to create a hydraulic spring; however other methods, such as coil springs are also contemplated.
Inboard portion 56 and outboard portion 58 of moldboard 48 can pivot about folding hinge 68 , thereby allowing moldboard 48 to be folded approximately in half, or at least reducing the overall length of moldboard 48 . This folded position is intended for used primarily when in the transport mode as depicted in FIG. 7A .
Reversible wing plow 10 can be put into transport mode by depressing button 124 . Transport position is used when the reversible wing plow 10 is not in use; non-use can occur when driving from one area to another or when an increased swath width is not necessary. When controller 120 receives input that button 124 has been depressed, controller 120 executes a preset program to activate the lift mode of hydraulic controls 102 . As discussed previously, upon activating the lift mode of hydraulic controls 102 , individual valves 114 , 116 and 118 are activated and fluid pressure is directed to turning cylinders 40 and 41 , thereby retracting turning cylinders 40 and 41 until they reach their equalized point (as shown in FIG. 5B ). Once this equalized point is reached, and no further hydraulic fluid can be displaced, a pressure spike occurs in hydraulic controls 102 . This pressure spike causes pressure sensor 117 to send a signal to controller 120 .
If no further operator manipulation is sensed, the controller 120 then executes a preset program to activate hydraulic controls 102 to send fluid pressure to folding cylinder 76 , thereby retracting folding cylinder 76 and pivotally folding moldboard 48 about folding hinge 68 . After a pre-programmed time has elapsed, controller 120 deactivates hydraulic controls 102 , thereby removing the pressure directed to folding cylinder 76 .
Controller 120 then executes a preset program to activate hydraulic controls 102 to send fluid pressure to locking cylinder 90 , causing locking pin 91 to drive forward and become seated in locking pin receiver 42 of hitch assembly 14 , thereby physically stopping any rotation of moldboard assembly 16 relative to hitch assembly 14 . Locking cylinder 90 is a safety mechanism so that even if there is a hydraulic failure, the moldboard assembly 16 will not inadvertently fall.
For transition from transport mode to operation mode (i.e., the driver side plowing position or the passenger side plowing position), the operator manipulates joystick 122 towards either the driver side or passenger side of prime mover 12 . Manipulation of joystick 122 activates controller 120 , which in this case, executes a preset program to activate the lift mode of hydraulic controls 102 . Upon activating the lift mode, hydraulic control 102 disengages locking cylinder 90 , thereby removing locking pin 91 from locking pin receiver 42 . Because both turning cylinders are already in the equalized point a pressure spike occurs in hydraulic controls 102 . This pressure spike causes pressure sensor 117 to send a signal to controller 120 . This input from pressure sensor 117 causes controller 120 to execute a preset program to activate the drop mode of hydraulic controls 102 . Once the drop mode is activated controller 120 takes into consideration the direction in which the operator has manipulated joystick 122 . Based on a present program, then controller 120 activates valves 114 to reverse the flow of hydraulic fluid to one of the turning cylinders 40 and 41 . The reversed turning cylinder 40 or 41 then extends, thereby overpowering the other turning cylinder 40 or 41 to continue rotation of moldboard assembly 16 in the direction that the operator has manipulated joystick 122 .
If the operator continues to hold joystick 122 in the same position after rotation of moldboard assembly 16 has subsided, controller 120 executes a preset program to activate the float mode of hydraulic controls 102 . The float mode removes retraction or extension pressure to turning cylinders 40 and 41 , and allows free movement of hydraulic fluid through the turning cylinders 40 and 41 , thereby allowing gravity to keep cutting edge 52 or 53 of moldboard 48 against the plowing surface, particularly in uneven terrain. Float mode is activated by deactivating individual valves 114 and 118 , but allowing valves 116 to remain active. After float mode is activated, the operator can release joystick 122 .
Controller 120 then executes a preset program to activate hydraulic controls 102 to send fluid pressure to folding cylinder 76 , thereby extending folding cylinder 76 and pivotally unfolding moldboard 48 about folding hinge 68 . After a preprogram time has elapsed, and moldboard 48 is fully extended, controller 120 deactivates hydraulic controls 102 , thereby removing the pressure directed to folding cylinder 76 .
The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof; therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
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A reversible wing plow including a hitch, a moldboard and a moldboard shifting mechanism. The hitch is coupleable to the rear of a prime mover. The moldboard is operably coupled to the hitch proximate an inboard end and rotatable about a first horizontal axis that extends outwardly from the hitch generally parallel to a direction of forward movement of the prime mover. The moldboard shifting mechanism includes first and second linear actuators, both of which are coupled to the hitch at one end and coupled to opposing sides of a rotation crank plate on the other end. The crank plate is further operably coupled to the moldboard, whereby the moldboard is rotatably shiftable to the driver or passenger side of the prime mover, or to a vertically oriented transport position.
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BACKGROUND OF THE INVENTION
This invention relates generally to metalworking and more particularly concerns a method and apparatus for finishing a machined workpiece. The invention will be specifically disclosed by way of example, in connection with a deburring or finishing tool used upon a machine tool especially adopted for removing burrs or sharp edges from the interface of two surfaces of a piston ring.
The machining of metals often leaves sharp corners, thin ridges of workpiece material or residual areas of roughness when a metalforming element is removed. Sharp edges are formed whenever two surfaces are machined to abruptly intersect. The thin edges of material and surface irregularities are commonly referred to as burrs.
Burrs may be formed in a variety of ways during a machining process. In general, they are formed whenever workpiece material is permitted to flow unrestrained toward an edge of the metalforming element. They may be produced, inter alia, when a metalforming element enters a workpiece (entrance burrs), when the metalforming element exits the workpiece (roll-over burr), at the edges of the cut (poisson burr) or when a chip is pulled rather than sheared from a workpiece (tear burr).
Whatever the source of burrs or sharp corners, it is imperative that they be removed from many workpieces. The prior art has witnessed a wide variety of deburring techniques. Many of the prior art deburring techniques are multi-step. They require a secondary production step in addition to the primary metalforming process. The expense and time delays precipitated by these multi-step processes make them undesirable from a production viewpoint.
One such commonly employed process involves manually engaging a workpiece with a rotary powered brush after machining. This process, in addition to requiring additional time, is also very frequently ineffective in removing sharp corners.
Another commonly employed technique involves placing a plurality of workpieces into an agitating barrel with abrasive materials. The barrel finishing technique, in addition to being a time consuming second step, is inherently non-selective and may take off critical portions of the workpiece and effect tolerances. Barrel finishing is also generally ineffective in removing burrs from recessed areas.
Abrasive jet blasting is a process in which a compressed air jet stream filled with particulate abrasive matter is directed against a surface. This technique is much more selective than barrel finishing but is unsatisfactory for hard to remove burrs or corners.
Various other deburring techniques have been used in the past, as for example, electro-chemical and thermal deburring. However, like the previously mentioned techniques, they are replete with disadvantages. For example, electro-chemical deburring is expensive and inflexible due to the special tooling required for each different sized workpiece; and thermal deburring may result in damage to the workpiece. Additionally, these techniques, like each of the other aforementioned ones, do not afford the luxury of simultaneously deburring the workpiece with the primary metal forming process.
Mechanical deburring tools do have the potential for simultaneous operation. Still, most prior art mechanical deburring tools have awkward and cumbersome physical structures, a disadvantage which is accentuated when operating upon hard to reach internal surfaces. Further, it has been found that, when using a finishing tool, workpiece material may tend to flow toward the edges of the cut if relative movement between the workpiece and the tool is constant and in a single direction. Thus, many of these tools, when being used to remove a single burr (or ridge) may themselves form a pair of similar, albeit smaller, burrs upon the edge of the workpiece interface. Similarly, a finishing tool which is planar is likely to form smaller burrs at an abrupt edge of the planar surface.
SUMMARY OF THE INVENTION
According to the invention, a finishing tool assembly for use with a machine tool has a housing which is pivotally mounted upon a base. An elongated rod is supported in the housing and extends outwardly in a direction transverse to the pivotal axis of the housing. Means are provided for oscillating the housing element about its pivotal axis and moving the rod in an arcuate path about the housing axis while the rod engages a workpiece about its periphery.
In the preferred embodiment, the housing is mounted for common reciprocatory movement with the metalforming element of a machine tool. A biasing means is associated with the housing tending to rotate the housing to a predetermined angular position about the pivotal axis of the housing. A rod extends transverse to the housing axis to contact a workpiece and cooperates with the workpiece to selectively overcome the biasing means in accordance to the reciprocatory movement of the metalforming element.
BRIEF DESCRIPTION OF THE DRAWINGS
There will now be given a detailed description to be read with reference to the accompanying drawings of an apparatus which is preferred embodiment of the invention and which has been selected to illustrate this invention by way of example.
In the accompanying drawings:
FIG. 1 is a perspective view of a grinding machine utilizing a form of the present invention, with details omitted for clarity of illustration.
FIG. 2 is a fragmentary perspective view depicting the finishing tool assembly on the grinding machine illustrated in FIG. 1 in greater detail.
FIG. 3 is a plan view of an end portion of the finishing tool assembly of FIG. 2 illustrating its relationship to a specific workpiece.
FIG. 4 is a cross-sectional side elevational view of the finishing tool assembly of FIGS. 1 through 3 with details omitted for clarity of illustration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, a grinding machine 10 is shown having a base 12 upon which a wheelhead 14 and workhead 16 are mounted. The wheelhead 14 contains a spindle housing 18 rotatably supporting a spindle 20. A grinding wheel 22 is supported upon one end of the spindle 20, and belt 26 is engaged with the other end of the spindle, opposite the spindle housing 18, to transmit rotary power generated by a motor 24. The wheelhead 14 is rigidly attached to a pivot bar 28, which is rotatably and longitudinally moved by actuators (not shown) to provide feed movment between the wheelhead 14 and workhead 16. An oscillator 30 provides supplemental oscillatory longitudinal movement of the pivot bar 28 and serves to eliminate feed lines upon a workpiece. The grinding machine described thus far is of a construction antedating the present invention and is of the general type disclosed in U.S. Pat. No. 4,096,667.
In the preferred embodiment of the invention, the general features of which are shown most clearly in FIG. 2, a support plate 32 extends from the wheelhead 14 to support a finishing tool assembly 34. The assembly 34 includes a tool housing 36 supporting an elongated hardened metal rod 38 used to finish a workpiece 39. The housing 36 is supported upon a carrier arm 40 which is in turn supported upon the support plate 32.
The rod 38 has an elongated cylindrical configuration with a substantially circular cross section which provides several advantages. The circular cross section configuration is symmetrical about the rod's longitudinal axis and therefor may be rotated about the axis without altering the distance from the housing to the contact area interface with the workpieces. It also provides a taper about the edges of the workpiece contact area and eliminates an abrupt edge of the contact surface. Further, this configuration assists in positioning the tool at a specific workpiece location, particularly when it is desired to finish an internal workpiece surface. The circular cross section of the rod 38 also presents a convex interface surface for contact with the workpiece, resulting in relatively high Hertzian stresses which assist in workpiece breakdown and burr removal. The Hertzian stresses are particularly pronounced when the rod's radius of curvature is small.
As most readily realized with a joint viewing of FIGS. 2 and 4, the housing 36 is pivotally mounted upon a carrier arm 40 about a pin 41 (FIG. 4). A cross bar 42 secured by screws 44, transverses the arm 40 in the vicinity of the housing 36. The cross bar 42 serves to support one end of an extension spring 46 whose opposite end is connected to the tool housing 36. The spring 46 tends to rotatably bias the housing about its pivot at pin 41 so as to engage an edge of the workpiece 39 with the periphery of the elongated metal rod 38. Thus, rotational movement of the housing is terminated whenever the rod 38 engages the workpiece or the housing contacts a stop 48 mounted in a cross bar 50 rigidly disposed upon the carrier arm 40 between the housing 36 and cross bar 42. As the support plate is oscillated parallel to the longitudinal axis of the pivot bar 28, under the influence of the oscillator 30, the bias of spring 46 is overcome and relaxed with each cycle of oscillatory motion. The finishing tool is thus oscillated without the necessity of an auxiliary power source. The spring 46 tends to return the housing 36 towards the stop and into constant engagement with workpiece 39 throughout the oscillatory movement. The interface force between the elongated rod 38 and the workpiece 39 may, of course, be varied by substituting springs (46) with different spring rates.
As most clearly depicted in FIG. 4, the elongaged rod 38 is also rotatable about its longitudinal axis simultaneously with the arcuate movement of pin 41. In the illustrated form, this longitudinal rotation of the rod 38 is achieved by a pawl 47 and ratchet 49 mechanism within the housing 36. The housing 36 has two internal perpendicular bores 54 and 56 of circular cross section, the bore 54 running substantially horizontal and the bore 56 running substantially perpendicular. Each of the bores has a portion of enlarged diameter (54a, 56a) as well as a portion of reduced diameter (54b, 56b) with the reduced portion of bore 56 communicating with enlarged portion of bore 54.
An actuator 58 is disposed within bore 54 and has a portion of reduced diameter 58a upon one end which fits within the reduced portion 54b of horizontal bore 54. The actuator 58 has a conical surface 58b upon the other end and which is mated against a conical surface 54c of bore 54. A piston 60 is axially movable within the enlarged vertical bore 56a and moves the pawl 47 within the bore 56b and into bore 54 where it engages a ratchet 49 about the periphery of actuator 58. A fluid passage 66 provides fluid communication between the bottom of enlarged bore 56a, beneath the piston 60 and reduced portion 54b. Hydraulic fluid lines 68 and 70 are connected to a fluid source (not shown) to selectively communicate pressurized fluid to ports 72 and 74 communicating with bores 56a and 54b respectively.
In operation, as pressurized fluid is introduced into hydraulic line 70, a compressive force is exerted against the end portion of actuator 58a urging it leftwardly as viewed in FIG. 4. The movement of actuator 58 forces the conical surface 58b into a tight frictional engagement against mating conical surface 54c of the bore 54, preventing rotation of the actuator 58. Fluid pressure within the bore 54b is also communicated through a fluid passage 66 to the underside of piston 60 in the bore 56a, urging the piston 60 and the pawl 47, which it carries, upwardly. Fluid in bore 56a above piston 60 is exhausted out bore 72 and conduit 68. When, through suitable valving (not shown) the pressurized fluid is diverted into conduit 68 and port 72, and fluid is exhausted from port 74 and conduit 70, piston 60 is urged outwardly. Pawl 47 engages ratchet 49 on a periphery of actuator 58 forcing rotation of the actuator and rod 38.
It should also be apparent that the rod 38 might also have any of several well-known mechanisms for imparting longitudinal axial movement.
Turning once again to FIG. 2, it can be seen that the carrier arm 40 is selectively pivoted about pin 76 (which is parallel but noncoincident to the housing pivot pin 41) according to the dictates of a piston which is reciprocably housed within a cylinder 78. A rod 80 extends from the piston and moves a link 84 connected to the piston rod 80 by a clevis joint 86. A pin 88 extending parallel to pins 76 and 41 (FIG. 4) intersects both the link 84 and carrier arm 40 to insure pivoting of the carrier arm 40 about pin 76 with linear movement of the piston contained within cylinder 78.
FIG. 3 illustrates the elongated rod 38 (in the solid line depiction) in engagement with the interior interface (corner) 94 of two substantially planar surfaces 90 and 92 of the workpiece 39 shown as a trapezoidal (keystone) piston ring whose face is being ground by the grinding wheel 22. As illustrated in the drawing by the arrow 80, the workpiece 39 is being rotated by the workhead 16 in a clockwise direction. The rod 38 as illustrated by arrow 82 is simultaneously being rotated about pivot pin 41 (FIG. 4) of a housing assembly 34 (due to the reciprocation of wheelhead 14) and about the longitudinal axis of rod 38 (by the pawl 47 and rachet 49). The conjugate movement between the workpiece 39 and rod 38 breaks the corner of the interface 94 between the substantially planar surfaces 90 and 92 and removes any burrs at this location. The phantom position of the housing assembly 34 in FIG. 3 shows the rod 38 and housing 36 in a retracted position out of engagement with the workpiece 39. This retracted position illustrated in phantom might be employed during rough or nonfinishing grinding modes of the grinding machine 10 and is obtained by pivoting the carrier arm 40 about pivot pin 76.
Although the invention has been illustrated in some detail according to the preferred embodiment shown in the accompanying drawings, and while the preferred illustration and embodiment has been described in some detail, there is no intention to limit the invention to such details. On the contrary, it is intended to cover all modifications, alternations and equivalents falling within the spirit and scope of the appended claims.
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A tool for deburring or finishing a workpiece is mounted for common reciprocatory movement with the wheelhead of a grinding machine. The tool, which is form of an elongated rod, is supported in a housing which is in turn pivoted about an axis transverse to the tool. A biasing means urges the tool toward a predetermined angular position about the pivotal axis of a housing. The tool cooperates with a workpiece to selectively overcome the bias and oscillate the tool in accordance with the relative reciprocatory movement between the grinding wheel and the workpiece.
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BACKGROUND OF THE INVENTION
[0001] (a) Field of the Invention
[0002] The present invention relates to a single cord activation mechanism for collecting a window blind, and more particularly to a mechanism which is used to operate a release of slats of a window blind by a method of single cord activation. The mechanism includes primarily a reel which is connected to the slats through a lifting cord, and whose one end is operated by an activation shaft with a smaller diameter, through a single activation cord. The slats can be opened by themselves with their deadweights, whereas they are collected through acting on the activation shaft and the reel associated therewith by the single activation cord, thereby achieving purposes of enlarging speed and collecting with safety.
[0003] (b) Description of the Prior Art
[0004] An operation of opening slats of a horizontal window blind can be performed manually or electrically. The manual operation is shown in FIG. 1 , wherein pluralities of slats 10 are located below a top rail 1 . A pull cord 2 links with each slat 10 and passes through a penetration 15 on the top rail 1 , and then reeves on an arresting member 100 to extend with an active pull cord 20 . There are at least two active pull cords according to the quantity of pull cords. Therefore, two cords extended from the pull cord 2 will be accumulated at the position of active pull cord 20 . The arresting member 100 creates a locking function to lock on any position of a section of the active pull cord 20 , so as to position the slats 10 in a half-open or full-open status.
[0005] The slats 10 can be dropped down by the deadweight effect associated with the gravity of earth. However, upon collecting slats 10 , the active pull cord 20 is used to pull up the slats 10 to stack them upward to achieve a purpose of collecting.
[0006] As the active pull cord 20 is made by two cords 200 , a tangle will usually be formed between them. In addition, since an activation stroke of the active pull cord 20 is the same as a collecting/releasing stroke of the slats 10 , a certain length will be dropped down for the active pull cord 20 after collecting the slats 10 , thereby forming a free hanging cord and causing a danger of winding and tying limbs of kids due to playing.
[0007] Referring to FIG. 2 , a recent method of electrically operating a window blind is to use a motor 13 to drive a reel 11 through a polygonal driving shaft 12 . An inner hole of the reel 11 provides for the driving shaft 12 to rotate radially, and the reel 11 is supported by a sliding seat 14 which is movable. The entire mechanism is installed inside a top rail 1 and can slide longitudinally. An outer surface of the reel 11 provides for a winding of a lifting cord 16 which passes through each slat 10 and combines with a ladder string 160 to position the slats 10 in an equal distance. As the motor 13 requires electricity, the mechanism will lose its convenience under a blackout condition.
SUMMARY OF THE INVENTION
[0008] In lieu of the aforementioned inconvenience of conventional collecting mechanisms, the present invention uses a single cord operation method to open and close the slats, whereas the slats can be dropped down by using the deadweight effect of slats themselves. In addition, the reel is driven to collect the slats by acting on the activation shaft through the single activation cord. The working principle is to use a shear force between strands of lifting cord to form a horizontal component of force, which in turn drives the reel to shift longitudinally, during the process of collecting the slats. In addition, the diameter of reel is larger than that of the activation shaft, therefore a linear velocity (length) of the activation cord can be enlarged by an enlargement of the reel, thereby providing a fast operation and shortening a length at lower end of the activation cord.
[0009] To enable a further understanding of the said objectives and the technological methods of the invention herein, the brief description of the drawings below is followed by the detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a perspective view of an activation mechanism of a conventional horizontal window blind.
[0011] FIG. 2 shows a perspective view of a conventional method of collecting slats electrically.
[0012] FIG. 3 shows a side view of the present invention.
[0013] FIG. 4 shows a schematic view of operation of a lifting cord of the present invention.
[0014] FIG. 5 shows a force diagram of FIG. 4 .
[0015] FIG. 6 shows a schematic view of a release shaft driving a lifting cord of the present invention.
[0016] FIG. 7 shows a force diagram of FIG. 6 .
[0017] FIG. 8 shows an end view of a relationship between a release shaft and an activation shaft of the present invention.
[0018] FIG. 9 shows a side view of FIG. 8 .
[0019] FIG. 10 shows a schematic view of a release shaft after dropping down slats of the present invention.
[0020] FIG. 11 shows a comparison between a stroke of lifting cord and a stroke of activation cord.
[0021] FIG. 12 shows a side view of screws of another implementation of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to FIG. 3 , a release shaft 3 is located on a sliding seat 30 which is installed in a top rail 1 . The release shaft 3 is coaxially connected to an activation shaft 4 with a smaller diameter. The activation shaft 4 is supported by another corresponding slide seat 40 . An outer surface of the release shaft 3 provides for winding a lifting cord 31 whose free end passes through a shed 18 installed in the top rail 1 and which is linked downward to slats 10 , with a terminal free end connected to a bottom rail 17 . The activation shaft provides for winding an activation cord 41 which passes through an arresting member 100 located on the top rail 1 . The arresting member 100 is a conventional arresting member and its function is to lock on any position of a section of the activation cord 41 , such that when pulling down the activation cord 41 , it should be shifted by an angle to escape from the arresting member 100 . As the operation of arresting member 100 is an ordinary design, it will not be described further.
[0023] The activation cord 41 wound around the activation shaft 4 will move up and down alternatively, relative to the lifting cord 31 on the release shaft 3 . Therefore, when dropping down the slats 10 , the release shaft 3 will be rotated accordingly, which in turn Will drive the activation shaft 4 to rotate in a same direction simultaneously.
[0024] When the slats 10 drop down due to their deadweights, the lifting cord 31 will be limited by the position of shed 18 . Therefore, when the release shaft 3 is pulled by the lifting cord 31 , it will be pushed rightward according to its sidelong component of force, which will in turn extend the activation shaft 4 rightward. In addition, as the activation cord 41 located on the activation shaft 4 will be collected when dropping down the slats 10 , and the release shaft 3 will move rightward, hence there will be no overlapping between each strand of activation cord 41 , thereby constituting a spiral shape collection.
[0025] Referring to FIG. 4 , when the lifting cord 31 is collected on the outer surface of release shaft 3 , a series of strands 310 aligned next to each other will be formed between a last strand 310 and the lifting cord 31 . During a process of collection, as the lifting cord 31 is positioned by the shed 18 and when an upper end of lifting cord 31 is wound on an initial position of the release shaft 3 , a sidelong shear will be formed at a previous strand 310 , resulting in a distance P 2 before shearing and a distance P 1 after shearing. Pluralities of strands 310 are aligned with an equal distance P 1 , and a position of point of action P will be changed into a position on an upper surface of release shaft 3 , due to a sidelong shear.
[0026] Referring to FIG. 5 , during a process of shifting the point of action P, a sidelong force of action F will be formed, which is composed of a vertical component of force F 1 and a horizontal component of force F 2 caused by the lifting cord 31 . The horizontal force of action F 2 branched out from the sidelong force of action F will be acting on a left side. Therefore, as shown in FIG. 4 , the force of action F 2 will push a previous strand 310 . As each strand 310 is winding on the outer surface of release shaft 3 which can freely slide as a free body in a longitudinal direction, the release shaft 3 will be pushed leftward by subjecting to the horizontal force of action F 2 .
[0027] Referring to FIG. 6 , when the lifting cord 31 is pulled down by an external force, a sidelong angle θ will be formed at the lifting cord 31 between the shed 18 and release shaft 3 , due to a positioning of shed 18 and a resistance force resulted from a horizontal shifting of release shaft 3 .
[0028] Referring to FIG. 7 , a downward vertical force of action F of the lifting cord 31 will be decomposed into a sidelong component of force F 1 and a horizontal component of force F 2 due to the aforementioned factors. Similarly, the horizontal component of force F 2 will result in a rightward force through the sidelong component of force F 1 and the force of action F, so as to push the release shaft 3 rightward.
[0029] Referring to FIG. 8 , the activation shaft 4 is coaxially connected to the release shaft 3 . Therefore, when the activation cord 41 is winding on the activation shaft 4 clockwise, the lifting cord 31 will be winding on the outer surface of release shaft 3 counterclockwise.
[0030] Referring to FIG. 9 , as the release cord 31 and the activation cord 41 are winding on the release shaft 3 and the activation shaft 4 in different direction, when the release shaft 3 is rotating counterclockwise and the lifting cord is moving downward, the activation cord 41 will be pulled up and collected. On the contrary, if the activation cord 41 is pulled down, the release shaft 3 will collect the lifting cord 31 .
[0031] Referring to FIG. 10 , it shows a schematic view of dropping down the slats. Similarly to dropping down the slats 10 due to the deadweight effect as shown in FIG. 3 , a locking status of the activation cord 41 by the arresting member 100 must be removed, so as to enable the activation cord 41 to freely move up. Whereas, the lifting cord 31 will pull the release shaft 3 through a downward movement of slats 10 , and push the release shaft 3 rightward according to the working principle depicted in FIG. 6 , which will in turn extend the activation shaft 4 rightward. Moreover, due to the working principles depicted in FIG. 8 and FIG. 9 , the activation shaft 4 will collect the activation cord 41 . On the other hand, upon collecting the slats 10 , the activation cord 41 will be escaped from the arresting member 100 and pulled, and simultaneously rotate the release shaft 3 through the activation shaft 4 , such that the release shaft 3 can collect the lifting cord 31 in a reverse direction, thereby pulling up the slats 10 and achieving a purpose of collecting the slats 10 .
[0032] Referring to FIG. 11 , a lifting stroke L 1 of the lifting cord 31 driven by the release shaft 3 is determined by multiplying a diameter D 1 of release shaft 3 by the ratio of the circumference of a circle to the diameter and a rotational speed (L 1 =π D N). As the release shaft 3 and the activation shaft 4 are connected coaxially, their rotational speeds will be identical. As the diameter D 1 of release shaft 3 is larger than the diameter D 2 of activation shaft 4 , the operation stroke L 1 of lifting cord 31 must be greater than a pulling stroke L 2 of activation cord 41 . If the diameter D 1 of release shaft 3 is twice as much as the diameter D 2 of activation shaft 4 , then the stroke L 1 will also be twice as much as the activation stroke L 2 of activation cord 41 . By taking an advantage that the strokes are not the same, a user can operate the activation cord 41 in a short range to operate a height of opening and closing of a large stroke lifting cord 31 . Correspondingly, an operation speed can be enlarged to operate an upward and downward movement of the slats 10 .
[0033] A stem 410 is fastened to the free end of activation cord 41 , so as to facilitate a grab with hands for activation. As the activation cord 41 can be extended downward, and its operation stroke L 20 is also located below, therefore for a window blind hanged up in a high position, a user can operate at a position close to a ground, by using this concept.
[0034] The concept of providing a grab with the stem 410 at the free end of activation cord 41 can be further applied to a terminal cord winder 42 which is connected to the free end of activation cord 41 . A shape of the cord winder 41 is used to provide for grabbing and the cord winder 41 can be an ordinary tool for winding cords, which will not be described further. By using the cord winder 42 to perform collection, the position of stem 410 can be at any height.
[0035] Referring to FIG. 12 , a sliding friction exists between the release shaft 3 and the sliding seat 30 , such that the release shaft 3 can move rightward and leftward in a longitudinal direction. To further specify that the release shaft 3 can collect the lifting cord 31 in a full pitch, male threads 32 with a pitch equal to the diameter of lifting cord 31 are located on the outer surface of release shaft 3 . The male threads 32 are acting on female screws 300 located in the sliding seat 30 . By a high sliding rate between the female screws 300 in the sliding seat 30 and the male threads 32 , the release shaft 3 can easily move longitudinally according to a specification of male threads, when pulling down the lifting cord 31 . The female screws 300 are located in a position with respect to a sliding hole 301 . By using the male threads 32 located on the release shaft 3 , the lifting cord 31 can be collected in an equal pitch, which in turn can move the activation shaft 4 axially with a uniform pushing velocity.
[0036] In addition to the aforementioned implementation of male threads 32 on the outer surface of release shaft 3 , the present invention can further install male threads 43 on the outer surface of activation shaft 4 . The male threads 43 fit with female screws 400 located at a position of sliding hole 401 of a sliding seat 40 , such that the activation cord 41 can be wound on the male threads 43 according to the threads, wherein the activation cord 41 and the lifting cord 31 have the same diameter. If both the release shaft 3 and activation shaft 4 are provided with the male threads 43 , their pitch must be identical. However, the diameter of release shaft 3 is larger than that of activation shaft 4 .
[0037] It is of course to be understood that the embodiments described herein is merely illustrative of the principles of the invention and that a wide variety of modifications thereto may be effected by persons skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims.
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A single cord activation mechanism for collecting a window blind, especially a mechanism which uses a single cord to collect slats of a window blind, is primarily composed of a release shaft with a larger diameter which is connected coaxially with an activation shaft. The entire structure is located in a top rail longitudinally. The release shaft provides for winding a lifting cord for opening and closing the slats. The activation shaft provides for winding an activation cord through an arresting member. A linear length of releasing operation can be enlarged by increasing the diameter of activation shaft, and a height of operation can be safely and easily acquired according to opening and closing the slats with the single activation cord.
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FIELD OF THE INVENTION
[0001] The invention relates to a method for producing prefabricated parts of mineral-bound building materials.
[0002] In particular the construction of buildings requires high effort of personnel, time and transport logistics. By the prefabricated house construction, this effort can be reduced.
BACKGROUND ART
[0003] There are various methods of producing prefabricated houses:
[0004] One possibility is in causing an enterprise to build a so-called turnkey house. Usually, the structural work of a turnkey house stands after ca. 6 weeks.
[0005] A further possibility is in obtaining prefabricated parts from a distributor and self undertaking the construction of the walls, floors and ceilings. In structurally weak areas, usually, very long transportation routes are to be covered since the factory, in which the prefabricated parts are produced, is mostly located in areas with optimum infrastructure for the factory manufacture, thus is usually located far away. Despite of the advantages of the prefabricated construction, this technology is only rarely employed due to the above described disadvantages.
[0006] In both possibilities, one hands over the manufacture of the prefabricated parts for manufacturing and logistical reasons.
[0007] The production of prefabricated parts usually occurs in factories, from which the prefabricated parts or the complete prefabricated houses are then transported to a desired erection site. Especially with greater building projects or projects with time pressure, e.g. after natural disasters, long construction times or long transportation routes are inacceptable. Here, remedy is to be provided.
[0008] Therefore, the invention is based on the object of disclosing a method for producing prefabricated parts of mineral-bound building materials, which allows producing different prefabricated parts, in particular walls, floors and ceilings, or complete buildings near the site of use of the prefabricated parts. Further, a manufacturing system is to be disclosed, which allows producing prefabricated parts of mineral-bound building materials near the site of use of the prefabricated parts.
SUMMARY OF THE INVENTION
[0009] In a method for producing prefabricated parts of mineral-bound building materials, in particular for construction of buildings, by means of a manufacturing system, the used manufacturing system includes at least one formwork table provided for casting the prefabricated parts of mineral-bound building materials as the essential component. The manufacturing system is mobile and it can be brought to the site of use of the prefabricated parts and in particular to the erection site of a building for manufacturing the prefabricated parts. Thus, this mobility allows transporting a complete small factory for manufacturing prefabricated parts of mineral-bound building materials to very different locations.
[0010] The required binders, aggregates as well as mixing water and possible additives for producing mineral-bound building materials can be easier transported than bulky prefabricated parts already produced from them, which often have a considerable weight due to their size. The transport logistics are much simpler since only building materials or the raw materials thereof as well as materials have to be made available on site, which usually can be provided on shorter transportation routes.
[0011] With the method the following prefabricated parts can be produced:
[0012] Wall, ceiling, floor, basement or stone elements, front elements, plaster plates, insulating elements or fence elements.
[0013] On site, in particular prefabricated parts with very different densities can be produced, e.g. of concrete and of a much lighter insulating material.
[0014] In some embodiments, the entire manufacturing system can fit in a cargo container, which can be transported to the erection site by means of a truck. The cargo container can be transported by air, by water or by land without problem. Thus, the manufacturing system can be transported to each location, to which a road leads.
[0015] Furthermore, it is provided that the formwork table is brought into a horizontal position for casting the prefabricated parts and is inclined about a horizontal axis for or after forming. In the horizontal position, a mixture of a mineral building material is placed in the formwork. In this position, the mineral building material can be flatly moved off. After the mineral building material is then set as far in the formwork, then it can be stripped. For stripping wall elements, the formwork table is inclined about the horizontal axis such that the dried prefabricated parts can be removed.
[0016] Advantageously, several formwork tables are provided, which can be displaced independently of each other. This entails the advantage that several prefabricated parts can be produced independently of each other at the same time. While a wet mixture of a mineral building material still sets on one formwork table, the already set prefabricated part can be removed on another formwork table. At the same time, a new mixture of a mineral building material can be cast in a third formwork of a further formwork table. In addition, it is advantageous that differently configured prefabricated parts can be manufactured at the same time. Floors, ceilings and walls can be provided with variable recesses for doors and windows. This allows the utilization of established standard shapes or else the realization of individual ideas. This means that for example a wall can be cast on one formwork table and another part can be cast on a second formwork table.
[0017] Preferably, the formwork table is inclined into its respectively required position via compressive force. Therein, the compressive force is advantageously introduced into the formwork table by means of a linear drive. The compressive force is introduced from a bottom of the formwork table opposing the formwork area. To this, the linear drive is mounted below the formwork table, wherein it extends between the formwork table and the respective ground or a corresponding substructure, for example a supporting structure.
[0018] In order to achieve displacement as well as inclination of the formwork table, which behaves as stable as possible as well as is balanced and associated with little distortions, it is provided that the compressive force is introduced in the region of the center of area of the formwork table.
[0019] With respect to a tensile force introduced for inclining the formwork table, the compressive force generated via the linear drive can provide increased safety. Thus, tensile forces are transmitted by corresponding pull means such as for example ropes or chains, the failure of which results in mostly abrupt tilting of the formwork table. The danger to the operating personnel arising from it as well as the possible damage to the system is avoided according to the invention in that the used linear drive has a protection against return. This return protection can already be present by construction if for example a self-locking spindle or rack drive is used.
[0020] Preferably, the linear drive is hydraulically driven. Preferably, it is a single-acting or double-acting lifting cylinder. Oil, water or an oil-water emulsion can be employed as the fluid for the hydraulic drive.
[0021] Advantageously, the hydraulic drive has or is coupled to a safety element. The safety element is provided for effectively preventing undesired lowering of the formwork table inclined out of its horizontal position and thus erected. For example, the safety element can be a check valve. In addition, pressure limiting valves can be provided, which protect from overpressure.
[0022] The actuating force required for actuating the linear drive can be effected both with muscle power and from a suitable drive. For increasing the actuating force, suitable force boosters, i.e. transmissions or also pressure boosters, are provided, which are coupled to a pump. Of course, the pump can also be operated by means of muscle power. Furthermore, the pump can also be operated by motor, for example via an electric motor or an internal combustion engine. The connection of the linear drive to an external hydraulic or pneumatic source for example of a motor vehicle (tractor, Unimog, truck) is also conceivable.
[0023] Preferably, each individual formwork table has two horizontal axes spaced parallel to each other. The individual formwork tables can each be inclined in respectively equal or mutually different directions about one of these axes. The advantage is that several prefabricated parts can be created in parallel in a manufacturing system with several formwork tables, which can be inclined towards the respectively required side and thus be erected on demand.
[0024] Thus, it can for example be advantageous that the side of the prefabricated part facing the respective formwork area of the formwork tables constitutes the exterior visible side of wall elements. In order not to have to rotate the prefabricated parts before their erection on the intended site in expensive manner, they can be suitably erected already by the choice of the inclination direction of the formwork table.
[0025] In particular, the formwork tables are movable. Preferably, they are supported on a supporting structure, which is displaced on rails out of the cargo container and into it upon non-use. The displacement can be effected on a railbound or non-railbound system. The formwork tables can be displaced and in particular moved into the cargo container upon non-use, after completed work, for protection from adverse weather or also for protection from theft.
[0026] It is possible that the end of the linear drive can be displaced analogously to the respective inclination direction of the formwork table. Preferably, the end of the linear drive facing away from the formwork table is detachably coupled to the supporting structure. For example, the coupling can be effected by detachably bolting. To this, the supporting structure has at least two mutually opposing receptacles, wherein the said end of the linear drive is selectively coupled to the one or the other receptacle.
[0027] Advantageously, the linear drive is coupled to that receptacle of the supporting structure opposing the horizontal axis, about which the formwork table is to be inclined.
[0028] The formwork table can have a chassis. By the chassis, the formwork table can be autonomously moved. Of course, the chassis can also be disposed on the supporting structure, on which several formwork tables are supported. The formwork table can be moved between its possible operating sites by the supporting structure. In the same manner, several formwork tables disposed on the supporting structure can thus also be collectively moved between their operating sites if the chassis is disposed on the supporting structure.
[0029] According to the configuration of the chassis, thus, operating sites difficult to access can also be reached, which are located on unfortified terrain. Apart from moving between possible operating sites for producing the prefabricated parts, thus, already produced or prefabricated parts still located in the formwork can also be brought to the site of their installation or their erection. This is in particular advantageous if suitable hoist with sufficient operating range is not present or employable on site in order to displace the prefabricated parts far enough.
[0030] In an advantageous development, the supporting structure supporting the formwork table(s) is formed such that it can be transferred from a transport size into an operating size by pulling apart. In other words, the supporting structure is thus varied in its dimensions, wherein it is pushed together as space saving as possible upon its stay within the cargo container, while it is pulled apart to its full or currently required size outside of the cargo container. In this manner, the supporting structure is extended or contracted. To this, the supporting structure is composed of individual elements coupled to each other via hinge connections.
[0031] In contrast to the production of prefabricated parts in closed buildings, the displacement of the formwork tables out of the cargo container offers the possibility of utilizing solar and wind energy for drying the prefabricated parts. The natural heat supply has positive ecological and economic effects.
[0032] The formwork tables can have hinges allowing unfolding of the formwork tables to a width in a use position, which exceeds the width of the cargo container. The capability of unfolding the formwork tables allows producing larger prefabricated parts. Moreover, there is the possibility of creating a large common area from the individual formwork tables, which allows high variance with respect to the size of the prefabricated parts. With the method, the possibility of creating single-floor bungalows as well as multi-level buildings, e.g. single- and multi-family houses, school buildings, hospitals or other public institutions, is given. Of course, prefabricated parts for open structures such as e.g. fences can also be produced.
[0033] Another possibility for enlarging the formwork tables is given via external modules, by which a use position is also allowed, which exceeds the width of the cargo container. For example, the external modules can be screwed to and/or pushed onto or into the formwork tables.
[0034] Preferably, the formwork tables are designed or extendable to a formwork area of at least 2.5 m×2.5 m to 5.0 m×5.0 m. In particular with a succession of several formwork tables, they can allow an overall formwork area of 5.0 m×10.0 m to 5.0 m×50.0 m. In the latter case, the supporting structure is extendable such that 10 of the formwork tables having the raster of 5.0 m×5.0 m in total can be supported thereon.
[0035] By connecting the individual linear drives to each other, the successive formwork tables can be inclined to the same direction at the same time in order to thus also allow stripping large prefabricated parts by erecting them.
[0036] Of course, herein, individual formwork tables can also be inclined in directions varying from each other or not at all. This depends on the respective dimensions of the prefabricated parts to be produced.
[0037] To this, the supporting frame is first extended to the required size and the required number of the formwork tables is supported thereon. On demand, the formwork tables are extended with respect to their respective formwork area via the previously demonstrated possibilities. Subsequently, they are coupled to the supporting frame for example via detachable bolts on one of the horizontal axes, around which the respective formwork table is to be inclined. Furthermore, the linear drives are each disposed between formwork table and supporting structure and detachably coupled to them. The required control of the linear drives is effected by their entire or partial coupling to each other.
[0038] The manufacturing system can be brought into the cargo container such that first the formwork tables are removed and folded up and/or the external modules are removed on demand. Subsequently, the supporting structure is pushed together and placed in the cargo container. Finally, the individual formwork tables are stacked on the supporting structure and the possible external modules are also brought into the cargo container.
[0039] The operation of the formwork table and the assembly of the finished prefabricated parts are simply and fast learnt. Already after relatively short instructions and short training periods, most of the works can be done autonomously by resident personnel.
[0040] Furthermore, a manufacturing system is contemplated, which serves for producing prefabricated parts of mineral-bound building materials. The manufacturing system includes at least one formwork table, which is provided for casting the prefabricated parts of mineral-bound building materials. The formwork table is supported on a supporting structure transportable to the site of use of the prefabricated parts, i.e. usually to the erection site of the building/structure to be built, together with the formwork table in a cargo container and displaceable and in particular movable out of the cargo container on site.
[0041] The manufacturing system is suitable for mineral building materials of all kinds Advantageously, the cargo container has the customary measure of a 20 and/or 40 feet container, which can also be transported by air or by sea without problem.
[0042] The supporting structure can have rollers movable on rails. The rails are carried along in the cargo container. In at least one embodiment, it is provided that a transport path of the formwork tables of up to 40 m is allowed.
[0043] However, it is basically also conceivable to fit the formwork tables without rails/rolling system and to transport the formwork tables out of the cargo container by stacker trucks or via a hydraulic pumping system independent of current.
[0044] In a further development, the supporting frame can have a chassis, via which the supporting structure is movable together with the at least one formwork table. The rail/roller system, by which the formwork tables are movable out of the container, is not meant by this chassis. The chassis serves for the movement unlinked to rails. The chassis can for example be a wheel chassis or a caterpillar drive. The caterpillar drive as a tracked chassis entails the advantage that it is also employable on rough terrain. The chassis can be driven, for example via an electric motor or an internal combustion engine. In this manner, larger dimensioned formwork tables and thus larger prefabricated parts with corresponding weight are also movable without problem.
[0045] In an advantageous development, the supporting structure can have longitudinal supports, which are translationally mutually displaceable at least in sections both for extending and for contracting the supporting structure.
[0046] Therein, the longitudinal supports can be guided both laterally to each other and in each other. Therein, the longitudinal supports can have a laterally open or self-contained cross-section in order to allow the required length variation of the supporting structure.
[0047] In a further development, it is provided that the supporting structure includes individual struts crossing the longitudinal supports of the supporting structure. In particular in order to obtain a variable yet sufficient reinforced system in combination with the telescoping longitudinal supports, it is provided that at least some of these struts are contractible in themselves and/or extendable.
[0048] In this manner, the supporting structure can be pulled apart from a transport position into an operating position without having to detach or attach possible elements. In result, thus, an extremely fast operational readiness of the manufacturing system is achieved.
[0049] An individual frame formwork is associated with each formwork table, which allows producing formworks variable in their height and width. In addition, fixture formworks for insulations or window and door formworks (wet-on-wet methods) as well as groove formworks for laying water and electricity pipes are associated with the individual frame formworks. A very precise definition of the desired material thickness is allowed by the individual frame formwork. Moreover, a precisely defined second layer, e.g. an insulating layer, can be applied.
[0050] In the individual frame formworks, the mixture of mineral-bound building materials can also be produced directly on site. If one uses for example regional raw materials to this, thus, this entails considerable CO 2 saving due to the cancelled transport paths.
[0051] The formwork tables have hinges, via which they can be unfolded to a width, which considerably exceeds the width of the cargo container.
[0052] However, it is similarly possible that the enlargement of the formwork tables is effected by use of external modules, by means of which the formwork tables can be enlarged to a width, which considerably exceeds the width of the cargo container.
[0053] The formwork tables are pivoted on the supporting structure. By the capability of pivoting around a horizontal axis, various operating angles of the formwork table can be adjusted.
[0054] Swivel bearings serve for erecting the respective formwork table from its horizontal position in that the formwork table is inclinable around at least one, preferably around at least two of the swivel bearings. To this, the swivel bearings are formed and disposed such that the formwork tables are inclinable in mutually different directions by an inclination angle around at least two horizontal axes extending parallel to each other.
[0055] Therein, the possible inclination angle can be 0° to 89°.
[0056] In order to allow a comfortable and practice-oriented production as well as erection as well as stripping of the prefabricated parts as proper as possible, at least one of the formwork tables can include a pivot bearing such that the formwork table is rotatable around a rotational axis extending perpendicularly to its formwork area.
[0057] Hereby, in case of need, the entire formwork area can be rotated in its plane in order to realize a feasible orientation of the formwork table for example with respect to the local circumstances.
[0058] The formwork tables include both longitudinal profiles and transverse profiles as well as cross-profiles extending obliquely to them. These profiles constitute a substructure of the respective formwork table, on which the actual formwork area is disposed. The substructure serves for required stiffening of the formwork table, in particular the formwork area. Advantageously, the obliquely extending cross-profiles are connected to each other in a common junction. Preferably, the cross-profiles extend between the respective corner regions of the substructure towards the junction. Therein, the cross-profiles can intersect each other in the junction.
[0059] It is provided that the junction is disposed in the region of the respective center of area of the formwork tables.
[0060] By the thus provided substructure, an extremely stable frame for the actual formwork area is provided, which forms a framework due to the obliquely extending cross-profiles together with the longitudinal profiles and transverse profiles. By the force triangles resulting from it, in particular the corner regions of the formwork tables in the plane thereof and thus the planar geometry of the formwork area are formed nearly non-relocatable. Hereby, the geometry of the formwork table is conserved even after often use even in raw handling the equipment on a construction site.
[0061] In an advantageous further development it is provided that the cross-profiles each form an angle between themselves and the formwork area of the formwork tables. Thus, the cross-profiles do not extend parallel to the plane of the respective formwork area, but are disposed at an angle to it. Preferably, the angle opens towards the junction of the cross-profiles.
[0062] In this manner, the framework constituted by the substructure extends below the formwork area of the formwork table not only in the plane of the formwork area, but also perpendicular to it. In result, an extremely stiff substructure is formed, which offers torsional rigidity of the formwork area as great as possible even with high surface pressures generated by introducing the mineral building material and the prefabricated part itself
[0063] In particular upon erecting the not yet completely set prefabricated parts by inclining the formwork table, thus, undesired deformations of the prefabricated parts can be effectively avoided, which mostly concentrate to the corner regions of the formwork table. Thus, the forces arising in the corner regions via the surface pressure are directly absorbed and divided in their components, which are effectively received and passed via the longitudinal as well as transverse profiles and in particular via the cross-profiles.
[0064] For inclining the individual formwork tables, it is provided that the inclination thereof around the respective horizontal axis is effected via an introduced compressive force. Preferably, a linear drive is provided for this. Advantageously, the linear drive is disposed between the supporting structure and the respective junction of the substructure of the formwork tables. The advantage is in the thus producible force introduction by the linear drive between two intrinsically stiff arrangements of the manufacturing system, namely the substructure and the supporting structure. Hereby, the effectiveness of the linear drive and in particular the control and exact adjustment of the required inclination angle is improved.
[0065] In particular by the coupling of the linear drive to the junction of the substructure of the individual formwork tables, central introduction of the compressive force to be applied is possible, which does without additional supports of the formwork tables. This is realized by the framework-shaped substructure of the formwork tables, which effects a pressure load distribution across the entire formwork area from the central junction. The advantage consists in a simple construction of the required lifting means in the form of the linear drive, which does without additional components.
[0066] In this context, it is provided that the linear drive is detachably coupled to the respective junction of the formwork tables and the supporting structure. In this manner, the linear drive can be relocated and also removed for bringing the manufacturing system into the cargo container without problem on demand. Thus, the linear drive can be coupled to different regions of the supporting structure according to direction and thus used horizontal axis for pivoting the formwork table in order to cause effectiveness as high as possible. To this, the supporting structure has at least two receptacles spaced from each other, via which the linear drive can be connected to the supporting structure.
[0067] In some embodiments, each one linear drive is present per formwork table.
[0068] In some embodiments, several formwork tables can be disposed on one supporting structure. Herein, it is advantageous that the respective formwork tables can occupy various operating positions at the same time.
[0069] Three formwork tables independent of each other can be disposed on a supporting structure. Thus, for example, a wet mixture of mineral-bound building materials can be placed on a first formwork table, while the mixture of mineral-bound building materials already dries on a second formwork table and at the same time the dried prefabricated part is removed on a third formwork table.
[0070] In the embodiment of several formwork tables on a supporting structure, the formwork tables are immediately adjacent. Hereby, an increased common working surface can be provided.
[0071] Preferably, a scale is disposed on the formwork tables in order to facilitate precisely setting the frame formwork.
BRIEF DESCRIPTION OF THE DRAWINGS
[0072] Below, the invention is explained in more detail based on an embodiment illustrated in the drawings. There shows:
[0073] FIG. 1 a manufacturing system according to an embodiment of the invention;
[0074] FIG. 2 a manufacturing system of FIG. 1 with formwork tables displaced out of the cargo container;
[0075] FIG. 3 the formwork tables with the supporting structure disposed on rails;
[0076] FIG. 4 a line drawing of a formwork table supported on a supporting structure;
[0077] FIG. 5 a variant of formwork tables in perspective representation;
[0078] FIG. 6 a side view of one of the formwork tables of FIG. 5 ;
[0079] FIG. 7 the formwork table of FIG. 6 in a variant in the same representation;
[0080] FIG. 8 a top view or bottom view of a supporting structure in an alternative configuration;
[0081] FIG. 9 a cross-section through a region of the supporting structure of FIG. 8 ;
[0082] FIG. 10 the supporting structure of FIG. 8 in expanded form in the same representation;
[0083] FIG. 11 the supporting structure of FIG. 8 in a further configuration in the same representation;
[0084] FIG. 12 the manufacturing system of FIG. 11 in expanded form of the supporting structure in a side view;
[0085] FIG. 13 a front view of the manufacturing system of FIG. 12 as well as
[0086] FIG. 14 the manufacturing system of FIG. 13 in the transport condition.
DESCRIPTION OF EMBODIMENTS
[0087] FIG. 1 shows one embodiment of a manufacturing system 1 according to the invention. It includes a conventional cargo container 2 . In the cargo container 2 , there are rails 3 , on which a movable supporting structure 4 ( FIG. 3 ) is supported. Three formwork tables 5 , 6 , 7 independent of each other are disposed on the supporting structure 4 . Furthermore, rollers 8 are disposed on the supporting structure 4 .
[0088] In FIG. 1 , the manufacturing system 1 is not yet in the state of use. The formwork tables 5 , 6 , 7 are folded such that they can be stored in the cargo container 2 without problem. Up to 40 m of formwork length with a formwork width of up to 5 m can be transported in the cargo container 2 . In this embodiment, the length is just 40 feet with a width of about 3 m.
[0089] FIG. 2 shows the manufacturing system 1 of FIG. 1 with extended rails 3 , on which the supporting structures 4 with the formwork tables 5 , 6 , 7 are displaced out of the cargo container 2 . The formwork tables 5 , 6 , 7 are now in the unfolded state. The rails 3 can also be extended to a length of up to 40 m not shown here.
[0090] In the position displaced out of the cargo container 2 , the formwork tables 5 , 6 , 7 can be directly taken into operation. However, the supporting structures 4 and the formwork tables 5 , 6 , 7 can also be operated on every other sustainable ground. For this purpose, the supporting structures 4 and/or the formwork tables 5 , 6 , 7 have individually adaptable adjusting spindles not shown here, which allow support also beyond the width of the supporting structure.
[0091] FIG. 3 again shows the rails 3 , on which the movable supporting structure 4 is located, on which in turn the formwork tables 5 , 6 , 7 are pivoted. Two of the three formwork tables 5 , 6 are unfolded in a horizontal position. The third formwork table 7 is inclined around a horizontal axis A. The supporting structure 4 is composed of two longitudinal supports 9 connected to each other by multiple transverse supports 10 . On the transverse supports 10 and the longitudinal supports 9 , there are the rollers 8 on the side facing the rails 3 . On the side of the longitudinal and transverse supports 9 , 10 of the supporting structure 4 facing the formwork tables 5 , 6 , 7 , there are several legs 11 supporting the formwork tables 5 , 6 , 7 . The formwork tables 5 , 6 , 7 are pivoted via swivel bearings S on each three legs located on the longitudinal supports such that they can be inclined around the horizontal axis A. The inclination angle W ( FIG. 4 ) amounts to maximally 85°. The formwork tables 5 , 6 , 7 are composed of several longitudinal and transverse profiles 12 , 13 . The formwork tables 5 , 6 , 7 are illustrated in the unfolded state in FIG. 3 . Differently sized prefabricated parts can be cast on the formwork tables 5 , 6 , 7 . In the unfolded state, the respective formwork table 5 , 6 , 7 is enlarged by 30 to 90% with respect to its folded size, in the illustrated case by about 45%. The unfolding of the fold-out part of the formwork table 5 , 6 , 7 is allowed via hinges 14 disposed between the formwork tables 5 , 6 , 7 and the supporting structure 4 . The pivoting itself is then performed via hydraulic means or crane systems not shown here. The hydraulic pressure can be established manually, electrically, per emergency power aggregate or by coupling to an external pressure source such as e.g. a truck or a construction machine.
[0092] FIG. 4 shows an illustration of the formwork table 5 , 6 , 7 on the supporting structure 4 in horizontal position and in erected position. Rollers 8 are disposed on the supporting structure 4 , which rest on a rail profile 15 . The rail profiles 15 are located bottommost in the image plane. The legs 11 supporting the formwork table 5 , 6 , 7 are disposed on the supporting structure 4 . On the leg 11 on the right in the image plane, there is the swivel bearing S, via which the supporting structure 4 is coupled to the formwork table 5 , 6 , 7 . The formwork table 5 , 6 , 7 is pivotable by an angle W along the horizontal axis A extending centrally through the swivel bearing S. The formwork table 5 , 6 , 7 is pivotable up to maximally 89° related to its horizontal position. On the formwork table 5 , 6 , 7 and the supporting structure 4 , there are receiving devices for yokes 16 of steel pipes not shown here, to which a hoist F can be attached, which then presents a possibility of capability of pivoting the formwork table 5 , 6 , 7 . In the embodiment of the formwork table 5 , 6 , 7 shown here, it has an external module 17 for increasing its width, which is well visible on the left in the image plane. The external module 17 is screwed to the formwork table 5 , 6 , 7 via screws 18 .
[0093] FIG. 5 shows two of the formwork tables 5 , 6 in an alternative configuration. The formwork tables 5 , 6 include both the longitudinal profiles 12 and the transverse profiles 13 , wherein they are supplemented by cross-profiles 19 extending obliquely to them. The cross-profiles 19 are connected to each other in a common junction 20 . The junction is in the region of the center of area of the respective formwork tables 5 , 6 .
[0094] Opposing the longitudinal and transverse profiles 12 , 13 extending parallel to the respective formwork area SF of the formwork tables 5 , 6 , the cross-profiles 19 each form an angle between themselves and the respective formwork area SF of the formwork tables 5 , 6 , which opens towards the junction 20 .
[0095] FIG. 6 schematically illustrates the construction of the alternative formwork tables 5 , 6 of FIG. 5 in a side view. As is apparent, a linear drive 21 in the form of a lifting cylinder for pivoting the formwork table 5 is disposed between the supporting structure 4 and the junction 20 of the formwork table 5 . Preferably, the linear drive 21 is a multi-stage lifting cylinder in order to obtain dimensions as compact as possible.
[0096] Furthermore, the supporting structure 4 has two opposing swivel bearings S such that the formwork table 5 can be inclined in different directions on demand. To this, in a manner not illustrated in more detail, the formwork table 5 is coupled to the swivel bearings S on only one of the two sides thereof via detachable bolts such that the respectively opposing swivel bearing S does not have any coupling to the formwork table 5 .
[0097] The linear drive 21 is detachably coupled to the junction 20 of the formwork table 5 and the supporting structure 4 . To this, in particular the supporting structure 4 has receptacles 22 spaced to each other, to which the linear drive 21 can be selectively coupled. Preferably, the receptacles 22 are formed as gimbal mount.
[0098] The selective coupling to one of the receptacles 22 depends on the direction of inclination of the formwork table 5 . If inclination of the formwork table 5 occurring around the left swivel bearing S with regard to the illustration of FIG. 6 is to be effected, the linear drive 21 is coupled to the supporting structure 4 via the right receptacle 22 , as illustrated. If inclination around the swivel bearing S illustrated on the right is to be effected, the linear drive 21 is coupled to the supporting structure 4 via the left receptacle 22 . Theoretically, a position in the middle is also possible such that the lower end of the linear drive 21 , more precisely the end coupled to the receptacle 22 , does not have to be displaced.
[0099] FIG. 7 shows an alternative configuration of a manufacturing system 1 . In order to allow mobility of the respective formwork table 5 , 6 , 7 as autonomous as possible, the supporting structure 4 has a chassis 23 . Presently, the chassis 23 is formed as a crawler-type chassis. The supporting structure 4 is movable together with at least one of the formwork tables 5 , 6 , 7 on suitable ground not illustrated in more detail via the chassis 23 .
[0100] FIG. 8 shows an alternative configuration of the supporting structure 4 . In the schematic illustration, longitudinal supports 9 a extending parallel to each other are apparent, which are segmentally pushed into each other.
[0101] FIG. 9 illustrates in a section A-A the arrangement of the longitudinal supports 9 a disposed in each other. The longitudinal supports 9 a are C profiles. The longitudinal supports 9 a disposed in each other have different cross-sectional sizes, whereby several, presently three longitudinal supports 9 a are inserted into each other. At the ends of their legs, the longitudinal supports 9 a have webs 24 perpendicular to them as well as facing each other such that the respectively outer longitudinal support 9 a embraces the longitudinal support 9 a respectively disposed therein on three sides, while the fourth side is encompassed by the webs 24 in certain areas. The webs 24 are dimensioned such that their overlying ends align with each other.
[0102] With regard back to FIG. 8 , diagonally extending struts 25 are disposed besides the transverse supports 10 connecting the longitudinal supports 9 a. The struts 25 cross a section of the supporting structure 4 presently pushed together in itself The advantage is in that a possible displaceability of the frame respectively formed by the longitudinal supports 9 a and the transverse supports 10 is effectively prevented by the struts 25 .
[0103] In the present arrangement, the supporting structure 4 pushed together to a third of its overall length extending in the direction of the longitudinal supports 9 a can support a formwork table 5 , 6 , 7 not illustrated in more detail here by supporting it. The part of the supporting structure 4 depicted in FIG. 8 is the fixed section Z 1 thereof
[0104] Moreover, the supporting structure 4 has further struts 25 a, which form a considerably smaller angle between themselves in the presently pushed together state of the supporting structure 4 than the struts 25 crossing the present section of the supporting structure 4 . The struts 25 a are movably coupled to the individual longitudinal supports 9 a in a manner not illustrated in more detail. Therein, each of the struts 25 a extends between the end regions of two longitudinal supports 9 a extending parallel to each other, wherein the end regions face in different directions. Therein, the respective strut 25 a is coupled to an end region of a longitudinal support with one of its ends, while the other end of the strut 25 a is coupled to a longitudinal support 9 a extending parallel thereto, but which is associated with an adjacent section of the supporting structure 4 .
[0105] For example, in order to enlarge the supporting structure 4 to its full length, the longitudinal supports 9 a disposed in each other are segmentally pulled apart in an expansion direction x of the supporting structure 4 .
[0106] FIG. 10 shows the supporting structure 4 of FIG. 8 expanded to its full length. Hereby, the supporting structure 4 has besides its fixed section Z1 variable sections Z2, Z3 adjoining thereto, which also serve for receiving as well as supporting formwork tables 5 , 6 , 7 not illustrated in more detail.
[0107] As is apparent, the struts 25 a experience a length variation during the expansion of the supporting structure 4 in the expansion direction x thereof. It results from a removal of anchor points 26 disposed on the respective longitudinal supports 9 a, between which the struts 25 a diagonally extend, which arises upon pulling apart the longitudinal supports 9 a. The struts 25 a are fixed to the anchor points 26 with their ends.
[0108] The struts 25 a are formed such that they allow length variation. To this, each of the struts 25 a has a strut body 27 , in which long elements 28 are each disposed towards both of its ends. The long elements 28 align with the respective strut body 27 . In another embodiment, each of the struts 25 a can also have only one strut body 27 with an individual long element 28 .
[0109] The long elements 28 can be guided in the strut bodies 27 in that the strut bodies 27 are formed hollow, for example as a round tube or as a tube angular in cross-section. Of course, the long elements 28 can also be correspondingly hollow formed and thus receive the strut body 27 in them.
[0110] The connection between strut body 27 and long elements 28 is formed such that tensile forces can be transmitted between them. According to requirement, the strut bodies 27 as well long elements 28 can also be formed such that compressive forces can be transmitted between them. The coupling between the strut bodies 27 as well as long elements 28 is both detachable and lockable. Hereby, the longitudinal supports 9 a can be pulled apart without problem if the coupling of the strut bodies 27 to the long elements 28 is detached. As soon as the longitudinal supports 9 a are pulled apart to the required dimensions of the supporting structure 4 , the coupling between the strut bodies 27 and the long elements 28 is locked such that stable crossing of the variable sections Z 2 , Z 3 is effected.
[0111] By the previously illustrated configuration of the struts 25 a, the supporting structure 4 can also have more than the three sections Z 1 , Z 2 , Z 3 illustrated here. The arrangement of the struts 25 a contractible in themselves as well as extendable in combination with the telescoping longitudinal supports 9 a offers an extremely simple possibility of expanding the supporting structure 4 to the required length within shortest time without detachment or arrangement of individual components being needed to this. According to configuration of the locking between the strut bodies 27 and the long elements 28 , the supporting structure 4 is additionally steplessly expandable such that a high degree of flexibility is achieved.
[0112] Despite of the extremely simple handling, hereby, an extremely safe system for the construction of a manufacturing system 1 according to the invention is provided, which offers an effectively reinforced supporting structure 4 adaptable to the local requirements with only few hand movements.
[0113] FIG. 11 shows the supporting structure 4 of FIG. 8 pushed together in a further variant. As is apparent, presently, it has a pivot bearing 29 in its fixed section Z 1 . The pivot bearing 29 is disposed on the transverse support 10 .
[0114] Of course, the pivot bearing can also be disposed on at least one of the formwork tables 5 , 6 , 7 not illustrated in more detail here. By the pivot bearing 29 , at least one of the formwork tables 5 , 6 , 7 not illustrated in more detail here is rotatable around a rotational axis (z) extending perpendicularly to its formwork area (SF) (see also FIG. 12 ).
[0115] FIG. 12 shows the supporting structure 4 pulled apart in expansion direction x in a side view. In this representation, each of the formwork tables 5 , 6 , 7 has a pivot bearing 29 . Furthermore, the center formwork table 6 is pivoted from its horizontal position, more precisely erected.
[0116] Pulling apart the supporting structure 4 in expansion direction x can be effected both manually and by motor. Thus, for example, a type of hoist can be disposed within or outside of the longitudinal supports 9 a such that by pulling via a pulling means, a corresponding extension or contraction of the supporting structure 4 can be effected. Furthermore, drives in the form of lifting cylinders, rack or rotary spindle drives are also conceivable. Preferably, the longitudinal supports 4 are guided into each other such that they only have a low backlash, which is required for shifting the longitudinal supports 9 a into each other without stress.
[0117] The stepping of the upper progression of the supporting structure 4 resulting from the longitudinal supports 9 a differing from each other in cross-section, can be compensated for by compensating elements not illustrated in more detail. These compensating elements can for example be disposed between the longitudinal supports or the transverse supports and the respective formwork tables 5 , 6 , 7 as well as their substructure.
[0118] Basically, leveling elements not illustrated in more detail can be disposed between the formwork tables 5 , 6 , 7 and the supporting structure 4 . The leveling elements can for example be screw elements, by rotation of which alignment of the formwork tables 5 , 6 , 7 in height with respect to the supporting structure 4 , in particular the respective ground is possible.
[0119] FIG. 13 shows the possible directions of pivoting the formwork tables 5 , 6 , 7 of the manufacturing system 1 in an illustration. As is apparent, the formwork tables 5 , 6 , 7 can be inclined via the swivel bearings S disposed on the two longitudinal sides of the supporting structure 4 , whereby the respective erection direction of the formwork tables 5 , 6 , 7 can be changed. Upon inclining the formwork tables 5 , 6 , 7 , the effect of the hinge 14 is cancelled, for example via suitable locking According to inclination direction, the linear drive 21 is correspondingly relocated in order to allow erecting the formwork tables 5 , 6 , 7 into the desired direction.
[0120] FIG. 14 shows the state of the manufacturing system 1 for the displacement thereof into the cargo container 2 not illustrated in more detail here. To this, the formwork tables 5 , 6 , 7 are inclined as far as the modules 17 connected to the formwork tables 5 , 6 , 7 via the hinges 14 can be folded. It is the objective to reduce the width of the formwork tables 5 , 6 , 7 reached via the modules 17 as much as the entire manufacturing system 1 maximally corresponds to the clear width of the internal space of the cargo container 2 . In this manner, the manufacturing system 1 having a considerably larger formwork area SF can be reduced to a compact size by corresponding displacement of the formwork tables 5 , 6 , 7 and the modules 17 in order to be transported within the cargo container 2 .
REFERENCE CHARACTERS
[0000]
1 —manufacturing system
2 —cargo container
3 —rails
4 —supporting structure
5 —formwork table
6 —formwork table
7 —formwork table
8 —rollers
9 —longitudinal support
10 —transverse support
11 —legs
12 —longitudinal profile
13 —transverse profile
14 —hinge
15 —rail profile
16 —yokes
17 —modules
18 —screws
19 —cross-profile
20 —junction
21 —linear drive
22 —receptacle
23 —chassis
24 —web
25 —strut
25 a —strut
26 —anchor point
27 —strut body
28 —long element
29 —pivot bearing
A—horizontal axis
F—hoist
W—angle
S—swivel bearing
SF—formwork area
x—expansion direction
Z 1 —section, fixed
Z 2 —section, variable
Z 3 —section, variable
z—rotational axis
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A method and manufacturing system for producing prefabricated parts of mineral-bound building materials, in particular for construction of buildings is disclosed. The manufacturing system includes at least one formwork table provided for casting the prefabricated parts of mineral-bound building materials as the essential component. The manufacturing system is mobile and it can be brought to the site of use of the prefabricated parts and in particular to the erection site of a building for manufacturing the prefabricated parts. Thus, this mobility allows transporting a complete small factory for manufacturing prefabricated parts of mineral-bound building materials to very different locations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to co-pending U.S. Provisional Patent Application No. 62/321,972 filed on Apr. 13, 2016, the entire content of which is incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to a tube for drywall or other types of finishing compound.
SUMMARY
[0003] In one embodiment, the disclosure provides a finishing head for attachment to a viscous material dispenser. The finishing head includes an adapter having an inlet attachable to the viscous material dispenser and defining a first axis, and an outlet defining a second axis perpendicular to the first axis. The finishing head further includes a finisher body having a cavity and an opening in a bottom face thereof, and a hollow pivot pivotably coupling the adapter to the finisher body about the second axis. The cavity of the finisher body is in fluid communication with the adapter outlet via the hollow pivot such that viscous material discharged from the adapter outlet passes through the hollow pivot before being discharged from the opening of the finisher body.
[0004] In another embodiment, the disclosure provides a finishing assembly for dispensing a viscous material. The finishing assembly includes a dispenser in which the viscous material is storable and a finishing head removably coupled to the dispenser to receive viscous material therefrom. The finishing head includes an opening in a bottom face thereof through which the viscous material is discharged and a blade proximate the opening to spread the discharged viscous material across a width of the finishing head.
[0005] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates a perspective view of a finishing tube assembly according to a first embodiment.
[0007] FIG. 2 illustrates a perspective view of a compound tube of the finishing tube assembly of FIG. 1 .
[0008] FIG. 3 illustrates a perspective view of a plunger of the compound tube of FIG. 2 .
[0009] FIG. 4 illustrates a perspective view of a finishing head of the finishing tube assembly of FIG. 1 .
[0010] FIG. 5 illustrates a sectional view of the finishing head of FIG. 4 taken along lines 5 - 5 .
[0011] FIG. 6 illustrates a bottom view of the finishing head of FIG. 4 .
[0012] FIG. 7 illustrates a sectional view of the finishing head of FIG. 4 taken along lines 7 - 7 .
[0013] FIG. 8 illustrates a bottom view of a blade holder of the finishing head of FIG. 4 .
[0014] FIGS. 9A-9D illustrate a plurality of blades for the blade assembly of the finishing tube assembly of FIG. 1 .
[0015] FIG. 10 illustrates a perspective view of a finishing tube assembly according to a second embodiment.
[0016] FIG. 11 illustrates a perspective view of a finishing head of the finishing tube assembly of FIG. 10 .
[0017] FIG. 12 illustrates a blown-up view of the components of a body of the finishing head of FIG. 11 .
[0018] FIG. 13 illustrates a sectional view of the finishing head of FIG. 11 taken from the bottom of rotation axis B.
[0019] FIG. 14 illustrates a bottom view of the finishing head of FIG. 11 .
[0020] FIG. 15 illustrates a perspective view of a finishing tube assembly according to a third embodiment.
[0021] FIG. 16 illustrates a perspective view of a finishing head of the finishing tube assembly of FIG. 15 .
[0022] FIG. 17 illustrates a blown-up view of the components of a body of the finishing head of FIG. 16 .
[0023] FIG. 18 illustrates a sectional view of the finishing head of FIG. 16 taken from the bottom of rotation axis C.
[0024] FIG. 19 illustrates a bottom view of the finishing head of FIG. 16 .
[0025] FIG. 20 illustrates a perspective view of a compound tube of the finishing tube assembly of FIG. 15 .
[0026] FIG. 21 illustrates a partial, sectional view of the compound tube of FIG. 20 .
[0027] FIG. 22 illustrates a perspective view of a tube cap of the compound tube of FIG. 20 .
[0028] FIG. 23 illustrates a side view of the finishing tube assembly according to the third embodiment.
[0029] FIG. 24 illustrates a perspective view of a caddy being used with a bucket and the finishing tube assembly of FIG. 15 .
DETAILED DESCRIPTION
[0030] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.
[0031] FIG. 1 illustrates a finishing head 12 and a dispenser or compound tube 14 , which, when combined, are referred to as a finishing tube assembly 10 . The finishing head 12 includes a head body 16 and a blade assembly 18 , described further hereafter. The compound tube 14 includes a tube body 20 , a plunger 22 , and a head attachment assembly 24 , also described further hereafter. For the purposes of this application, the finishing tube assembly 10 is preferably for drywall finishing on a joint between pieces of drywall. Drywall finishing is described herein as an example application, but the finishing tube assembly 10 may also be applied to other various types of joints or seams that need to be sealed or finished. The finishing tube assembly 10 may apply material other than drywall compound to almost any surface, not limited to joints, such as fiber reinforced plastic sheeting or tiling. Furthermore, the finishing tube assembly 10 may be used with an appropriately shaped blade to leave an adhesive on wallboard, so the operator can place fiber reinforced plastic sheet on the wall board (e.g., to waterproof bathroom walls).
[0032] FIGS. 1-3 illustrate the compound tube 14 for the finishing tube assembly 10 , including the tube body 20 , the plunger 22 , and the head attachment assembly 24 . In the embodiment illustrated in FIGS. 1 and 2 , the tube body 20 is a cylinder that has a constant diameter throughout its longitudinal length. The tube body 20 defines a longitudinal axis A. The tube body 20 may have a polygonal cross-section in other embodiments. The interior of the tube body 20 defines a cavity 26 that is configured to store joint compound. Illustrated in FIG. 3 , the plunger 22 includes a pole 28 , a grip 30 at a first end 32 of the pole 28 , and a double-banded plug 34 at a second end 36 of the pole 28 . In the embodiment illustrated in FIGS. 1-3 , the grip 30 is spherical and configured to be grasped and pushed by an operator, as explained in greater detail below. In other embodiments, the grip 30 may be a handle (not illustrated) having finger slots or may be generally shaped to be gripped comfortably. The double-banded plug 34 includes two rubber seals 38 that are shaped to snugly fit within the inner diameter of the tube body 20 so that the double-banded plug 34 is able to efficiently push finishing compound out of the tube body 20 , as explained in greater detail below. The compound tube 14 includes a cap 40 positioned at a first end 42 of the tube body 20 . The cap 40 is coupled to the tube body 20 by a pair of clips 44 , as illustrated in FIG. 2 . The center of the cap 40 includes a cylindrical opening (not illustrated) that is shaped so that it is slightly larger than the diameter of the pole 28 of the plunger 22 , enabling the pole 28 to slide within the cylindrical opening. Accordingly, the plunger 22 is centered in the tube body 20 by the relationship between the plug 34 and tube body 20 as well as by the pole 28 and the cap 40 such that a longitudinal axis of the pole 28 is aligned with the first axis A. The head attachment assembly 24 is positioned at a second end 46 of the tube body 20 and includes a pair of clips 48 that are spaced 180 degrees from each other. The head attachment assembly 24 is configured to couple the compound tube 14 and the finishing head 12 , as explained in greater detail below.
[0033] FIGS. 1 and 4-6 illustrate the finishing head 12 according to a first embodiment, including the head body 16 and the blade assembly 18 . The head body 16 includes a cone portion 50 and a block portion 52 that is integrally formed with the cone portion 50 . As illustrated in FIG. 5 , a channel 54 extends through the head body 16 of the finishing head 12 . The blade assembly 18 is coupled to the head body 16 of the finishing head 12 and includes a blade holder 56 and a blade 100 .
[0034] As illustrated in FIGS. 4 and 5 , the cone portion 50 of the body includes a cylindrical mating portion 58 that is configured to couple to the compound tube 14 such that finishing compound is capable of flowing from the cavity 26 of the tube body 20 to the channel 54 of the finishing head 12 . The cylindrical mating portion 58 has two extensions 60 configured to couple to the pair of clips 48 of the head attachment assembly 24 . An O-ring (not illustrated) may be positioned about a seat 62 on the cylindrical mating portion 58 to provide a liquid-tight seal between the finishing head 12 and the compound tube 14 when they are coupled. As illustrated in FIG. 4 , the head body 16 widens throughout the cone portion 50 until the cone portion 50 reaches the block portion 52 . The block portion 52 includes a top face 52 a , a bottom face 52 b opposing the top face 52 a , a front face 52 c , and two side faces 52 d , 52 e that oppose each other. The cone portion 50 extends from the top face 52 a of the block portion 52 . The blade assembly 18 is coupled to the front face 52 c of the block portion 52 , as described in greater detail below. As illustrated in FIG. 6 , the bottom face 52 b of the block portion 52 includes an opening 64 that communicates with the channel 54 . The block portion 52 includes two extensions 66 , one extending from each side face 52 d , 52 e , that project in a direction nearly perpendicular to the front face 52 c , as shown in FIG. 5 . A wheel 68 is positioned on each of the extensions 66 . In other embodiments, a skid or skids (not illustrated) may be positioned at the end of each extension 66 in place of one or both of the wheels 68 . In the embodiment illustrated in FIGS. 4 and 5 , the cone portion 50 generally extends from the block portion 52 at an angle of 34 degrees. In other embodiments, the cone portion 50 may extend from the block portion 52 at any angle between 10 and 80 degrees.
[0035] The head body 16 of the finishing head 12 may be made from a plurality of different materials and constructed by a variety of methods. In the illustrated embodiment, the head body 16 is molded from a plastic, such as polypropylene (PP), polyvinyl chloride (PVC), polyethylene (PE), among others, so as to be lightweight, to minimize areas on the head body 16 that are difficult to clean, and to include some non-stick properties so that joint compound does not easily clog the channel 54 of the head body 16 . In other embodiments, the cone portion 50 and the block portion 52 may be molded independently and then coupled together in an assembly step to form the head body 16 . In other embodiments, the head body 16 may be made from a metal.
[0036] The channel 54 of the finishing head 12 extends from the cylindrical mating portion 58 to the opening 64 of the block portion 52 . As illustrated in FIGS. 4-6 , a cross section of the channel 54 changes shape along the length of the cone portion 50 of the head body 16 . At an entrance 54 a of the channel 54 , i.e., at the cylindrical mating portion 58 , the cross section of the channel 54 is cylindrical. Along the length of the cone portion 50 , the cross section of the channel 54 widens in one direction and narrows in a second direction. The cross section of the channel 54 changes so that at an end 54 b of the channel 54 , i.e., at the bottom face 52 b of the block portion 52 , the cross section of the channel 54 is much wider than the entrance 54 a of the channel, but the overall cross sectional area of the channel 54 at the end 54 b is similar to the area at the entrance 54 a of the channel 54 . In some embodiments, the cross section al area of the channel 54 at the end 54 b is equal to the cross sectional area at the entrance 54 a of the channel 54 . In other embodiments, the cross sectional area of the channel 54 at the end 54 b of the channel 54 may be smaller or larger than the cross sectional area of the channel 54 at the entrance 54 a of the channel 54 .
[0037] The finishing head 12 is attached to the compound tube 14 such that a continuous flow path is formed from the cavity 26 of the tube body 20 to the opening 64 of the head body 16 . In the embodiment illustrated in FIG. 1 , the pair of clips 48 of the head attachment assembly 24 on the compound tube 14 are coupled to the extensions 60 of the head body 16 of the finishing head 12 . In other embodiments, the compound tube 14 and the finishing head 12 may be coupled to each other in other ways. In yet other embodiments, the tube assembly and the finishing head 12 may be integrally formed.
[0038] FIGS. 1 and 4-8 illustrate the blade assembly 18 for the finishing head 12 , including the blade holder 56 and the interchangeable blade 100 . The blade holder 56 has a top wall 70 , a bottom wall 72 opposing the top wall 70 , a first end wall 74 , an opposing second end wall 76 , and a front wall 78 . The front wall 78 includes a front face 78 a and an opposite rear face 78 b , which together with the front face 52 c of the block portion 52 defines a blade slot 80 . The blade holder 56 is attachable to the front face 52 c of the block portion 52 of the finishing head 12 and projects from the finishing head 12 , and in particular from the front face 52 c of the block portion 52 in a direction perpendicular to a plane defined by the front face 52 c , so that the blade holder 56 is outside a footprint of the bottom face 52 b of the block portion 52 . Blade holder 56 defines the blade slot 80 for the blade 100 . The blade slot 80 is formed between the rear face 78 b of the front wall 78 , the front face 52 c of the head body 16 , and the bottom wall 72 , with the bottom of the blade slot 80 open for insertion of the removable blade 100 . The blade holder 56 includes one or more cleaning slots 84 which extend from the top wall 70 of the blade holder 56 to the bottom wall 72 of the blade holder 56 . The cleaning slots 84 extend into the blade slot 80 and provide easy access to clean the blade slot 80 without having to remove the blade holder 56 from the finishing head 12 .
[0039] As best shown in FIG. 5 , a portion of the front wall 78 forms an overhang 82 that extends vertically (as shown in FIG. 5 ) beyond the bottom wall 72 of the blade holder 56 , creating a staircase shape in cross section, with the overhang 82 as a “riser” and the bottom wall 72 as a “step.” The overhang 82 projects laterally (as shown in FIG. 5 ) from the front face 52 c and extends from the first end wall 74 of the blade holder 56 to the second end wall 76 of the blade holder 56 . In other embodiments, the overhang 82 may not extend the entire length of the blade holder 56 . For example, the blade holder 56 may include multiple overhangs 82 positioned at the end walls 74 , 76 of the blade holder 56 or multiple overhangs 82 positioned at the end walls 74 , 76 and at the center of the blade holder 56 .
[0040] The block portion 52 of the head body 16 also includes fastener openings 86 for coupling the blade holder 56 to the head body 16 . In the illustrated embodiment, the blade holder 56 is coupled to the head body 16 via three fasteners (not illustrated). A first fastener extends through a fastener opening 88 of the blade holder 56 through the front wall 78 near the first end wall 74 of the blade holder 56 . A second fastener extends through a fastener opening 86 of the blade holder 56 through the center of the front wall 78 of the blade holder 56 . Finally, a third fastener extends through a fastener opening 86 of the blade holder 56 through the front wall 78 near the second end wall 76 of the blade holder 56 . In other embodiments, any suitable number of fasteners and fastener openings may be used for the blade holder 56 and the head body 16 . In yet other embodiments, the blade holder 56 may be integrally formed as one piece with the head body 16 so the blade holder 56 and the head body 16 are all one-piece.
[0041] As previously described and shown in FIG. 5 , the blade slot 80 extends between the overhang 82 of the blade holder 56 and the front face 52 c of the block portion 52 . The blade slot 80 also extends from one side face 52 d to the opposite side face 52 e and is open below the first and the second end walls 74 , 76 of the blade holder 56 (i.e., a blade 100 received in blade slot 80 may extend beyond the first and the second end walls 74 , 76 of the blade holder 56 ). As shown in FIG. 7 , the bottom wall 72 of the blade holder 56 may include a curved portion 90 to provide clearance between the blade 100 and the bottom wall 72 of the blade holder 56 , allowing the blade 100 to bend or flex where the curved portion 90 permits in a direction perpendicular to the plane of the front face 52 c (i.e., vertically as shown in FIG. 7 ). The curved portion 90 extends a substantial, but not the entire, length of the blade holder 56 , as illustrated in the embodiment of FIG. 4 . There are non-curved portions 92 adjacent each of the first and second end walls 74 , 76 of the blade holder 56 in the embodiment illustrated in FIG. 7 . In other embodiments, the curved portion 90 may extend shorter or longer than the illustrated embodiment. In the illustrated embodiment, the curved portion 90 of the blade slot 80 is a uniform curved shape. However, in other embodiments, the curved portion 90 may be shaped and dimensioned in a non-uniform manner (e.g., flat or angled) to provide room for the blade 100 to bend at various places along its length. In yet other embodiments, the blade holder 56 does not include a curved portion 90 and the blade slot 80 is flat for its entire length, restricting the blade 100 from bending. In some embodiments, the blade holder 56 may be fully closed near one or both end walls 74 , 76 (i.e., there may be side walls (not illustrated) extending from the overhang 82 to the front face 52 c near each end wall 74 , 76 of the blade holder 56 ) to better capture the blade 100 within the blade slot 80 .
[0042] FIGS. 9A-9D show a plurality of blades 100 for the finishing head 12 . Blade design depends on the composition of the compound or other material to be expelled from the cavity in the head body 16 , the surface upon which the material will be deposited, and the operator's preferences, among other things. Thus, the ability of the blade holder 56 to accommodate various blade shapes is helpful. Each blade 100 may include a blade body 102 with two niches 104 on a generally flat upper edge 106 of the blade 100 . Some blades 100 (e.g., the blade 100 shown in FIG. 9A ) may include a generally flat bottom edge 108 , while other blades 100 (e.g., the blades 100 shown in FIGS. 9C and 9D ) may include a substantially curved bottom edge 108 with a curve 110 . A height of the blade 100 is defined between the upper edge 106 and the bottom edge 108 . The blades 100 may include radiused or sharp (e.g., cornered) edges. The blades 100 are also preferably sufficiently thick in cross section to avoid breaking and quickly wearing down, but may have varying degrees of thickness. Other blades 100 may include a bottom edge 108 of varying degrees of curvature where the curve 110 may be along the bottom edge 108 at different places than those of the illustrated blades 100 . Yet other blades 100 (e.g., the blade 100 shown in FIG. 9B ) may include a plurality of curves 110 . There are many other blades 100 and blade designs not illustrated herein that are capable of being used with the finishing head 12 .
[0043] In one example, the blade 100 illustrated in FIGS. 1 and 4-7 includes flat portions 112 extending from each end 114 , 116 of the blade 100 about ½ inch and the curve 110 in a middle section 118 of the blade 100 . However, as stated above, that flat portion 112 may extend shorter or farther than ½ inch and the curve 110 may extend closer to or further from the upper edge 106 of the blade 100 . The blades 100 may have radiused edges, among other things. The blades 100 may be produced in a variety of materials and in a variety of cross sections. However, preferably, the blades 100 are produced from a type of plastic so they may be easily mass produced. Furthermore, the blades 100 may be color coded to help identify which blade 100 to use at a particular time, or just for general identification purposes. Various materials and cross sections of the blade 100 can be selected as needed. While a completely rigid blade 100 will work well in many situations, it is beneficial for the blade 100 to be just flexible enough to flex over imperfections on a wall or other application surfaces without having to lift the ends 114 , 116 of the blade 100 off the wall. In some embodiments, the blade 100 is rigid enough to hold the intended shape, but is flexible enough so that the ends 114 , 116 of the blade 100 will remain in contact with the wall while the middle section 118 flexes over any imperfections on the wall surface.
[0044] When assembled with the blade holder 56 , the blade 100 extends into the blade slot 80 where the blade 100 is retained by pinch points 94 ( FIGS. 6 and 8 ) between the overhang 82 of the blade holder 56 and the head body 16 . The pinch points 94 are formed by reducing the distance between the overhang 82 and the front face 52 c of the head body 16 to create frictional engagement of the blade 100 within the blade slot 80 . One pinch point 94 is near the first end wall 74 of the blade holder 56 and another pinch point 94 is near the second end wall 76 of the blade holder 56 . As illustrated in FIG. 8 , the rear face 78 b of the front wall 78 is not parallel with the front face 78 a of the front wall 78 . In other words, the thickness of the overhang 82 is not uniform along the length of the overhang 82 . The overhang 82 is shaped so that the ends of the front wall 78 are closer to the front face 52 c of the head body 16 . Because the pinch points 94 are also near ends 114 , 116 of the blade 100 and the blade holder 56 , the blade 100 may flex upward where the blade slot 80 provides clearance until the blade 100 contacts the bottom wall 72 of the blade holder 56 . The niches 104 of the blade 100 fit around the end walls 74 , 76 of the blade holder 56 so that the blade 100 does not laterally slide within the blade slot 80 , specifically in the directions parallel to pivot axis A. In the illustrated embodiment, the blades 100 extend slightly beyond the end walls 74 , 76 of the blade holder 56 .
[0045] In other embodiments, the front face 52 c of the block portion 52 of the head body 16 may be curved and the overhang 82 may be shaped so that the rear face 78 b and the front face 78 a are parallel along the length of the overhang 82 . In yet other embodiments, the front face 52 c may be shaped as described above (i.e., substantially flat) and the rear face 78 b and the front face 78 a may be parallel along the length of the overhang 82 . In this embodiment, the blade 100 may be wider at the ends 114 , 116 so the blade 100 itself is shaped to provide frictional engagement between the head body 16 and the blade 100 . Alternatively, the blade 100 may have a uniform width along its length, but may be wide enough so that the blade 100 is frictionally engaged along the entire length of the blade slot 80 . In other words, the blade slot 80 has one pinch point 94 that extends the entire length of the blade slot 80 . The blade 100 may be coupled to the head body 16 in other ways, such as by fastening the blade 100 to the head body 16 with Velcro, magnets, or fasteners.
[0046] The blade 100 is easily inserted into the blade slot 80 by placing the blade 100 along the front face 52 c of the block portion 52 and manually pushing gently on one end 114 , 116 of the blade 100 and then pushing gently on the other end 114 , 116 of the blade 100 . Once the blade 100 is sufficiently inserted into the blade slot 80 , the pinch points 94 between the overhang 82 and the head body 16 hold the blade ends 114 , 116 in place. Because the blades 100 extend beyond the end walls 74 , 76 of the blade holder 56 , the blade 100 is also easily removable and replaceable. The blade 100 is removable in a reverse action as that described above. The blade 100 is pushed gently on one end 114 , 116 to exceed the holding force provided by the pinch point 94 so the blade 100 is at least partially removed from the blade slot 80 . The operator can then grab the blade 100 and remove it completely by pulling the blade 100 from the blade slot 80 . Or, the operator can push the other end 114 , 116 of the blade 100 from the blade slot 80 .
[0047] The ease of insertion and removal of one blade 100 allows the operator to switch between blades 100 very efficiently and quickly. By being able to quickly switch between blades 100 , the operator may be able to quickly switch between projects by changing to a blade 100 of a different shape. For example, if a different crown or shape for the applied compound is desired, the operator simply replaces the current blade 100 with another blade 100 that will give the operator the desired result. There is no need to include, in the finishing head 12 , a complex mechanism for manipulating the blade's shape or configuration, and that saves cost and weight that may tire the operator. The variability of the shapes of the blades 100 allows for the finishing tube assembly 10 to be used for a variety of different projects, as described above.
[0048] In operation, the blade 100 is inserted into the finishing head 12 before or after the cavity 26 of the tube body 20 is filled with a joint compound. The cavity 26 is filled with joint compound by inserting the opening 64 on the bottom face 52 b of the block portion 52 and drawing back on the grip 30 of the plunger 22 (i.e., away from the finishing head 12 ). The double-banded plug 34 will follow the grip 30 and slide from the second end 46 of the tube body 20 toward the first end 42 of the tube body 20 and therefore draws joint compound through the channel 54 of the head body 16 of the finishing head 12 and into the cavity 26 of the tube body 20 . Because at least part of the finishing head 12 will have been inserted into the joint compound while filling the cavity 26 , the operator may need to clean the bottom face 52 b of the block portion 52 and the blade 100 , if the blade 100 had been in the blade slot 80 . In some cases, the operator will elect to skip cleaning the bottom face 52 b of the block portion 52 prior to continuing. The finishing head 12 is then placed against a joint on the application surface. In this position, the wheels 68 and the blade 100 are preferably against the application surface. Manual pressure is applied by the operator to the double-banded plug 34 through the grip 30 so that compound is extruded from the opening 64 . The operator draws the finishing tube assembly 10 along the joint so that the blade 100 travels over the extruded joint compound causing the extruded joint compound to assume the general shape of the bottom edge 108 of the inserted blade 100 on the joint. In general, the blade 100 maintains its nominal shape and does not flex. Therefore, the joint compound applied to the joint will have generally the same shape that is manufactured into the blade 100 . However, sometimes the middle section 118 of the blade 100 (or another section depending on the selected blade 100 ) must travel over elevated areas on the application surface that are significantly higher than the rest of the application surface. In this case, the middle section 118 of the blade 100 is able to float over these elevated areas by flexing upward where the bottom wall 72 of the blade holder 56 provides clearance in the blade slot 80 . When the operator completes application of the joint compound to that particular area, the operator may easily remove the current blade 100 and insert a different blade 100 with a different shape or configuration. Alternatively, the operator may remove the blade 100 , exposing the blade slot 80 for easy cleaning of the blade slot 80 .
[0049] FIGS. 10-14 illustrate a finishing tube assembly 210 according to a second embodiment of the disclosure. The finishing tube assembly 210 includes a finishing head 212 that is different than the finishing head 12 according to the first embodiment of the disclosure. The remaining structures (e.g., the compound tube 14 , 214 ) are the same as the finishing tube assembly 10 , and therefore only the differences between the finishing tube assembly 10 according to the first embodiment and the finishing tube assembly 210 according to the second embodiment will be discussed below. Similar parts of the finishing tube assembly 210 will include reference numbers that are the same as the finishing tube assembly 10 , plus 200.
[0050] FIGS. 11 and 12 illustrate that the finishing head 212 includes a head body 216 that is made up of a plurality of parts. The head body 216 includes an adaptor or tube outlet 296 , a first cap 298 , a second cap 300 , and a finisher body or finisher component 302 with a pocket 304 for accepting the tube outlet 296 therein. The tube outlet 296 is generally T-shaped and includes a cylindrical mating portion 258 at a first end 306 of a cone portion 250 , where the head body 216 joins the compound tube 214 , and a first branch 308 and a second branch 310 at a second end 312 of the cone portion 250 . The first branch 308 and the second branch 310 extend from the cone portion 250 at opposing 90 degree angles such that the first branch 308 and the second branch 310 form the T-shape of the tube outlet 296 with the cone portion 250 . The first branch 308 and the second branch 310 of the tube outlet 296 are configured to fit within the pocket 304 of the finisher component 302 , as illustrated in FIG. 13 . The first branch 308 and the second branch 310 each include a seat 314 for an O-ring (not illustrated) to provide a seal between the tube outlet 296 and the first cap 298 and the second cap 300 . The first cap 298 is shaped to fit around the first branch 308 and the second cap 300 is shaped to fit around the second branch 310 . The second cap 300 is a mirror image of the first cap 298 . The first cap 298 and the second cap 300 each include a flap 316 , 318 that, when assembled, respectively fit over a first cut-out 320 and a second cut-out 322 of the finisher component 302 . The first cap 298 and the second cap 300 each also include a ring portion 324 , 326 that, when assembled, respectively fit into a first mating portion 328 and a second mating portion 330 of the finisher component 302 . The finisher component 302 is similarly shaped to the block portion 52 , described above, and also includes extensions 266 at the end of which wheels 268 and/or skids (not illustrated) may be placed. The finisher component 302 includes a top face 302 a , a bottom face 302 b opposing the top face 302 a , a front face 302 c , and two side faces 302 d , 302 e that oppose each other. As illustrated in FIG. 12 , the pocket 304 , the first cut-out 320 , and the second cut-out 322 are formed in the top face 302 a of the finisher component 302 . As illustrated in FIG. 14 , the opening 264 is in the bottom face 302 b of the finisher component 302 and provides an exit or port for the compound. In the embodiment illustrated in FIG. 14 , the opening 264 is not shaped the same as the opening 64 of the first embodiment. The middle section of the opening 264 is wider than the end sections of the opening 264 . The wider middle section provides less resistance for flow of the joint compound through the opening 264 so that joint compound is more likely to flow out of the middle section of the opening 264 . In other embodiments, the opening 264 may be shaped as described above (e.g., like the opening 64 ).
[0051] The channel 254 of the finishing head 212 extends from the cylindrical mating portion 258 of the tube outlet 296 to the opening 264 in the bottom face 302 b of the finisher component 302 . As illustrated in FIG. 13 , a cross section of the channel 254 changes along the length of the cone portion 250 of the head body 216 . As illustrated in FIG. 13 , joint compound is not capable of flowing in a straight line through the channel 254 . Joint compound must flow through one of the first branch 308 and the second branch 310 of the tube outlet 296 . The channel 254 continues through one of the first branch 308 and the second branch 310 and into the finisher component 302 . The channel 254 extends through the finisher component 302 to the opening 264 .
[0052] When in use, the finishing head 212 is attached to the compound tube 214 such that a flow path is formed between the cavity 226 of the tube body 220 to the opening 264 of the head body 216 , as explained above. The finishing head 212 is rotatable about a rotation axis B that is parallel to a plane of the bottom face 302 b of the finisher component 302 . The longitudinal axis A forms a rotation angle with the plane of the bottom face 302 b of the finisher component 302 . Specifically, the tube outlet 296 rotates about the rotation axis B with respect to the first cap 298 , the second cap 300 , and the finisher component 302 . The tube outlet 296 is rotatable such that, in operation of the finishing tube assembly 210 , the rotation angle may be any angle between 5 and 85 degrees. In other embodiments, the rotation angle may be any angle between 0 and 90 degrees. In some embodiments, the finishing head 212 may include a biasing mechanism (not illustrated) to urge the tube outlet 296 to a rotation angle that is preferable for operation of the finishing tube assembly 210 . The biasing mechanism may, for example, include a torsion spring (not illustrated) that is positioned along the rotation axis B between the tube outlet 296 and the finisher component 302 . The biasing mechanism (not illustrated) may also, for example, include a pair of extension springs (not illustrated) positioned on the exterior of the finishing head 212 . The pair of extension springs (not illustrated) may be pulling in opposite directions to allow for rotation about the rotation axis B in both directions, but also urges the tube outlet 296 to the rotation angle that is preferable for operation of the finishing tube assembly 210 if the tube outlet 296 is rotated in either direction about the rotation axis B.
[0053] Operation of the finishing tube assembly 210 is similar to the finishing tube assembly 10 of the first embodiment. In operation, the compound tube 214 is rotatably coupleable to the finishing head 212 , via the coupling between the compound tube 214 and cylindrical mating portion 258 of the tube outlet 296 , so that the bottom face 302 b of the finisher component 302 may remain flat against the application surface while the rotation angle of the compound tube 214 varies as is most appropriate and comfortable for the operator.
[0054] In some cases, a pre-filled tube or bag (not illustrated), for example a caulk-type tube, may be used with the finishing tube assembly 10 , 210 . For example, the finishing head 12 , 212 is removed from the compound tube 14 , 214 providing access to the cavity 26 , 226 of the tube body 20 , 220 . As described above, the operator draws back on the grip 30 , 230 of the plunger 22 , 222 so that the accessible volume of the cavity 26 , 226 becomes larger. The operator may then cut an opening, or otherwise open the pre-filled tube or bag, and position the bag in the cavity 26 , 226 against the double-banded plug 34 , 234 with the opening facing toward the attachment assembly 24 , 224 . The operator then couples the finishing head 12 , 212 to the compound tube 14 , 214 via the attachment assembly 24 , 224 so that the finishing tube assembly 10 , 210 may be used on a joint, as described above. When the pre-filled tube or bag is empty, the operator will remove the finishing head 12 , 212 so that the pre-filled tube or bag may be removed. The above-described process may then be repeated as necessary.
[0055] FIGS. 15-24 illustrate a finishing tube assembly 410 according to a third embodiment of the disclosure. The finishing tube assembly 410 includes a finishing head 412 and a compound tube 414 that are different than the finishing heads 12 , 212 and compound tubes 14 , 214 , respectively, according to the first and second embodiments of the disclosure. However, the finishing tube assembly 410 is similar to the finishing tube assemblies 10 , 210 according to the first and second embodiments such that differences will be described herein. The elements of the finishing tube assembly 410 according to the third embodiment that are similar to a respective element of the finishing tube assembly 210 according to the second embodiment are labeled as the same number plus “200.”
[0056] FIG. 15 illustrates that the finishing tube assembly 410 includes a finishing head 412 and a dispenser or compound tube 414 . The compound tube 414 is coupled to the finishing head 412 via a tube cap 532 , as described in greater detail below.
[0057] FIGS. 16-19 illustrate that the finishing head 412 includes a head body 416 that is made up of a plurality of parts. The head body 416 includes an adaptor or tube outlet 534 , a first hollow pivot 536 , a second hollow pivot 538 , and a finisher body or finisher component 540 having a pocket 542 for accepting the tube outlet 534 and at least part of the first and second hollow pivots 536 , 538 .
[0058] The finisher component 540 includes a top face 540 a , a bottom face 540 b opposing the top face 540 a , a front face 540 c , and two side faces 540 d , 540 e that oppose each other. The finisher component 540 also includes two loops 544 on opposite sides of the pocket 542 , a raised back end 546 , and two wheels 468 that are positioned on opposite sides of the raised back end 546 . Each of the two loops 544 includes a notch 548 for locating and securing a respective hollow pivot 536 , 538 . The back end 546 forms a shape which funnels joint compound toward its center if an operator were to draw the back end 546 over a joint into which too much joint compound was extruded. As illustrated in FIG. 19 , the bottom face 540 b of the finisher component 540 includes an opening 464 that is adjacent a trailing edge 550 of the finisher component 540 (i.e., the bottom edge, relative to FIG. 17 , of the front face 540 c ) and that provides an exit or port for the compound to leave the finishing head 412 . The front face 540 c of the finisher component 540 includes fastener openings 486 for coupling the blade holder 456 to the finishing head 412 . In the illustrated embodiment, the blade holder 456 is coupled to the finisher component 540 via three fasteners (not illustrated). In other embodiments, any suitable number of fasteners and fastener openings 486 may be used to couple the blade holder 456 to the finisher component 540 . In yet other embodiments, the blade holder 456 may be integrally formed as one piece with the finisher component 540 so the blade holder 456 and the finisher component 540 are one-piece.
[0059] The tube outlet 534 , like the tube outlet 296 according to the second embodiment, is generally T-shaped and hollow. The tube outlet 534 includes a cylindrical mating portion 552 at a first end 554 , which defines an inlet and where the head body 416 joins the compound tube 414 , and a first and second branch 556 , 558 , which define outlets, at a second end 560 . Two knobs 562 radially extend from the cylindrical mating portion 552 . As illustrated by FIG. 17 , an inlet axis D, defined by the cylindrical mating portion 552 , and an outlet axis E, defined by the first and second branch 556 , 558 , are perpendicular. The first branch 556 and the second branch 558 extend from the cylindrical mating portion 552 at opposing 90 degree angles and are configured to fit within the pocket 542 of the finisher component 540 , as illustrated in FIG. 18 . The first branch 556 and the second branch 558 each include an annular depression 564 , 566 which respectively house an end of the first hollow pivot 536 and the second hollow pivot 538 , as explained in greater detail below. The tube outlet 534 also includes a securing clip 568 which is rotatably coupled to the tube outlet 534 and secures the finishing head 412 to the compound tube 414 , as explained in greater detail below. In another embodiment, the securing clip 568 may include a biasing mechanism to influence the securing clip 568 toward the cylindrical mating portion 552 of the tube outlet 534 .
[0060] The second hollow pivot 538 is a mirror of the first hollow pivot 536 . The first hollow pivot 536 and the second hollow pivot 538 each include a generally cylindrical body 570 that is hollow and a pull handle 572 that is attached to the cylindrical body 570 . The first and second hollow pivots 536 , 538 each include an open axial end 574 and an aperture 576 that extends through the side of the cylindrical body 570 , as illustrated in FIG. 18 . The pull handle 572 is a U-shaped handle coupled to an end 578 that is opposite the open axial end 574 . Each of the first hollow pivot 536 and the second hollow pivot 538 include a tab 580 that radially extends from the cylindrical body 570 at the end 578 adjacent the pull handle 572 . The tabs 580 fit within the notches 548 of the two loops 544 of the finisher component 540 . Each of the first hollow pivot 536 and the second hollow pivot 538 also include two seats 582 , 584 adjacent the ends 574 , 578 of the cylindrical body 570 for positioning an O-ring (not illustrated) around the generally cylindrical body 570 to provide liquid tight seals between the components of the finishing head 412 .
[0061] To assemble the finishing head 412 , the tube outlet 534 is positioned in the pocket 542 of the finisher component 540 and the first and second hollow pivots 536 , 538 are inserted through a respective loop 544 such that the end 574 of the first hollow pivot 536 and the end 574 538 extend into the annular depression 564 of the first branch 556 and the annular depression 566 of the second branch 558 , respectively, as illustrated in FIG. 18 . As illustrated in FIG. 16 , the hollow pivots 536 , 538 are each inserted such that the tabs 580 fit into the notches 548 of the loops 544 . The pull handles 572 of the first and second hollow pivots 536 , 538 allows an operator to pull the hollow pivots 536 , 538 from the assembled position to quickly and simply disassemble the finishing head 412 , for example to clean the finishing head 412 . Similar to the second embodiment described above, the tube outlet 534 is pivotable about a pivot axis C relative to the finisher component 540 and the first and second hollow pivots 536 , 538 . The abutment between the tabs 580 of the hollow pivots 536 , 538 and the notches 548 of the loops 544 of the finisher component 540 prevents the hollow pivots 536 from significant rotation relative to the finisher component 540 .
[0062] In the assembled state, the finishing head 412 provides a channel 454 for joint compound that extends from the cylindrical mating portion 552 of the tube outlet 534 to the opening 464 on the bottom face 540 b of the finisher component 540 . As illustrated in FIG. 18 , a cross section of the channel 454 changes along the length of the finisher component 540 . In the illustrated embodiment of FIG. 18 , the channel 454 narrows from the first end 554 to the second end 560 of the tube outlet 534 . As illustrated in FIG. 18 , joint compound is not capable of flowing in a straight line through the channel 454 to the opening 464 and must flow through one of the first branch 556 and the second branch 558 of the tube outlet 534 .
[0063] First, joint compound flows into the channel 454 at the cylindrical mating portion 552 from the compound tube 414 . The joint compound then flows through one of the first and second branch 556 , 558 of the tube outlet 534 and into a respective one of the first hollow pivot 536 and the second hollow pivot 538 through the open axial end 574 . The joint compound continues through the hollow pivot 536 , 538 and into the finisher component 540 via the aperture 576 in the side of the hollow pivot 536 , 538 . Because more joint compound is needed in the center of the joint as opposed to the edges, joint compound is funneled toward the center of the opening 464 by the shape of the opening 464 . As illustrated in FIGS. 18-19 , the opening 464 is provided by two trapezoids 586 , 588 . The two parallel edges 590 A, 590 B, 592 A, 592 B of each trapezoid 586 , 588 are parallel with the trailing edge 550 of the finisher component 540 . The first trapezoid 586 , which directly communicates with the apertures 576 of the hollow pivots 536 , 538 , is oriented such that the larger of the two parallel edges 590 A is farther from the trailing edge 550 than the smaller of the two parallel edges 590 B. The second trapezoid 588 is arranged opposite to the first trapezoid 586 , i.e., the smaller of the two parallel edges 592 B is farther from the trailing edge 550 than the larger of the two parallel edges 592 A. Like the opening 264 according to the second embodiment, the wider middle section of the opening 464 provides less resistance for flow of the joint compound out of the finishing head 412 . In other embodiments, the opening 464 may be shaped as described above (e.g., like the opening 64 , 264 according to the first or second embodiment).
[0064] FIGS. 15 and 20-24 illustrate the compound tube 414 according to the third embodiment of the finishing tube assembly 410 . Similar to the compound tube 14 , 214 described above, the compound tube 414 includes the tube body 420 , the plunger 422 , and the head attachment assembly 424 . Unlike the compound tube 14 , 214 described above, the head attachment assembly 424 further includes a tube cap 532 .
[0065] As illustrated in FIGS. 21 and 22 , the tube cap 532 includes two extensions 594 that couple to the two clips 448 of the head attachment assembly 424 and that are adjacent a first end 596 of the tube cap 532 . A segment 598 at the first end 596 of the tube cap 532 extends into the cavity 426 of the tube body 420 such that the end of the segment 598 provides a limit for the double-banded plug 434 , as illustrated in FIG. 21 . The segment 598 includes a seat 600 for an O-ring 602 to provide a seal between an exterior of the tube cap 532 and an interior of the tube body 420 . The tube cap 532 also includes two radially extending fingers 604 and two depressions 606 for coupling to the finishing head 412 at a second end 608 of the tube cap 532 . The two depressions 606 may be used to locate the compound tube 414 relative to the finishing head 412 . Specifically, the second end 608 of the tube cap 532 is placed around the tube outlet 534 and the two depressions 606 respectively fit about the two knobs 562 of the cylindrical mating portion 552 of the tube outlet 534 such that when the compound tube 414 is correctly located on the finishing head 412 , the securing clip 568 may be rotated about one of the radially extending fingers 604 to couple the finishing head 412 to the compound tube 414 , as illustrated in FIGS. 15, 23, and 24 . The securing clip 568 fits about either of the two fingers 604 . In some embodiments, the securing clip 568 may be unnecessary as the tube outlet 534 frictionally couples to an interior of the tube cap 532 . In the illustrated embodiment of FIG. 21 , the interior of the tube cap 532 includes a radially extending seat 610 provided for the tube outlet 534 . In other embodiments, the cylindrical mating portion 552 of the tube outlet 534 does not reach the seat 610 .
[0066] FIG. 24 illustrates a caddy 612 to be used with the third embodiment of the finishing tube assembly 410 and a bucket 614 filled with joint compound, as explained in greater detail below. The caddy 612 includes a first section 618 for the bucket 614 to be positioned and supported thereon and a second section 616 to be used with the finishing tube assembly 410 . In the illustrated embodiment of FIG. 24 , the first section 618 includes a circular raised lip 620 to locate the bucket 614 so that the bucket 614 is not accidentally moved during operation. The second section 616 may be separated from the first section 618 by a holder 622 having two curled claws 624 spaced by a gap 626 . The holder 622 may act as an anchor to which the finishing head 412 may be retained while the compound tube 414 is removed from the finishing head 412 to refill the compound tube 414 . The finishing tube assembly 410 , specifically the finishing head 412 , may be wheeled or otherwise positioned into an area 628 underneath the curled claws 624 such that the curled claws 624 hook about the finishing head 412 on opposite sides of the compound tube 414 , which extends through the gap 626 between the two curled claws 624 .
[0067] When fully assembled, the finishing head 412 is attached to the compound tube 414 such that a flow path is formed between the cavity 426 of the tube body 420 to the opening 464 of the finisher component 540 . The finisher component 540 is rotatable about the pivot axis C relative to the tube outlet 534 and the compound tube 414 . As illustrated by FIG. 23 , the longitudinal axis A forms a rotation angle α with an axis F that is defined by the bottom face 540 b of the finisher component and is perpendicular to the pivot axis C. The finisher component 540 is rotatable such that the rotation angle α may be between 5 and 100 degrees in the illustrated embodiment. In other embodiments, the rotation angle α may be between 0 and 135 degrees. In some embodiments, the finishing head 412 and/or the compound tube 414 may include a biasing mechanism (not illustrated) to urge the finisher component 540 to a rotation angle α that is preferable for operation of the finishing tube assembly 410 . The biasing mechanism may, for example, include a torsion spring (not illustrated) that is positioned along the pivot axis C between the tube outlet 534 and the finisher component 540 . The biasing mechanism may also, for example, include a pair of extension springs (not illustrated) positioned on the exterior of the finishing head 212 . The pair of extension springs may be pulling in opposite directions to allow for rotation about the pivot axis C in both directions, but also urges the finisher component 540 to the rotation angle α that is preferable for operation of the finishing tube assembly 410 if the compound tube 414 is rotated in either direction about the pivot axis C.
[0068] In operation, the finishing tube assembly 410 may be fully assembled, as described above, and the finishing head 412 may be positioned beneath the curled claws 624 such that the compound tube 414 may extend through the gap 626 and may be rested upon the holder 622 . An operator may bend down and unlatch the securing clip 568 from one of the fingers 604 so the compound tube 414 may be separated from the finishing head 412 by pulling the compound tube 414 away from the finishing head 412 . The finishing head 412 will abut the curled claws 624 , keeping the finishing head 412 in the area 628 beneath the claws 624 . The cavity 426 is filled with joint compound by inserting the tube cap 532 into the bucket 614 and pulling back on the grip 430 of the plunger 422 (i.e., away from the tube cap 532 ). The double-banded plug 434 will follow the grip 430 and slide from the second end 446 of the tube body 420 toward the first end 442 of the tube body 420 and therefore draw joint compound through the tube cap 532 and into the cavity 426 of the tube body 420 . Because the finishing head 12 will not have been inserted into the joint compound while filling the cavity 426 , the operator will not need to clean the finisher component 540 or the blade 100 . In some cases, the operator may clean the tube cap 532 prior to continuing. The tube cap 532 is then positioned about the cylindrical mating portion 552 of the tube outlet 534 with the depressions 606 of the tube cap 532 positioned about the knobs 562 . The securing clip 568 is then rotated about the finger 604 to securely couple the finishing head 412 to the compound tube 414 . As stated above, in some embodiments, the operator may not need to rotate the clip 568 about the finger 604 . The finishing tube assembly 410 is pulled from the caddy 612 and the finishing head 412 is placed against a joint of an application surface. In this position, the wheels 468 and the blade 100 are preferably against the application surface. Manual pressure is applied by the operator to the double-banded plug 434 through the grip 430 so that joint compound is extruded from the opening 464 . The operator draws the finishing tube assembly 10 along the joint so that the blade 100 travels over the extruded joint compound causing the extruded joint compound to assume the general shape of the bottom edge 108 of the inserted blade 100 on the joint. The compound tube 414 is rotatably coupled to the finisher component 540 so that the bottom face 540 b of the finisher component 540 may stay flat against the application surface while maintaining a comfortable grip for the operator. The rotation angle α varies as is most appropriate and comfortable for the operator. In general, the blade 100 maintains its nominal shape and does not flex. Therefore, the joint compound applied to the joint will have generally the same shape that is manufactured into the blade 100 . When the operator completes application of the joint compound to that particular area, the operator may easily remove the current blade 100 and insert a different blade 100 with a different shape or configuration. Alternatively, the operator may remove the blade 100 , exposing the blade slot 80 for easy cleaning of the blade slot 80 . In some cases, the operator may continue to a new joint. If the operator uses all of the joint compound in the cavity 426 , the operator may position the finishing tube assembly 410 in the caddy 612 , as described above, and the above process may be repeated as necessary.
[0069] Various features and advantages of the disclosure are set forth in the following claims.
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A finishing head for attachment to a viscous material dispense includes an adapter having an inlet attachable to the viscous material dispenser and defining a first axis, and an outlet defining a second axis perpendicular to the first axis. The finishing head further includes a finisher body having a cavity and an opening in a bottom face thereof, and a hollow pivot pivotably coupling the adapter to the finisher body about the second axis. The cavity of the finisher body is in fluid communication with the adapter outlet via the hollow pivot such that viscous material discharged from the adapter outlet passes through the hollow pivot before being discharged from the opening of the finisher body.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 11/059,688 filed on Feb. 17, 2005, now U.S. Pat. No. 7,520,083.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to firearms and, more particularly, to systems for mounting various accessories to firearms.
2. Background Art
It is well known to use various accessories, such as infrared and night vision scopes, laser spotters and the like, with firearms. In the case of small firearms, such accessories are typically mounted to an accessory mount directly securable to the firearm.
However, in the case of larger firearms producing a significant recoil force, such as the MK-19 grenade machine gun or the M-2HB machine gun, such accessories are usually mounted to an accessory mount securable to the cradle or another fixed support of the firearm. This eliminates the effect of the recoil force on the accessory, thus minimizing the risks of injury to the operator. One example of such a mount is the MK RANGER, which adapts to the MK-64 or MK-93 cradle used with the MK-19 grenade machine gun, and receives a laser. A disadvantage of such mounts is that the precision of the position of the accessories with respect to the firearm is influenced by the positioning of the firearm on the cradle or support.
Accordingly, there exists a need for an accessory mount for releasably securing at least one accessory directly on a firearm having a significant recoil force while minimizing the risks of injury to the operator.
Also, existing accessory mounts directly securable to firearms usually provide no adjustment, or a very limited adjustment, of an orientation of the accessory with respect to the firearm. Accordingly, there exists a need for an accessory mount for releasably securing at least one accessory directly on a firearm while allowing adjustment of the accessory with respect to the firearm about at least two axes.
Moreover, some firearms have a lateral drift which varies with the angle of elevation of the firearm and needs to be compensated in order to have effective and precise targeting. This is the case for the MK-19 grenade machine gun mentioned above. Accordingly, there exists a need for an accessory mount for releasably securing at least one accessory directly on a firearm which automatically compensates for the lateral drift while varying the angle of elevation of the accessory.
SUMMARY OF INVENTION
It is therefore an aim of the present invention to provide an accessory mount for releasably securing at least one accessory to a firearm which allows for adjustment of the accessory about two axes.
It is another aim of the present invention to provide an accessory mount for releasably securing at least one accessory to a firearm which automatically adjusts an azimuth of the accessory when the angle of elevation thereof is varied to compensate for a lateral drift of the firearm.
It is a further aim of the present invention to provide an accessory mount for releasably securing at least one accessory directly on a firearm which includes a system for dampening the recoil force produced by the firearm.
Therefore, in accordance with the present invention, there is provided an accessory mount for releasably securing at least one accessory to a firearm, the mount comprising a connecting portion attachable to the firearm, a first member connected to the connecting portion, the first member being rotatable with respect to the connecting portion about a first axis substantially perpendicular to a firing direction of the firearm, a second member connected to the first member, the second member being rotatable with respect to the first member about a second axis substantially perpendicular to the first axis, and a first attachment system connected to the second member for releasably receiving a first of the at least one accessory.
Also in accordance with the present invention, there is provided an accessory mount for releasably securing at least one accessory to a firearm, the mount comprising a base portion attachable to the firearm, a body portion engaged to the base portion to be slidable along a first axis substantially parallel to a firing direction of the firearm, an attachment portion connected to the body portion for releasably receiving the at least one accessory, and a dampener system connected to the base and body portions, the dampener system acting along the first axis to dampen a recoil force produced by the firearm.
Further in accordance with the present invention, there is provided an accessory mount for releasably securing at least one accessory to a firearm, the mount comprising a connecting portion attachable to the firearm, an attachment portion releasably receiving the at least one accessory and connected to the connecting portion to allow a first rotation varying an azimuth of the at least one accessory and a second rotation varying an angle of elevation of the at least one accessory, and control means adjusting the second rotation to obtain a desired value of the angle of elevation of the at least one accessory and automatically producing the first rotation to correct a lateral drift of the firearm.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment of the present invention and in which:
FIG. 1 is a perspective view of a mount according to a preferred embodiment of the present invention showing a relative position between a body and base corresponding to a forward reaction force after a recoil of the firearm, and with an exploded portion showing a mounting of a control system providing no lateral drift correction;
FIG. 2 is a perspective view of the mount of FIG. 1 showing the relative position between the body and base corresponding to the recoil of the firearm, with an exploded portion showing a mounting of the control system providing a lateral drift correction;
FIG. 3 is a perspective view, partly exploded, of the mount of FIG. 2 from an opposed point of view and showing knob covers in place over adjustment knobs;
FIG. 4 is a perspective view of the mount of FIG. 3 from an alternative point of view and showing the adjustment knobs without the knob covers;
FIG. 5 is a top view of the mount of FIG. 2 ;
FIG. 6 is a top view of the mount of FIG. 2 showing a first simultaneous azimuth adjustment of first and second attachment systems providing the lateral drift correction;
FIG. 7 is a side view of the mount of FIG. 1 or 2 showing a first simultaneous adjustment of the angle of elevation of the first and second attachment systems;
FIG. 8 is a top view of the mount of FIG. 2 showing a second azimuth adjustment of the second attachment system;
FIG. 9 is a side view of the mount of FIG. 1 or 2 showing a second adjustment of the angle of elevation of the second attachment system; and
FIG. 10 is a perspective exploded view of the mount of FIG. 2 showing the various main components thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now generally to FIGS. 1 , 2 and 10 , an accessory mount according to a preferred embodiment of the present invention is shown at 10 . The mount 10 comprises a base 12 and a body 14 which are slidingly connected together through a dampening system 16 to form a connecting portion of the mount 10 . The mount 10 also comprises an attachment portion including a first element 18 connected to the body 14 by a first pivot 20 , a second element 22 connected to the first element 18 by a second pivot 24 , and a third element 26 connected to the second element 22 by a third pivot 28 .
The first pivot 20 provides a rotation about an axis perpendicular to the longitudinal axis of the base 12 , which corresponds to the firing direction of the firearm, such that the first element 18 rotates in a substantially horizontal plane when the firing direction is substantially horizontal. The second pivot 24 provides a rotation about an axis perpendicular to the axis of the first pivot 20 , such that the second element 22 rotates in a plane perpendicular to the plane of rotation of the first element 18 . The third pivot 28 provides a rotation about an axis perpendicular to the axis of the second pivot 24 such that the third element 26 rotates in a plane perpendicular to the plane of rotation of the second element 22 .
Referring to FIGS. 1-2 , a first attachment system 30 is connected to the second element 22 , and a second attachment system 32 is connected to the third element 26 . Both attachment systems 30 , 32 are standard accessory attachment systems, such as Picatinny-type rails which are composed of a series of spaced apart ribs. Preferably, the first attachment system 30 is directly connected to the second element 22 while the second attachment system 32 is connected to the third element 26 through a fourth pivot 34 . The fourth pivot 34 provides a rotation about an axis perpendicular to the axis of the third pivot 28 , such that the second attachment system 32 rotates in a plane perpendicular to the plane of rotation of the third element 26 .
The mount 10 thus provides for a variety of adjustments for accessories mounted thereon. As shown in FIG. 6 , rotation about the first pivot 20 provides a first simultaneous azimuth adjustment “A” of the first and second attachment systems 30 , 32 through the first, second and third elements 18 , 22 , 26 . As shown in FIG. 7 , rotation about the second pivot 24 provides for a first simultaneous angle of elevation adjustment “B” for the first and second attachment systems 30 , 32 through the second and third elements 22 , 26 . As can be seen in FIG. 8 , rotation about the third pivot 28 provides a second azimuth adjustment “C” for the second attachment system 32 through the third element 26 . Finally, as can be seen in FIG. 9 , rotation about the fourth pivot 34 provides a second angle of elevation adjustment “D” for the second attachment system 32 .
The various components of the mount 10 will now be described in more details.
As can be best seen in FIGS. 1 , 2 and 10 , the base 12 includes a rail portion 40 which is adequately shaped to engage a given firearm (not shown). The rail portion 40 is adapted to be securely mounted to the firearm such as by fasteners or the like. Holes 42 are provided in the rail portion 40 for air circulation purposes. An arm 44 is releasably fastened onto the rail portion 40 by means of bolts or the like and can be readily detached from the rail portion 40 whenever it is desired to install the mount 10 on another firearm equipped with a rail similar to the rail portion 40 .
The arm 44 includes a top cylindrical bore 45 as well as part of the dampening system 16 , namely first and second hydraulic cylinders 46 , 48 . The first and second hydraulic cylinders 46 , 48 respectively receive first and second pistons 50 , 52 . The pistons 50 , 52 each have one end inside the respective cylinder 46 , 48 and another end secured to the body 14 . The hydraulic cylinders 46 , 48 and pistons 50 , 52 are parallel to the firing direction of the firearm such that the pistons 50 , 52 extend out of the cylinders 46 , 48 in opposite directions from each other. This allows for dampening to occur both during the recoil (see FIG. 2 ) and the reaction forward movement (see FIG. 1 ) following it. Although hydraulic dampeners are illustrated, it is also considered to use alternative dampening systems.
As can also be best seen in FIGS. 1 , 2 and 10 , the body 14 includes a housing 60 defining a cavity for receiving the dampening system 16 , as well as first and second circular openings 62 , 64 in the housing 60 to accommodate the movement of the first and second hydraulic cylinders 46 , 48 , respectively. The housing 60 also includes first and second aligned holes 65 , which are aligned with the cylindrical bore 45 of the base 12 to receive a shaft (not shown) slidingly engaging the base 12 and the body 14 . A guide 66 extends from the housing 60 in a direction parallel to the firing direction of the firearm. The guide 66 is shaped as a shaft having a grooved end. As seen in FIGS. 7 and 10 , the housing 60 also includes a pair of lugs 66 which form part of the first pivot 20 .
As can be seen in FIG. 3 , the first element 18 preferably includes a series of holes 70 to minimize a weight thereof. The first element 18 includes a lug 72 (see FIGS. 7 and 10 ) which is attached to the lugs 66 of the body 14 by a pin (not shown) to form the first pivot 20 . The first element 18 also includes a control system receiving portion 74 which includes a window 76 having a pointer 78 and a light (not shown) therein. The light is preferably mounted in a recess in a side wall of the window 76 to minimize light emissions outside of the window 76 . The first element 18 further includes a push button 80 for activating the light, and a closable battery casing 82 for receiving a battery powering the light.
As seen in FIGS. 1-2 , a control system generally shown at 90 allows a user to adjust the rotation of the second element 22 about the second pivot 24 . The control system 90 includes a shaft 92 which is rotationally retained by the first element 18 and by the guide 66 , and passes through the second element 22 located therebetween (see FIG. 10 ). The shaft 92 is threaded on the end retained by the guide 66 . The second element 22 includes a pair of lugs 94 with aligned bores 96 near the shaft 92 . An arcuate plate 98 includes similar lugs 100 with aligned bores 102 which are engaged to the lugs 94 of the second element 22 by a pin 104 going through the aligned bores 96 , 102 . The guide 66 is thus sandwiched between the mounted arcuate plate 98 and the second element 22 . The arcuate plate 98 includes an arcuate slot 106 and has one flat side 108 and one side defining an arcuate groove 110 surrounded by an inclined plane 112 . A retaining knob 114 engages the threaded end of the shaft 92 over the arcuate plate 98 .
As can be best seen in FIG. 3 , the other end of the shaft 92 is keyed to a dial 116 having numerical indications usually indicating a target distance (not shown) aligned with the window 76 , to an adjustment knob 118 having a profile easily grasped by a user, and to a standard quick locking system 120 which, when engaged, prevents the rotation of the shaft 92 . Preferably, the dial 116 is reversible and includes two sets of numerical indications corresponding to two different firearms. The numerical indications are disposed so that only one set is visible through the window 76 .
As can be best seen in FIGS. 7 and 10 , the shaft 92 supports a gear 122 which is keyed thereto. The second element 22 includes an arcuate gear member 124 which is meshed with the gear 122 . The arcuate gear member 124 , as well as the arcuate slot and groove 106 , 110 of the installed plate 98 , each define an arc of circle having its center at the second pivot 24 .
The control system 90 allows the user to adjust the rotation of the second element 22 by turning the adjustment knob 118 until a desired numerical indication on the dial 116 is aligned with the pointer 78 in the window 76 . Turning the adjustment knob 118 turns the gear 122 through the shaft 92 , which activates the rotation of the second element 22 by rotating the arcuate gear member 124 about the second pivot 24 , thus varying the angle of elevation of the first and second attachment systems 30 , 32 . The user can than lock the second element 22 at the desired angle of elevation by engaging the quick locking system 120 .
The control system 90 also produces an automatic correction of a lateral drift of the firearm. As explained above, the guide 66 is sandwiched between the arcuate plate 98 and the second element 22 , such as to be snugly received in a channel formed between the two. When the arcuate plate 98 is mounted as shown in FIG. 2 , i.e. with the inclined plane 112 in contact with the guide 66 , the channel thus created forms an angle with respect to the plane of rotation of the second element 22 . As the second element 22 is rotated about the pivot 24 , the guide 66 sliding in the angled channel will force a rotation of the first element 18 about the first pivot 20 .
In the case where no lateral drift correction is required, the arcuate plate 98 is mounted as shown in FIG. 1 , i.e. with the flat side 108 against the guide and the retaining knob 118 sliding on a flat surface within the arcuate groove 110 . As the second element 22 is rotated about the second pivot 66 , the guide 66 will thus slide in a channel parallel to the plane of rotation of the second element 22 . In that case, no rotation will occur about the first pivot 20 and the first element 18 and body 14 will act as an integral member.
As shown in FIG. 4 , the user can also adjust the rotation of the third element 26 about the third pivot 28 by turning a small knob 126 . The small knob 126 is keyed onto a threaded shaft (not shown), which is retained in the third element 26 and threadably received in the second element 22 . Similarly, the user can adjust the rotation of the second adjustment system 32 about the fourth pivot 34 by turning a second small knob 128 . The second small knob 128 is keyed onto a second threaded shaft (not shown) which is similarly retained in the third element 26 and threadably received in the second adjustment system 32 . As shown in FIG. 3 , each of the small knobs 126 , 128 is equipped with a removable knob cover 130 , 132 which, when engaged over the respective knob 126 , 128 , prevents the knob 126 , 128 from being accidentally turned.
In operation, the user determines if the firearm to be used requires a lateral drift correction and mounts the arcuate plate 98 accordingly. The user then attaches the mount 10 to the firearm through the rail portion 40 , and desired accessories to the first and second attachment systems 30 , 32 . The user first adjusts the angle of elevation of the accessories by turning the adjustment knob 118 until a desired numerical indication of the dial 116 is aligned with the pointer 78 in the window 46 . If needed, the user can press the push button 80 such as to activate the light in the window 76 to better see the numerical indications on the dial 116 . Turning the adjustment knob 118 will simultaneously rotate the second and third elements 22 , 26 about the second pivot 24 through the action of the gear 122 and arcuate gear member 124 . When the desired orientation of the second element 22 is obtained, the quick locking system 120 is engaged to prevent accidental rotation of the control system 90 .
If the arcuate plate 98 is mounted as shown in FIG. 2 , turning the adjustment knob 118 will also provide the lateral drift correction by simultaneously rotating the first, second and third elements 18 , 22 , 26 about the first pivot 20 through the action of the guide 66 and inclined plane 112 of the arcuate plate 98 . If the arcuate plate 98 is mounted as shown in FIG. 1 , no rotation will occur about the first pivot 20 and the first element 18 will form an integral member with the body 14 .
The user can then adjust the azimuth and angle of elevation of the accessory mounted onto the second attachment system 32 by turning the small knobs 126 , 128 which will respectively rotate the third element 26 about the third pivot 28 and the second attachment system 32 about the fourth pivot 34 . Once the desired orientation is obtained, the knob covers 130 , 132 are engaged to the small knobs 126 , 128 to prevent accidental rotation thereof
When the firearm is fired, the recoil force as well as the reaction forward force will be dampened by the dampening system 16 . This will minimize the risk of injury to the user by limiting the range and speed of the movement of the accessories caused by the recoil of the firearm.
The various user controls of the mount 10 (i.e. the knobs 118 , 126 , 128 , the quick locking system 120 , the knob covers 130 , 132 , the push button 80 ) are disposed and designed such as to be operable with a single hand, thus simplifying the use of the mount 10 .
The present invention thus provides for releasable attachment of at least one accessory directly to a firearm while providing separate adjustment of two accessories with respect to a firing direction about at least two axes.
The present invention also advantageously provides lateral drift correction when needed while being usable with firearms requiring no lateral drift correction.
The present invention further provides a dampening system dampening the recoil force produced by a firearm, such that accessories can be mounted directly on firearms producing a significant recoil force while minimizing the risks of injury to the user.
The embodiments of the invention described above are intended to be exemplary. Those skilled in the art will therefore appreciate that the foregoing description is illustrative only, and that various alternatives and modifications can be devised without departing from the spirit of the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A mount comprising a connecting portion attachable to a firearm, a first member connected to the connecting portion to be rotatable about a first axis, a second member connected to the first member to be rotatable about a second axis substantially perpendicular to the first axis, and an attachment system connected to the second member for receiving an accessory. Also, a mount attachable to a firearm and having a dampener system connected to base and body portions thereof, the dampener system acting to dampen a recoil force produced by the firearm. Further, a mount attachable to a firearm and allowing a first rotation varying an azimuth of an accessory and a second rotation varying an angle of elevation of the accessory, and control means adjusting the second rotation to obtain a desired value and automatically producing the first rotation to correct a lateral drift of the firearm.
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BACKGROUND
[0001] The present invention is directed to electronic components, and more particularly to a connector for mounting an LED to a printed circuit board (PCB).
[0002] The use of high intensity LEDs for general-purpose illumination, and in specialty lighting applications such as large signs and video display applications, has increased in recent years. Typically LEDs are mounted to PCBs by soldering them directly to the preprinted circuits. PCBs are most commonly manufactured using automated wave soldering techniques for mass production. If an LED fails after the PCB has been manufactured, the PCB is usually discarded and replaced with a replacement PCB, since field soldering of LEDs is, in most cases, inefficient and impractical. Although the cost of a replacement LED is negligible, the cost of labor and downtime associated with field soldering a replacement LED to a PCB is frequently greater than the cost to replace the entire PCB.
[0003] Some special purpose LED connectors have threaded bases and require machined assemblies to receive the threaded bases. These connectors feature multiple interconnecting parts. Internal threads must be machined in a connector body. Threaded LED terminations are accomplished by a screw action that is time consuming and adds to assembly costs. Moreover, the placement of the contacts on the PCB must be tightly controlled for the contact interfaces between the LEDs and the connectors to be reliable. Contact interfaces for the component parts of the PCBs may have a high variability in contact normal loads, which leads to early failures. Conversely, if the contact placement is tightly controlled, the fabrication costs may be greatly increased, making the devices impractical from a cost perspective.
[0004] What is needed is a connector to terminate a threaded LED that is reliable and permits the LED to be urged or snapped into position in the connector in a single motion. Other features and advantages will be made apparent from the present specification. The teachings disclosed extend to those embodiments that fall within the scope of the claims, regardless of whether they accomplish one or more of the aforementioned needs.
SUMMARY
[0005] In one embodiment, the present invention is directed to a connection receptacle for mounting a high powered LED having a threaded base section to a printed circuit board. The connection receptacle includes a hollow cylindrical body portion with an interior sidewall, a first end and a second end opposite the first end. The sidewall defines a hollow cavity adjacent the first end to receive the base section of the LED. The second end has a plurality of conductive contact elements configured to electrically contact the LED. A first electrical contact element includes at least one prong extending partially into the cavity. The prong is sufficiently flexible to allow the threaded portion to pass the at least one prong for insertion, and partially return to engage with the threaded portion to maintain the threaded portion inside the cavity. The prong also is configured to permit removal of the LED rotationally with respect to the cavity. The contact elements are in electrical communication with the LED and the threaded base section when the threaded base section is inserted within the body portion.
[0006] In another embodiment, the present invention is directed to LED assembly. The LED assembly includes an LED having a threaded base section and a core electrode in electrical communication. The core electrode is axially parallel to the threaded base section. A connection receptacle for receiving the LED includes a hollow cylindrical body portion with an interior sidewall, a first end and a second end opposite the first end. The sidewall defines a hollow cavity adjacent the first end to receive the base section of the LED. The second end has a plurality of conductive contact elements with which to electrically contact the LED. A first electrical contact element includes at least one prong extending partially into the cavity. The prong is sufficiently flexible to allow the threaded portion to pass the at least one prong for insertion, and partially return to engage with the threaded portion to maintain the threaded portion inside the cavity. The prong also is also configured to permit removal of the LED rotationally with respect to the cavity. The contact elements are in electrical communication with the LED and the threaded base section when the threaded base section is inserted within the body portion.
[0007] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an upright perspective view of an LED/connector assembly.
[0009] FIG. 1A is an exploded view of the the LED/connector assembly.
[0010] FIG. 2 is a reverse perspective view of an assembled LED/connector.
[0011] FIG. 3 is a cross-sectional view through the center of an assembled LED/connector.
[0012] FIG. 4 is an exploded view of the connector portion.
[0013] FIG. 5 is a cross-sectional view of the connector portion.
[0014] FIG. 6 is a perspective view of an alternate contact portion having 3-prongs.
[0015] FIG. 7 is a top plan view of the connector portion.
[0016] FIG. 8 is a perspective view of an alternate embodiment.
[0017] FIG. 9 is a perspective view of the alternate embodiment of FIG. 8 , and an LED.
[0018] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring to FIGS. 1-3 , an assembled LED/connector 10 includes an LED assembly 12 inserted into a connection receptacle 14 . A pair of connector contacts 16 , 18 protrude from the connection receptacle 14 . A core LED electrode 20 extends through the center of the LED assembly 12 and provides an electrical connection to one of two internal LED terminals (not shown). A threaded base-portion 22 of the LED assembly 12 extends from a rim portion 24 that is electrically connected to the remaining internal LED terminal. The rim portion of the LED may be conductive, but is not required to be conductive for the connector to work properly. The internal LED of the LED assembly 12 is electrically connected between the threaded base portion 22 and the core LED electrode 20 . The threaded base portion 22 and the core LED electrode 20 are otherwise insulated from each other to avoid short-circuiting the LED. An exemplary threaded-base integrated LED assembly 12 is manufactured by CAO Group, Inc., of West Jordan, Utah.
[0020] The connection receptacle 14 includes a hollow cylindrical cavity 26 that receives the threaded base portion 22 . The interior cavity 26 of the connection receptacle 14 has a generally straight, smooth sidewall 28 with an inner-diameter that is slightly larger than the outer diameter of the threaded base portion 22 of the LED assembly 12 , so that the threaded base portion 22 can be inserted into the connection receptacle 14 without rotation—i.e., by urging the LED assembly 12 directly downward into the interior cavity 26 of the connection receptacle 14 , as indicated by direction arrow 23 in FIG. 1A .
[0021] Once the LED assembly 12 is urged into the connection receptacle 14 , a pair of contact elements 16 , 18 engage the core threaded base portion 22 and the core LED electrode 20 , respectively. The first contact element 16 includes a deflectable prong 30 . The first contact element 16 may be made from electrically conductive structures, such as a metallic foil, e.g., copper alloy conductive strip. Preferably the foil strip is sufficiently flexible to permit the prong 30 to deflect as the threaded base portion 22 is urged into the cavity 26 . The prong 30 engages one of the threads of the threaded base portion 22 , which provides electrical contact and prevents the LED assembly 12 from backing out of the cavity 26 . The LED assembly 12 is secured in position by the prong 30 , and is removable by conventional rotational means—i.e., by rotating the threaded base portion 22 of the LED assembly 12 in the direction in which it is configured to reverse, typically counterclockwise, although opposite-hand thread types exist and function much the same, with opposite rotation for installation and removal. Thus, the LED assembly 12 is installable in the connection receptacle 14 by simply urging it into the cavity 26 , but removable only by rotating it in the appropriate direction.
[0022] The second contact element 18 includes an end portion 32 that is bent or turned back at an acute angle to the contact element 18 . The end portion 32 has an inwardly curved tip portion 34 . The end portion 32 is elastically deflectable, similar to the prong 30 and engages the core LED electrode 20 when the LED assembly 12 is pressed into the cavity 26 . The curvature of the tip portion 34 allows the LED electrode 20 to slidingly engage the end portion 32 in both directions of movement, i.e., so that the end portion 32 does not gouge into the core electrode 20 and prevent its removal.
[0023] The cavity 26 has an inwardly protruding ledge 36 disposed intermediately of the opposite ends of the connection receptacle 14 . The ledge 36 reduces the inner radius of the cavity 26 to trap the core LED electrode 20 and guide it into the lower cavity portion 38 . Preferably, there is a tapered transition segment 40 that connects the lower cavity portion 38 with the ledge 36 , and which helps to center the end of the core electrode into the lower cavity portion 38 . The lower cavity portion 38 has an internal diameter that preferably provides a close clearance fit for the core LED electrode. The end portion 32 protrudes at least partially into the lower cavity portion 38 and presses against the core electrode 20 under spring tension. The flex in the second contact portion 18 from the bent intersection with the end portion 32 provides the spring tension.
[0024] Referring next to FIGS. 5 and 6 , the connection receptacle 14 is preferably made of a molded, high temperature resin, e.g., glass-filled, nylon-66 or other electrically insulating, high temperature resin, and includes a pair of internal channels 42 , 44 arranged on opposite sides of the receptacle 14 . The first contact element 16 is installed in the channel 42 that runs adjacent to both the upper cavity 26 and the lower cavity 38 and protrudes from the lower end of the connection receptacle 14 . In one embodiment the first contact element 16 is a flat strip of metal conductor with three step portions 46 , 48 , 50 of progressive width. The step portion between 46 and 48 provides a stop limit for seating the contact element 16 when the element is placed in the receptacle 14 . The contact element also has a pair of bent prongs 30 , 52 that protrude inward. The first prong 30 , as discussed above, retentively and electrically engages the threads on the threaded base portion 22 . The first prong 30 is shown as a single protruding member, however, additional prongs may be included, e.g., two prongs or three prongs arranged in series, which are preferably spaced apart by a single-thread distance for improved engagement with a corresponding number of threads. The second prong 52 deflects to allow it to pass behind a portion of the inner wall of the cavity 26 and spring back to latch in position in an opening (not shown) adjacent to the ledge 36 .
[0025] The second contact element 18 is inserted into a slot 44 in the connection receptacle 14 adjacent to the lower cavity 38 . The contact element 18 includes an intermediate locking member 54 , which slides into the slot 44 of the inner wall, and locks the contact element into position by engagement of detents 56 located on either edge of the locking member 54 .
[0026] Referring next to FIGS. 6 and 7 , an alternate embodiment shows a novel 3-pronged contact to deflect and mate on threads. Contact portion 16 has three web portions 46 a - 46 c which may be substituted for the single step portion 46 of the contact portion 16 shown in FIG. 4 . Two prongs 46 b and 46 c project outwardly on opposite sides of the center prong 46 a and are bent inwardly to partially envelop the circumference of the threaded portion 22 . Deflectable prongs 30 a - 30 c project inwardly from the respective web portions 46 a - 46 c to engage the conductive threaded portion 22 of the LED assembly 12 . The distal ends 60 a - 60 c of prongs 30 a - 30 c , respectively, may be staggered in length to engage the thread portion 22 approximately equally, to cooperate with the helical pitch of the individual threads. In this way, it is apparent that the prongs 30 a - 30 c are deflected by the threaded portion 22 when the LED assembly 12 is inserted in a first direction indicated by arrow 70 . The prongs 30 a - 30 c then spring back and mate against the threads of the threaded portion 22 and act as ratchet pawls and electrical contacts to prevent the LED assembly 12 from backing out of the connection receptacle 14 linearly. However, the LED assembly 12 is rotatable about its axis, and can be removed in cooperation with the prongs 30 a - 30 c by twisting in one rotational direction, as well as further tightened by twisting the threads in the opposite rotational direction. Thus, the LED assembly 12 may be securely installed into the connection receptacle 14 by a pushing motion, or by threading, but the LED assembly 12 is prevented from backing out of the connection receptacle 14 by the prongs 30 a - 30 c , unless the threads 22 are used.
[0027] Referring next to FIGS. 8 and 9 , in an alternate embodiment, the connector portion 14 may include solder terminals 70 for soldering wires 72 to the connector portion. The LED 12 is inserted into and removed from the connector portion 14 in the same manner as described above. In the embodiment of FIGS. 8 & 9 , however, the connector portion 14 is configured for attaching leadwires 72 instead of the contact pins described above. The leadwires permit the connector portion 14 to be secured to a surface (not shown) other than a PCB, by a hex nut 74 .
[0028] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A connector for mounting an LED to a printed circuit board (PCB) includes a hollow cylindrical body portion with an interior sidewall that defines a hollow cavity at one end to receive the LED threaded base section. The second end has a plurality of conductive contact elements with which to electrically contact the LED. A first electrical contact element includes at least one prong extending partially into the cavity. The prong is flexible for the threaded portion to pass the prong for insertion, and partially return to electrically engage the threaded portion to maintain the threaded portion inside the cavity. The prong also permits removal of the LED rotationally with respect to the cavity. The contact elements are in electrical communication with the LED and the threaded base section when the threaded base section is inserted within the body portion.
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BACKGROUND TO THE INVENTION
Field of the Invention
The present invention relates to a linear compressor, particularly but not solely for use in refrigerators.
SUMMARY OF THE PRIOR ART
Compressors, in particular refrigerator compressors, are conventionally driven by rotary electric motors. However, even in their most efficient form, there are significant losses associated with the crank system that converts rotary motion to linear reciprocating motion. Alternatively a rotary compressor which does not require a crank can be used but again there are high centripetal loads, leading to significant frictional losses. A linear compressor driven by a linear motor would not have these losses, and can be designed with a bearing load low enough to allow the use of aerostatic gas bearings as disclosed in U.S. Pat. No. 5,525,845, where a connecting rod that is compliant to lateral movement allows for the low bearing load.
A discussion of aerostatic gas bearings is included in “Design of Aerostatic Bearings”, J W Powell, The Machinery Publishing Company Limited, London 1970. However with normal manufacturing tolerances and equipment production of effective gas bearings is difficult.
Conventional compressors are mounted within a hermetically sealed housing which in use acts as a reservoir of refrigerant gas. Refrigerant gas is drawn into the compressor from this reservoir and is exhausted through an exhaust conduit leading from the compressor, through the housing.
Operation of the compressor involves the reciprocation of moving parts leading to vibration of the compressor unit, in all three axis. To reduce the external noise effect of this vibration the compressor is mounted on isolation springs within the sealed housing.
With a linear compressor the piston vibrates relative to the cylinder in only one axis, with consequent reaction forces on whichever part, if either, is fixed. One solution proposed to this problem is to operate a pair of compressors synchronously in a balanced and opposed configuration. However this arrangement would be too complex and costly for use in a commodity item such as a domestic refrigerator. Another proposed solution is the addition of a resonant counterweight to reduce the vibration. However this approach limits the operation of the compressor because the counterweight is a negative feedback device and is limited to the fundamental unbalance force. A further solution is proposed in “Vibration characteristics of small rotary and linear cryogenic coolers for IR systems”, Gully and Hanes, Proceedings of the 6 th International Cryocooler Conference, Plymouth, Massachusetts, 1990. This solution involves independently supporting the piston part and the cylinder part of the compressor within the housing so that the “stator acts as a counterweight”. However in implementing this design in a domestic refrigerator there is a problem when the piston mass is low. In such a compressor, as the discharge pressure increases, the force of the compressed gas acts as a spring force (the “gas spring”) which increases the running speed as the discharge pressure increases. This is a problem because the frequency of the “third” vibration mode (where the piston and the cylinder vibrate in phase with each other but out of phase with the compressor shell) is only slightly above the frequency of the desirable “second” mode (where the shell does not vibrate and the piston and cylinder are out of phase). Thus the shell starts to vibrate intolerably as the “gas spring” starts to operate and effectively raises the “second” mode frequency to, and eventually above, the “third” mode frequency.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a compact linear compressor which goes some way to overcoming the abovementioned disadvantages.
In one aspect the invention consists in a linear compressor including;
a cylinder part including a head, a cylinder and a cylinder liner within said cylinder, said cylinder liner having a bore therethrough and openings through said cylinder liner into from an outside surface of said cylinder liner to said bore, a piston part, a linear motor configured to operate between said piston part and said cylinder part, a main spring connecting between said cylinder part and said piston part and operating in the direction of reciprocation of said piston part relative to said cylinder part, said piston part including a radially compliant but axially stiff linkage and a piston, said linkage connecting between said piston and said main spring, said piston moving within said bore of said cylinder liner, a gas bearing manifold adapted to receive a supply of gases compressed by said compressor, wherein an outer surface of said cylinder liner mates against an inner surface of said cylinder, one said surface having one or more grooves extending in a tortuous path from said gas bearing manifold to each of said openings through said cylinder liner, said grooves enclosed by the other said surface to constitute passages.
In a further aspect the invention consists in a free piston compressor having:
a cylinder outer part, a cylinder inner part within the cylinder outer part and having a bore therethrough, a piston reciprocable within said bore, and openings through said cylinder inner part from an outer surface to said bore, said openings distributed to, with a flow of gases therethrough in use, provide gas bearing support to said piston, the improvement comprising:
a gas bearing supply manifold at, or adjacent, the interface between said cylinder inner part and said cylinder outer part, an inner surface of said cylinder outer part mating against said outer surface of said cylinder inner part, and grooves on at least one of said inner surface and said outer surface extending in a tortuous path from said manifold to said openings said grooves enclosed by the other said surface to constitute enclosed passages.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a linear compressor according to the present invention,
FIG. 2 is a plan view of a first embodiment of a main spring for the linear compressor of FIG. 1 ,
FIG. 3 is a plan view of an alternative second embodiment of the main spring for the linear compressor of FIG. 1 ,
FIG. 4 is a perspective view of a preferred third embodiment of the main spring of the compressor for FIG. 1 ,
FIG. 5 is a perspective view of the main spring of FIG. 4 from an alternative direction,
FIG. 6 is a perspective view of a cylinder liner according to one preferred form of the present invention, and
FIG. 7 is a perspective view of a cylinder liner according to a second preferred form of the present invention.
DETAILED DESCRIPTION
A practical embodiment of the invention, shown in FIG. 1 , involves a permanent magnet linear motor connected to a reciprocating free piston compressor. The cylinder 9 is supported by a cylinder spring 14 and by a discharge tube 18 within the compressor shell 30 . The piston 11 is supported radially by the bearing formed by the cylinder bore plus its spring 13 via the spring mount 25 . A main spring 15 connects between the piston part 11 and the cylinder part 9 . The total reciprocating movement is the sum of the movement of the piston 11 and the cylinder 9 .
This reciprocating movement draws gas in through a suction tube 12 through a suction port 26 through a suction muffler 20 and through a suction valve port 24 in a valve plate 21 into a compression space 28 . The compressed gas then leaves through a discharge valve port 23 , is silenced in a discharge muffler 19 , and exits through a discharge tube 18 .
The cylinder 9 is supported by the discharge tube 18 and the cylinder spring 14 which have a combined stiffness, k cylinder , in the axial direction. The piston 11 is supported radially by gas bearings which will be described later. During resonant oscillation of the piston and cylinder the main spring has a stiffness, k main , such that the second mode resonant frequency, f natural , can be estimated from the relation,
f natural = 1 2 · π · k main · m piston + m cylinder m piston · m cylinder
Where m pistons , m cylinder , are the sprung masses of the piston and cylinder springs, f n ,f natural is usually 10 to 20 Hz less than the desired running frequency to allow for the increase in frequency due to the stiffness of the compressed gas, the effective cylinder spring (a combination of spring 14 and 18 ), and piston spring 13 . The stiffness of the piston spring k piston is selected according to the relationship
k piston = k cylinder × m piston m cylinder
The spring forces are transferred to the piston via the rod end 25 and the radially compliant piston rod 124 . The electromagnetic forces are transferred to the piston via the piston flange 7 , from the bi-polar magnets 22 . The bi-polar magnets 22 are bonded to each other and to the piston flange 7 .
The compressor motor comprises a two part stator and an armature. The stator includes an inner stator 6 and a back iron 5 . The inner stator carries coils 1 and 2 . The armature includes bi-polar magnets 22 . The magnetic interaction of the stator 5 , 6 and armature magnets 22 generates reciprocating force on the piston 11 (attached to the armature by flange 7 ).
An oscillating current in coils 1 and 2 , not necessarily sinusoidal, will give rise to substantial movement of the piston 11 relative to the cylinder 9 provided the oscillation frequency of the current is close to the natural resonant frequency of the mechanical system. This oscillating force creates a reaction force on the stator parts. Thus the inner stator 6 must be rigidly attached to the cylinder 9 by adhesive, shrink fit or clamp etc. The back iron 5 is clamped or bonded to the stator mount 17 .
The stator mount 17 also clamps the outer ends of the main spring 15 and also keeps the relatively weak back iron 5 round and concentric with the inner stator 6 . The entire compressor assembly is hermetically sealed inside the compressor shell 30 .
In the present invention it is proposed that the main spring 15 has a stiffness much greater than the stiffness of the effective cylinder spring, and of the piston spring. This “main spring” raises the “second” mode frequency above the “third” so that the “gas spring” then only separates the modal frequencies further.
The actual running frequency (the “second” mode frequency) is determined by a complicated relation of using the mass of piston and cylinder and by the stiffness of the piston spring, cylinder spring, and main spring 15 . Also when the discharge pressure is high the equivalent spring stiffness of the compressed gas must be added to that of the main spring. However, with the cylinder spring quite soft (say with a stiffness 1/100 of the main spring) the running frequency is found reasonably accurately by:
f running = 1 2 · π · ( k main + k gas ) · m piston + m cylinder m piston · m cylinder
External vibration due to sources, other than from the desirable second mode due to piston/cylinder movement, can be almost eliminated by reducing the oscillating mass and by ensuring that the piston and cylinder springs are relatively soft. The effective cylinder spring stiffness can be reduced to a minimum by having no cylinder spring at all, leaving only the inherent stiffness (from around 1000 N/m) of the discharge tube 18 (or where a cooling tube is used the stiffness of both discharge and cooling tube are combined ie 2000 N/m). With the effective cylinder spring stiffness only including the stiffness of the discharge tube (say 1000 N/m) the stiffness of the piston spring should be:
k piston = m piston m cylinder × 1000
For a ten to one cylinder to piston mass ratio this suggests a very soft piston-spring (100 N/m).
For the compressor with a main spring to resonate at roughly 75 Hz with a piston mass of around 100 g and a ten to one cylinder to piston mass ratio, the main spring stiffness (K main ) needs to be about 20,000N/m. Typically the value of the gas spring will be lower-than that of the main spring but not substantially lower. In the above case the running frequency is expected to be 99 Hz with the gas spring (k gas ) of approximately 15,000N/m.
The piston 11 is supported radially within the cylinder by aerostatic gas bearings.
The cylinder part of the compressor includes the cylinder 9 , having a bore therethrough, and a cylinder liner 10 within the bore. The cylinder liner 10 may be made from a suitable material to reduce piston wear. For example it may be formed from a fibre reinforced plastic composite such as carbon fibre reinforced nylon with 15% PTFE (preferred), or may be cast iron with the self lubricating effect of its graphite flakes. Referring additionally to FIGS. 6 and 7 , the cylinder liner 10 has openings 31 therethrough, extending from the outside cylindrical surface 70 thereof to the internal bore 71 thereof. The piston 11 travels in the internal bore 71 , and these openings 31 form the gas bearings. A supply of compressed gas is supplied to the openings 31 by a series of gas bearing passages 8 . The gas bearing passages 8 open at their other ends to a gas bearing supply manifold 16 , which is formed as an annular chamber around the cylinder liner 10 at the head end thereof between the liner 10 and the cylinder 9 . The gas bearing supply manifold 16 is in turn supplied by the compressed gas-manifold 20 of the compressor head by a small supply passage 73 . The small size of the supply passage 73 controls the pressure in bearing supply manifold 16 , thus limiting the gas consumption of the gas bearings.
The gas bearing passages 8 are formed as grooves 80 or 81 in either the bore 74 of the cylinder or in the outer wall 70 of the cylinder liner. These grooves 80 or 81 combine with the wall of the other cylinder or the cylinder liner to form enclosed passages 8 leading to the openings 31 . It will be appreciated that while the grooves could be provided in either part they are more readily formed in the liner part than in the cylinder part, being on an outer surface rather than an inner surface. Being able to machine the grooves into a surface of one or other part rather than having to drill or bore passages is a significant manufacturing improvement.
It has been found that the pressure drop occurring in the gas bearing passages needs to be similar to the pressure drop occurring in the exit flow between the piston and the bore of the cylinder liner. Since the gap between the piston 11 and the cylinder liner bore 71 (for an effective compact compressor) is only 10 to 15 microns, the sectional dimensions of the passages 8 need to be very small, for example, 40 microns deep by 120 microns wide. These small dimensions make manufacturing the bearing passages difficult.
However, with reference to FIGS. 6 and 7 , in the preferred embodiment of the present invention matching the pressure drops is made easier by increasing the length of the passages 8 so that the cross-sectional area of the passages can also be increased. The longer but larger cross-section passages have a flow resistance similar to narrower shorter passages. Taking the earlier examples, the dimensions might become 70 microns deep by 200 microns wide. This takes advantage of the ability to form grooves 80 or 81 of any appropriate shape in the surface of the liner part 10 or of the cylinder part 9 which then forms the passages 8 in conjunction with the other part. The grooves can be formed having any path, and if a tortuous path is chosen the length of the grooves can be significantly greater than the direct path between the gas bearing supply manifold and the respective gas bearing forming openings. Two possible options are depicted in FIGS. 6 and 7 , being helical paths 80 and serpentine paths 81 respectively. The lengths of the respective paths are chosen in accordance with the preferred cross-sectional area of the passage, which can be chosen for easy manufacture (either machining or possibly by some other form such as precision moulding).
Higher running frequencies reduce motor size but require more spring stiffness, and consequently higher stresses in the springs. Thus it is important for compressor longevity that the highest quality spring material be used. In the conventional linear compressors main springs made from pressed spring steel sheet are often used. However, the edges cut in the pressing operation require careful polishing to regain the original strength of the spring steel sheet.
In the preferred embodiment of the present invention the main spring is formed from circular section music wire. As depicted in first embodiment FIG. 2 the main spring can be wound to form a spiral spring 15 . The spiral spring 15 has a pair of spiral arms 50 , 51 which are 180 degrees out of alignment so that the path of each arm is between adjacent turns of the other arm. The piston mounting point 52 is at the centre of connecting bridge 53 at the centre and the cylinder mounting point 54 for each arm of the spring at the outer end of the arm.
The very high fatigue strength of music wire is utilised effectively and there is no need for a subsequent polishing operation. If increased lateral stiffness is required the music wire could be deformed by 10% to give an elliptical section. To simplify the attachment of the main spring, square section wire could be used, or the connection ends of the spring may be stamped to a flattened shape, as depicted.
However, an alternative and second embodiment of the main spring is depicted in FIG. 3 . This spring may also be formed from music wire and take advantage of its high fatigue strength.
In FIG. 3 the spring 59 includes a pair of mounting points 60 , 61 for mounting to one of the compressor parts (the cylinder part) and a central mounting point 62 for mounting to the other compressor part (the piston part). The spring 59 includes a pair of curved sections 63 , 64 of substantially constant radius of curvature which are each centered on a respective cylinder mounting point 60 , 61 . These sections meet in material continuity at the piston mounting point 62 . Each section curves smoothly at its other end 65 , 66 to be radially aligned with the cylinder mounting point 67 , 68 . The sharper transition curve at 65 , 66 is preferably selected to maintain a substantially even stress distribution along the transition. The cylinder mounting ends 67 , 68 are preferably aligned with the line between the cylinder mounting points 60 , 61 . To get the best performance for the overall space occupied by the spring, the constant curvature sections 63 , 64 of the spring 59 are as long as possible. Consequently they extend for approximately 325 degrees from the piston mounting point 62 , before curving more sharply to the cylinder mounting point 60 or 61 respectively. This configuration allows the spring sections to narrowly avoid interfering with one another. The total spring assumes an approximate figure-eight shape.
The constant radius curves 63 , 64 are placed in torsion by the displacement (out of plane) of the piston mounting point 62 relative to the cylinder mounting points 60 , 61 . Being constant radius, the torsion stresses along each of the sections 63 , 64 are also substantially constant. Due to the radial, or substantially radial direction at of the cylinder mounting sections 67 , 68 any torsion stresses in the portion of the spring at the cylinder mounting are at a minimum and mounting of the spring 59 to the cylinder part is improved. The central mounting point 62 of the spring ing has high torsion stresses, however this does not significantly complicate that mounting because that the mounting can be made to encircle the spring arm with a resilient (eg: rubber) boot to allow for movement of the spring arm within the mounting. Movement of the spring arm within the mounting will be cyclical and, due to the symmetry of the spring (the spring is rotationally symmetric through 180 degrees), the cyclic forces should not cause the mounting to creep or walk along the spring arm. It should be noted that this spring configuration has been particularly developed for incorporating the wire formed approach rather than the stamped plate approach. However (subject to limitations in some more complex embodiments referred to below) springs of this geometric form could also be manufactured using the stamped plate method, but some of the advantages (for example, uniform stresses are particularly suitable with wire of constant cross section) would not be realised.
It should be appreciated that variations on the spring of FIG. 3 are also possible without departing from the scope of the invention. In particular, if the spring is formed so that a spring arm is perpendicular to the line between the compressor mountings at the compressor mounting then the arm can continue to form an equivalent (although mirrored) loop, below or above a first loop, back to the other compressor mounting. That loop would of course have a second piston connection point below or above the first loop. At the other compressor connection point the ends can meet, or alternatively this second loop may be continued through the connection point to form a third loop, below (or above as necessary) the second loop, back to the first compressor mounting point (or at least to a mounting point immediately above or below). This chaining of loops can proceed to include as many loops as necessary to achieve a required spring constant. Clearly this is a planar spring configuration that cannot be constructed by stamped plate methods.
However the preferred third embodiment for the main spring is depicted in FIGS. 4 and 5 .
In the third embodiment the main spring takes a form other than that of a planar spring. It retains many of the conceptual features of the second embodiment and therefore where similar features are apparent the same reference numerals have been used.
The spring 15 has a pair of free ends for mounting to one of the compressor parts, for example the cylinder part. The spring 15 has a further mounting point for mounting to the piston part.
The spring 15 includes a pair of curved sections 63 , 64 of substantially constant radius of curvature which each pass around their respective mounting end. Each of these curved sections extends over a length of approximately 360°. Each section curves smoothly at both of its ends. At the ends 65 , 66 they curve such that the lengths 67 , 68 of them at the cylinder mounting ends are radially aligned. The sharper transition curve at 65 , 66 is selected to maintain a substantially even stress distribution along the transition. The spring 15 of FIGS. 4 and 5 improves on the spring 59 of FIG. 3 in that the constant curvature sections 63 , 64 of the spring 15 may be rendered of any degree length including beyond 360. In the example depicted they are each of approximately 360° in length.
In the manner depicted in FIGS. 4 and 5 the mounting points 60 , 61 of spring 15 are at an upper side thereof. The central mounting point 62 is at a lower side thereof. The constant curved sections 63 , 64 each curve smoothly at their lower ends to be radially aligned and continuous with one across a diameter of the general circle of the spring at the mounting point 62 . The alignment of this diameter is substantially perpendicular to the alignment of the ends 67 , 68 at the cylinder part mounting points 60 , 61 .
The constant radius curve 63 , 64 are placed in torsion by the displacement of the piston mounting point 62 relative to the mounting points 60 , 61 . The torsion along each of the sections 63 , 64 is also substantially constant. Due to the radial or substantially radial direction of the cylinder mounting sections 67 , 68 and the piston mounting point 62 , any torsion stresses at the cylinder mounting ends and at the piston mounting point are at a minimum and mounting of the spring 15 to both the cylinder parts and the piston part is improved.
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A linear abstract includes a cylinder part and a piston part. A spring connects the cylinder part and the piston part and operates in the direction of reciprocation of the piston part relative to the cylinder part. The piston part includes a radially compliant but axially stiff linkage and a piston. The cylinder part includes a cylinder and a cylinder liner therewithin. A bore runs through the cylinder liner and the piston reciprocates in the bore. Gas bearing passages are formed between the cylinder and the cylinder liner leading to openings through the wall of the cylinder liner to the bore. A gas bearing manifold receives compressed gases and supplies the compressed gases to the gas bearing passages. The gas bearing passages follow a tortuous path to the openings.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to waste gas dispersion and more particularly to such dispersion by mixing with atmospheric air without combustion.
2. Description of the Prior Art
It has heretofore been proposed to discharge waste gas into the atmosphere through open vertical pipes with or without a shroud surrounding the discharge end of the pipe and to introduce a fire suppressing material, such as carbon dioxide, into the waste gas prior to discharge from the pipe. This has not proven satisfactory because of the likelihood of reignition upon discontinuance of the supply of the suppressing material.
It has also been proposed to supply a fire suppressing material, such as carbon dioxide, at the discharge end of the pipe and while this may render the combustion smokeless and not visible it does not, in fact, snuff out the flame.
No successful effect has been made, to my knowledge, prior to my invention in Fluidic Seals for which an application for U.S. Letters Patent was filed on July 15, 1977, Ser. No. 815,992 and now U.S. Pat. No. 4,092,908, to prevent ignition by static electricity generated by the waste gas flow.
In my prior U.S. Pat. No. 4,038,024 for Flare Stack Gas Burner there is disclosed a stack with a plurality of outwardly extending hollow vanes at the top with fixed inclined nozzles for discharge of combustible gas in flat streams for admixture with air to provide a hollow frusto-conical vortex combustion path to provide smokeless combustion. No other purpose was proposed or then intended but the structure there disclosed is useful for waste gas dispersal without combustion. In the structure of the present invention combustion is not desired and provisions are made to avoid the generation of static electricity and to introduce fire suppressing material to extinguish any combustion which might occur due to lightning or other causes.
SUMMARY OF THE INVENTION
In accordance with the invention waste gas dispersion stacks are provided, suitable for use on-shore and off-shore, for disposal of combustible waste gas without combustion by rapid dispersion into the atmosphere to reduce the waste gas concentration to below combustible or explosive levels, with provisions for rapid discharge into contact with atmospheric air for admixture therewith, for preventing generation of static electricity by liquid particles in the waste gas, and for controlled introduction into the waste gas of a fire suppressing material in the event of ignition of the waste gas.
It is the principal object of the invention to provide a waste gas dispersion stack which is effective for rapid and effective mixture of the waste gas with atmospheric air to reduce the concentration of the waste gas to a non-combustible or non-explosive level.
It is a further object of the invention to provide a waste gas dispersion stack with greatly reduced tendency to formation of static electricity which could cause ignition.
It is a further object of the invention to provide a waste gas dispersion stack with improved introduction and admixture of a fire suppressing material.
It is a further object of the invention to provide a waste gas dispersion stack with controlled introduction of a fire suppressing material into the waste gas being delivered for dispersion.
It is a further object of the invention to provide a waste gas dispersion stack having simple but effective controls for a fire suppressing material which is introduced into the waste gas being delivered for dispersion.
It is a further object of the invention to provide a waste gas dispersion stack with introduction of fire suppressing material and which may be automatically or manually controlled as desired.
It is a further object of the invention to provide a waste gas dispersion stack which is free from enclosures or shrouds which restrict the discharge.
It is a further object of the invention to provide a waste gas dispersion stack which can employ various fire suppressing materials for extinguishing any fire which may occur.
It is a further object of the invention to provide a waste gas dispersion stack with introduction of fire suppressing material into the waste gas being delivered for discharge and with high and low pressure supplies of fire suppressing material.
It is a further object of the invention to provide a waste gas dispersion stack which may incorporate a plurality of individual waste gas stacks in a tower and in which the individual stacks form legs of the tower.
It is a further object of the invention to provide a waste gas dispersion stack suitable for on-shore and off-shore use.
Other objects and advantageous features of the invention will be apparent from the description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The nature and characteristic features of the invention will be more readily understood from the following description taken in connection with the accompanying drawings forming part hereof in which:
FIG. 1 is a vertical elevational view of one form of waste gas dispersion stack in accordance with the invention for on-shore use;
FIG. 2 is a vertical elevational view of another form of waste gas dispersion stack in accordance with the invention for on-shore or off-shore use, parts being shown in section to simplify the illustration;
FIG. 3 is a vertical elevational view of another form of waste gas dispersion stack in accordance with the invention for off-shore use;
FIG. 4 is a horizontal sectional view taken approximately on the line 4--4 of FIG. 2;
FIG. 5 is a horizontal sectional view taken approximately on the line 5--5 of FIG. 2;
FIG. 6 is an enlarged view in elevation, parts being broken away to show the details of construction of a preferred form of discharge head;
FIG. 7 is a top plan view of the discharge head shown in FIG. 6;
FIG. 8 is a fragmentary vertical sectional view taken approximately on the line 8--8 of FIG. 6; and
FIG. 9 is a diagrammatic view of control apparatus for the supply of fire suppressing material particularly related to the structure of FIGS. 2, 4 and 5.
It should, of course, be understood that the description and drawings herein are illustrative merely and that various modifications and changes can be made in the structure disclosed without departing from the spirit of the invention.
Like numerals refer to like parts throughout the several views.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more particularly to the drawings in FIG. 1 a waste gas dispersion stack is shown which includes a supply connection 15 to a supply of waste gas, a knock-out drum 16 of conventional type for removal of liquid and liquid droplets carried with the waste gas delivered to the supply connection 15.
From the top of the drum 16 a vertical stack pipe 17 extends upwardly and has, at the upper end thereof, a discharge head 18.
The drum 16 can be supported on a foundation 19 and the pipe 17 and discharge head 18 can be supported in a tower 20 of a height determined by the height of the pipe 17 and head 18, and with access platforms 21 and 22 at desired elevations.
A liquid drum pipe 23 can be provided for removal of liquid from the drum 16.
The stack shown in FIG. 1 is preferably for on-shore use but can be adapted to off-shore use as illustrated in FIG. 3. An off-shore platform is shown at 25 with a tower 20a inclined from the vertical and with an upright pipe 17a extending from a knock out drum 16a carried by the platform 25 and to which the waste gas for dispersion is supplied. The pipe 17a carries a discharge head 18 at its upper end.
Referring now more particularly to FIGS. 6, 7 and 8, a preferred form of waste gas discharge head 18 is there illustrated.
The head 18 preferably includes a lower tubular portion 27 for detachable connection to the pipe 17 at flanges 28 for maintenance and replacement when required.
The tubular portion 27 also preferably has carried therein a fluidic seal or diode 29 such as is shown in my application for U.S. patent filed July 15, 1977, Ser. No. 815,992 now U.S. Pat. No. 4,092,908 issued June 6, 1978 and which permits of free outward flow over curved surfaces 30 which do not tend to generate static electricity if liquid particles are present but presents an obstacle to return or backward flow in the tubular portion 27 and in the pipe 17 whether occasioned by wind conditions or contraction by cooling of hot gas upstream in the system.
If there is no likelihood of the gas containing liquid droplets a fluidic diode as shown in my prior U.S. Pat. No. 3,730,673 may be employed.
The waste gases to be dispersed may in on-shore installations, consist of combustible gas, including hydrogen, methane or other waste hydrocarbon containing gases from oil refining and other chemical plant operations, and in off-shore installations may be natural gas.
The tubular portion 27 is closed at its upper end by a cover plate 32 which is secured in place.
A plurality of vanes 33 are provided secured to and preferably extending radially outwardly from the tubular portion 27. Each of the vanes 33 has spaced parallel vertical side walls 34, an outwardly extending upwardly inclined bottom wall 35, an outer vertical end wall 36, and an inner short horizontal connecting wall 38. The interiors of the vanes 33 are in communication with the interior of the pipe 27 through vertical openings 39 in the pipe 27.
The upper horizontal margins of the walls 34 have converging plates 40 secured thereto to provide inclined nozzles 41 with elongated nozzle openings 42. The outer ends of the nozzle wall plates 40 are closed by upper extension 43 of the end walls 36 and the inner ends of the nozzle wall plates 40 are closed by inner end wall plates 44.
In order to prevent burning of the waste gas a fire suppressing material may be introduced into the waste gas passing to the vanes 33 for dispersion. Any suitable material may be employed such as carbon dioxide gas, dry fire suppression chemical with nitrogen propellant, or halon.
A source of a fire suppression agent is shown as cylinders 50, housed in a small building 51 at the base of the tower 20, and connected by a pipe 52 with a manually controlled valve 53, for delivery into the pipe 17.
Referring now to FIGS. 2, 4 and 5, a waste gas dispersion stack is there illustrated with a plurality of stack pipes for dispersing larger quantities of waste gas than with the stacks previously described.
A central vertical pipe 17b similar to the pipe 17 is provided, to which a pipe 55 from a knock-out drum 16b is connected. The knock-out drum 16b has a waste gas supply connection 15 extending thereto.
The pipe 55 and drum 16b are preferably disposed beneath a floor 56. The pipe 17b has a pipe 52 connected thereto as before, for the supply of fire suppressing material to the pipe 17b.
A plurality of upright pipes 17c, 17d and 17e are provided, similar to the pipe 17, but are spaced around the pipe 17b to provide a tower. The lower parts of the pipes 17c, 17d and 17e are in converging relation with vertical portions extending upwardly therefrom, braces 58 connected respectively to the pipe 17b providing rigidity. Platforms 59 with connecting ladders 60 may also be provided for access.
Each of the pipes 17c, 17d and 17e is connected, as before, to its knock-out drum 16c, 16d, 16e. The drums 16c, 16d and 16e have waste gas supply pipes 15 connected thereto and fire suppressant agent supply pipes 52c, 52d and 52e respectively connected thereto.
The pipe 17b has a discharge head 18 connected thereto with vanes 33 as previously described for the discharge of waste gas.
Each of the pipes 17c, 17d and 17e has a gas discharge head 18 mounted thereon and tilted outwardly as shown in FIG. 2 for better outward distribution of the gas around the streams from the inner vanes 33.
In order to sense the conditions at and upwardly beyond the vanes 33, a plurality of thermocouples TC are employed, enclosed within protective thermocouple mounting tubes 62 having viewing openings 63 and being carried on brackets 64 and 65.
Referring now to FIG. 9 a control system is there shown for the control of the delivery of fire suppressing medium in response to the conditions sensed by the thermocouples TC adjacent the vanes 33.
The large central dicharge head 18 on the pipe 176 has three thermocouples TC1, TC2 and TC3, (see FIG. 9) preferably equally spaced around the peripheries of the vanes 33. The thermocouples TC1, TC2 and TC3 are employed for the control of fire suppressing material at high pressure from high pressure sources 66, 67 and 68 through pipe 52 to the pipe 17b.
Additional pairs of thermocouples TC4 and TC5, TC6 and TC7, and TC8 and TC9 are provided on each discharge head preferably diametrically disposed as in FIG. 6 and 7 for each of the discharge heads 18 for the pipes 17c, 17d and 17e to control fire suppressing material at low pressure from the low pressure sources 70, 71 and 72.
The thermocouples TC4 and TC5 are connected to relays RL1 and RL1a, the thermocouples TC6 and TC7 are connected to relays RL2 and RL2a, the thermocouples TC8 and TC9 are connected to relays RL3 and RL3a and the thermocouples TC1, TC2 and TC3 are connected to relays RH1, RH2 and RH3, these relays being connected to a power source S1.
The relays RH1, RH2 and RH3 (see FIG. 9) respectively control contacts HC1, HC2 and HC3 which are normally open but are closed upon activation of their respective controlling thermocouples through indicator lamps A1, A2 and A3 and windings of relays CR1, CR2, CR3 and CR4, with bypass connections, for controlling corresponding contacts CCR1, CCR2, CCR3 and CCR4 so that upon energization of any two of the thermocouples TC1, TC2 and TC3 a signal will be supplied to valves HDCV1, HDCV2 or HDCV3 of the high pressure sources 66, 67 and 68 for the supply of fire suppressing material to the pipe 52. These valves have manual bypass controls 73, status indicators 74, and pressure indicators 75.
The relays RL1 and RL1a, RL2 and RL2a, RL3 and RL3a are connected to the power source S2 and respectively control contacts LC1 and LC1a, LC2 and LC2a, and LC3 and LC3a which are closed upon energization to illuminate signal lamps L1, L2 and L3, if both thermocouples of their controlling pair are energized, and energize valves LDCV1, LDCV2 and LDCV3 of the low pressure sources 70, 71 and 72 to supply fire suppressing material to the respective pipes 52c, 52d and/or 52e. These valves have manual bypass controls 73a, status indicators 74a, and pressure indicators 75a like the high pressure valves.
The mode of operation will now be pointed out.
In the form of the invention illustrated in FIGS. 1 and 3 waste gas to be dispersed is supplied through the pipe 15, and through the knock-out drum 16 and 16a where liquid is separated before the gas advances in the pipe 17 or 17a. If any small liquid particles are carried with the waste gas and not separated by the drum 16 or 16a the inclusion of the fluidic diode 29 with static prevention rings 30 eliminates any tendency to generate static electricity and also prevents air from entering the top of the stack.
As the waste gas advances upwardly in the tubular portion 27 of the discharge head 18 it passes outwardly through the openings 39 and into the vanes 33 and upwardly therein for discharge through the slots 42 at an angle to the vertical and in a vortex path.
The discharging gas exiting through the slots 42 entrains air along the outsides of the vanes 33 for mixture with the waste gas to dilute the waste gas and render it too lean for combustion or for explosion.
In the event that because of lightning or for some other cause the waste gas should be ignited at discharge and before it has been effectively dispersed then fire suppressing medium can be supplied to the pipe 17 manually controlled by the valve 53.
With the control system as shown in detail in FIG. 9 the thermocouples TC upon activation by heating attendant upon combustion of the discharging waste gas effect the delivery of fire suppressing medium at high pressure from the high pressure sources 66, 67 and 68 as desired or additionally from the low pressure sources 70, 71 and/or 72 as called for by the heat sensing thermocouples TC.
It will thus be seen that effective apparatus has been provided for discharge of waste gas in diluted non-combustible or non-explosive condition and with elimination of static electricity which might cause ignition and with provisions for rendering the waste gas non-flammable.
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Waste gas dispersion stacks are described, suitable for use on-shore and off-shore, for disposal of combustible gas without combustion by rapid dispersion into the atmosphere to reduce the waste gas concentration to below combustible or explosive levels, provisions being made to avoid ignition due to static electricity generation and to extinguish the flame by controlled utilization of an extinguishing medium if ignition should occur due to lightning or other causes. The stacks include single and multiple discharge pipes with diffuser or discharge heads for good mixing with air to provide a lean gas-air mixture.
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TECHNICAL FIELD
[0001] The present invention relates generally to semiconductor assemblies and more particularly to a semiconductor assembly comprising a press pack module.
BACKGROUND ART
[0002] Many different types of electrical converters make use of press pack modules for their easiness to bring them into series connection with the help of a mechanical stack, where more than one module is provided in series. Press pack modules are made to be mounted in between cooler or pressure plates and pressure is applied to that stack to ensure proper electrical and thermal contact between the individual press pack modules. For HVDC converters, up to 20 modules can be put in series connection into one stack and more than a hundred stacks can be needed for the complete converter. This means that a large number of heavy and sometime expensive mechanical parts are needed to create those stacks.
[0003] An example of a prior art press pack stack is disclosed in FIG. 1 . As seen in this figure, a standard stack comprises two or more rods, equally spread around the stack. Two yokes are provided, one at each end of the stack, to enclose the stack. Furthermore, a spring packet is provided on the top of the stack to provide a pressure thereon. In some press stack packs this spring packet is omitted and instead special yokes are provided which allow the use of their inherent mechanical elasticity as spring force.
[0004] Another example of a press pack stack is disclosed in the U.S. patent application publication US2010/0133676 A1.
SUMMARY
[0005] An object of the present invention is to provide a press pack stack with a simplified mechanical design.
[0006] According to the invention, there is provided a semiconductor assembly comprising a stack comprising a semiconductor module and a cooler, wherein the semiconductor module is provided in contact with the cooler, the stack having a first side and a second side; a clamping assembly being adapted to exert a force on the stack; the semiconductor assembly being characterised in that the stack is provided with a through hole between the first side and the second side and that part of the clamping assembly extends through the through hole of the stack, wherein the part of the clamping assembly extending through the through hole of the stack comprises an electrically conductive part configured to conduct electricity. Thereby, a compact mechanical arrangement is provided while obtaining improved electrical properties, such as lower inductance and more even current distribution.
[0007] In an embodiment, a single bus bar is provided. Thereby, the number of parts and thereby the weight are kept to a minimum.
[0008] In an embodiment, an insulation element is provided to electrically insulate the electrically conductive bus bar from the semiconductor module. In this way, an end portion of the stack can be contacted by means of the bus bar.
[0009] In an embodiment, the through hole is provided at the centre of the stack. This ensures even distribution of the forces exerted on the stack and reduces the mechanical parts for stacking, in turn reducing the complexity and the costs of the assembly.
[0010] In an embodiment, the semiconductor module is generally flat and has a first planar side and a second, opposite, planar side. This enables a compact design with reliable electrical and thermal connection to adjacent coolers. This is particularly advantageous when the first and second planar sides function as module power connections.
[0011] In an embodiment, the cooler is arranged such that substantially the entire area of a side of the semiconductor module ( 20 a ) is in contact with the cooler. Good electrical and thermal connections across the entire area of the semiconductor module sides are thereby ensured.
[0012] In an embodiment, the cooler is electrically conductive, so that it can be used for connecting to the semiconductor module.
[0013] In an embodiment, the semiconductor module and the cooler are circular. This provides a design with a small footprint and also improves the homogeneity of the electromagnetic coupling in the module.
[0014] In an embodiment, the clamping assembly comprises a first clamping element adapted to exert a force on the first side of the stack and a second clamping element adapted to exert a force on the second side of the stack. In this way, the semiconductor assembly can be provided as a separate part for subsequent connection to a piece of electrical equipment.
[0015] In an embodiment, the semiconductor assembly comprises a piece of electric equipment, preferably a capacitor, wherein the bus bar at a first end portion is electrically connected to the first side of the stack and at a second end portion is electrically and mechanically connected to a first pole of the piece of electric equipment. By integrating the clamping assembly into the piece of electrical equipment, a compact design is achieved and the lengths of the electrically conductive paths are kept to a minimum, improving the electrical properties of the assembly.
[0016] In an embodiment, the stack comprises a plurality of semiconductor modules and a plurality of coolers, wherein each of the semiconductor modules is provided between two of the coolers. In this way, a large number of semiconductor modules can be included in one stack.
[0017] In an embodiment, the stack comprises two semiconductor modules and three coolers, wherein a connection is preferably provided for electrical connection to a central, second cooler of the three coolers. The stack then lends itself to operating as a phase leg in an inverter, for example. In this case, the semiconductor modules comprise high voltage semiconductors, such as Isolated Gate Bipolar Transistors.
BRIEF DESCRIPTION OF DRAWINGS
[0018] The invention is now described, by way of example, with reference to the accompanying drawings, in which:
[0019] FIG. 1 shows a prior art press pack stack,
[0020] FIG. 2 shows a sectional view of a semiconductor assembly in the form of a simple press pack stack according to the invention,
[0021] FIG. 3 shows a cross-sectional top view of a semiconductor module comprised in the semiconductor assembly of FIG. 2 ,
[0022] FIG. 4 shows a side view of a second embodiment of a semiconductor assembly in the form of a press pack stack according to the invention,
[0023] FIG. 5 shows a side view, partially in section, of a third embodiment of a semiconductor assembly in the form of a press pack stack according to the invention,
[0024] FIG. 6 shows a sectional view of a fourth embodiment of a semiconductor assembly in the form of a press pack stack according to the invention mounted to a piece of electrical equipment in the form of a capacitor,
[0025] FIG. 7 shows an exploded perspective view of the capacitor of FIG. 6 , and
[0026] FIG. 8 shows the capacitor of FIG. 7 after assembly.
DESCRIPTION OF EMBODIMENTS
[0027] In the following, a detailed description of preferred embodiments of a semiconductor assembly according to the invention will be given.
[0028] FIG. 1 has been discussed in the background art section and will not be further dealt with herein.
[0029] FIG. 2 shows a sectional view of a semiconductor assembly according to the invention, generally designated 10 . This semiconductor assembly is a simple form of a press pack stack comprising just one semiconductor module 20 a and a cooler 30 a abutting each other, i.e., being in direct physical contact or engagement with each other. This semiconductor module 20 a is generally flat and has a first planar side 22 and a second, opposite, planar side 24 . Referring to FIG. 3 , showing a cross-sectional view of the circular semiconductor module 20 a, a central through hole 26 is provided in the semiconductor module between the first and second sides 22 , 24 . A plurality of semiconductors 28 , such as Isolated Gate Bipolar Transistors (IGBTs) are provided in the module and are electrically connected to the first and second planar sides of the semiconductor module 22 , 24 , and these sides therefore function as module power connections.
[0030] Again referring to FIG. 2 , a cooler 30 a with a first planar side 32 and a second planar side 34 opposite to the first planar and abutting or engaging the first side of the semiconductor module 20 a. The cooler 30 a is provided with a central through hole 36 between the opposite planar sides, which hole is aligned with the through hole 26 of the semiconductor module 20 a. The cooler has good electrical and thermal conductivity and it is thus preferred that the cooler is made of a material with good electrical conductivity, such as copper or aluminium, and that channels for coolant (not shown), such as water, are provided inside the cooler. The cooler 30 a is circular with a diameter equal to or exceeding the diameter of the semiconductor module 20 a, in order to ensure electrical and thermal conduction between the semiconductor module 20 a and the cooler across 30 a the entire first side 22 of the semiconductor module 20 a.
[0031] The semiconductor module 20 a and the cooler 30 a together form a stack, generally designated 38 .
[0032] A clamping assembly, generally designated 40 , is adapted to exert a force F on the stack 38 , in this case on the first side 32 of cooler 30 a in the direction towards the semiconductor module 20 a, whereby the cooler 30 a acts as a yoke. Thus, the clamping assembly 40 extends through the through hole 26 of the semiconductor module 20 a and the through hole 36 of the cooler 30 a. The part extending through the through holes 26 , 36 is an electrically conductive bus bar 42 , which has a first, threaded, end portion 42 a, on which a clamping element in the form of a nut 44 a is threaded, and a second end portion 42 b opposite to the first end portion 42 a. The electrically conductive bus bar may be an aluminium rod or alternatively a central steel rod provided with a jacket of aluminium. Although this embodiment comprises an electrically conductive part in the form of a bus bar, the electrically conductive part extending through the through hole may be embodied in many different forms, such as a bar or a strip, which conducts electricity within an inverter, a substation, a battery bank or any other electrical apparatus.
[0033] It is assumed that the semiconductor module 20 a rests with its second side 24 on a fixed plane, shown with dashed line in the figure. This fixed plane may be another cooler, an additional yoke, or the surface of a piece of electric equipment, as will be described below. Thus, when the nut 44 a is tightened, a downward directed force F will be exerted on the yoke or cooler 30 a. Since the yoke or cooler 30 a is rigid, this force will be transmitted onto the semiconductor module 20 a. Since the semiconductor module 20 a cannot give way due to the fixed plane on which the second side 24 thereof abuts, the semiconductor module 20 a and the cooler 30 a will be pressed into tight contact with each other, ensuring good electric and thermal conductivity there between.
[0034] A second embodiment of a semiconductor assembly will now be described with reference to FIG. 4 . In this embodiment, a plurality, namely four semiconductor modules 20 a , 20 b , 20 c , 20 d , are provided in a stack. Correspondingly, a plurality of coolers, namely five coolers 30 a , 30 b , 30 c , 30 d , 30 e, are provided in such a way that each of the semiconductor modules 20 a - d is provided between two of the coolers 30 a - e . This means that the semiconductor modules 20 a - d and the coolers 30 a - e are arranged alternately in a stack 38 having a first upper end as shown in the figure and a second, opposite lower end.
[0035] A clamping assembly 40 comprises a bar 42 with a first upper threaded end portion 42 a and a second lower threaded end portion 42 b. A first clamping element in the form of a first nut 44 a is threaded onto the first end portion 42 a of the bar and a second clamping element in the form of a second nut 44 b is threaded onto the second end portion 42 b of the bar.
[0036] A spring package 46 is arranged between the first nut 44 a and the first, uppermost cooler 30 a, as shown in the figure. The spring package is shown as a being built up from a plurality of cup springs but it will be realized that other forms of springs may be provided.
[0037] A first yoke insulation element 48 a is provided between the spring package 46 and the first cooler 30 a so as to provide electrical insulation there between. Correspondingly, a second yoke insulation element is provided between the second nut 44 b and the lowermost cooler 30 e so as to provide electrical insulation there between.
[0038] Connections (not shown in the figure) are provided for electrical connection to the semiconductor modules 20 a - d and optionally to one or more of the coolers 30 a - e.
[0039] The semiconductor assembly 10 is in this embodiment held together by means of the clamping assembly 40 , without relying on any fixed plane as in the embodiment shown in FIG. 2 . This means that this semiconductor assembly may be releasably mounted to a piece of electrical equipment, such as a capacitor or a transformer.
[0040] A third embodiment of a semiconductor assembly will now be described with reference to FIG. 5 . In this embodiment, a plurality, namely two semiconductor modules 20 a, 20 b, are provided in a stack 38 . Correspondingly, a plurality of coolers, namely three coolers 30 a, 30 b, 30 c, are provided in such a way, that each of the semiconductor modules 20 a, 20 b is provided between two of the coolers 30 a - c . This means that also in this embodiment the semiconductor modules 20 a , 20 b, and the coolers 30 a - c are arranged alternately in a stack 38 having a first upper end as shown in the figure and a second, opposite lower end.
[0041] A clamping assembly 40 comprises a bar 42 with an upper threaded end portion 42 a. The lower end portion 42 b of the bar 42 is attached to a piece of electrical equipment, such as a capacitor. A clamping element in the form of a nut 44 a is threaded onto the upper end portion 42 a of the bar.
[0042] A spring package 46 , similar to the one shown in FIG. 4 , is arranged between the first nut 44 a and the first, uppermost cooler 30 a, as shown in the figure. The spring package 46 exerts a force directly on the first, uppermost cooler 30 a, which in this embodiment functions as a yoke. The yoke insulating elements shown in FIG. 4 are in this embodiment omitted.
[0043] In this embodiment, where the stack of coolers and semiconductor modules is shown in section, an insulation element 50 is provided to electrically insulate the central bar 42 from the semiconductor modules 20 a, 20 b. The insulation element 50 also electrically insulates a negative DC connection or terminal “−DC” and a positive DC connection or terminal “+DC” from each other. However, the insulation element 50 does not extend all the way up to the spring package 46 which means that the first, uppermost cooler 30 a is in electrical connection with the bar 42 . This means that since the bar 42 , in this case acting as a bus bar and being in electrical connection with the negative DC connection, is in direct electrical connection with the first, uppermost cooler 30 a, also this first cooler will take the same electrical potential, i.e., “−DC”.
[0044] An electrically insulating means 62 is provided between the negative DC connection or terminal “−DC” and the positive DC connection or terminal “+DC” to electrically separate these from each other.
[0045] Connections in the form of the uppermost and lowermost coolers 30 a , 30 c are provided for electrical connection to the semiconductor modules 20 a , 20 b.
[0046] A phase connection is provided for electrical connection to the central, second cooler 30 b, which, being electrically insulated from the bus bar 42 , takes the electrical potential “−DC” or “DC”, in dependence of the operation of the semiconductor modules 20 a, 20 b. In this embodiment, the semiconductor assembly 10 is therefore suitable for providing the phase voltage of a converter, such as an HVDC converter.
[0047] A fourth embodiment of a semiconductor assembly will now be described with reference to FIGS. 6-8 . In this embodiment, a plurality, namely two semiconductor modules 20 a, 20 b are provided in a stack 38 . Correspondingly, a plurality of coolers, namely three coolers 30 a, 30 b, 30 c are provided in such a way, that each of the semiconductor modules 20 a, 20 b is provided between two of the coolers 30 a - c . This means that also in this embodiment the semiconductor modules 20 a, 20 b and the coolers 30 a - c are arranged alternately in a stack 38 having a first upper end as shown in the figure and a second, opposite lower end.
[0048] A clamping assembly 40 comprises a bar 42 with an upper threaded end portion 42 a. A clamping element in the form of a nut 44 a is threaded onto the upper end portion 42 a of the bar 42 , acting as a bus bar. The lower end portion 42 b of the bar 42 is attached to a piece of electrical equipment in the form of a capacitor 60 , preferably by means of a screw joint, wherein the capacitor is provided with a screw thread electrically connected to one of the electrical connections.
[0049] A spring package 46 in the form of a cup spring is arranged between the nut 44 a and the first, uppermost cooler 30 a, as shown in the figure. The spring package 46 exerts a force on the first, uppermost cooler 30 a through a dedicated yoke 49 , i.e., a yoke not functioning as a cooler, and a yoke insulation element 48 a.
[0050] The bus bar 42 is provided with a bus bar insulation 50 to electrically insulate the bus bar 42 from the semiconductor modules 20 a, 20 b.
[0051] The design of the capacitor 60 will now be discussed. The front side 60 a of the capacitor casing exhibits a plurality of terminals or poles, a first set labelled “−DC” and referring to a first pole of the capacitor, and a second set labelled “+DC” and referring to a second pole of the capacitor. The first set of terminals is usually at the same electrical potential as the casing of the capacitor 60 .
[0052] An insulating sheet in the form of a lamination 62 , see particularly FIGS. 7 and 8 , is provided on the front side 60 a of the capacitor 60 and has a size which almost covers this front side 60 a. First openings 62 a are provided in the lamination 62 for the second set of terminals “+DC” and a second, central opening 62 b is provided for the bus bar 42 . The lamination 62 is made of an electrically insulating material.
[0053] In front of, i.e., outside of the lamination 62 , there is provided a conductive sheet 64 of electrically conductive material, such as sheet metal. First openings 64 a are provided in the conductive sheet 64 for the second set of terminals “+DC” and a second, central opening 64 b is provided for the bus bar 42 . However, the diameter of the central opening 64 b of the conductive sheet is substantially larger than the diameter of the bus bar 42 to ensure electrical insulation there between. The conductive sheet 64 is provided with a circular area 64 c around the central opening 64 b which is adapted for tight contact with the innermost cooler 30 c.
[0054] During assembly, the lamination 62 is fitted onto the second set of terminals “+DC” and the conductive sheet 64 is then also fitted onto this second set of terminals. Electrical and mechanical connection between the second set of terminals “+DC” and the conductive sheet 64 is provided by means of soldering, brazing or bolting etc. The bus bar 42 is then screwed or otherwise attached to the capacitor 60 , providing the potential “−DC” to the bus bar 42 . The different parts shown in FIG. 4 are then threaded onto the bus bar 42 in the order innermost to outermost as shown in FIG. 4 , ending with the nut 44 a, which is screwed onto the threaded outer end portion 42 a of the bus bar 42 until a desired force is exerted on the stack of coolers and semiconductor modules or by applying a force, such as a hydraulic force, and turning the nut to lock the spring.
[0055] Connections are provided for electrical connection between a control unit 70 and the semiconductor modules 20 a, 20 b.
[0056] A phase connection is provided for electrical connection to the central, second cooler 30 b, which, being electrically insulated from the bus bar 42 , takes the electrical potential “−DC” or “+DC”, in dependence of the operation of the semiconductor modules 20 a, 20 b. In this embodiment, the semiconductor assembly 10 is therefore suitable for providing the phase voltage of a converter, such as an HVDC converter.
[0057] Preferred embodiments of a semiconductor assembly have been described. It will be appreciated that these made be modified within the scope defined by the appended claims without departing from the inventive idea.
[0058] A piece of electrical equipment, such as a capacitor, has been described with an insulating sheet in the form of a lamination. It will be appreciated that this idea is applicable not only to the inventive semiconductor assembly described herein, but also to other assemblies, such as an assembly comprising the prior art press pack stack shown in FIG. 1 .
[0059] Although specific polarities have been set out in the drawings, it will be realized that any voltages and currents can be applied to the semiconductor assembly without departing from the inventive idea.
[0060] In the described preferred embodiments, the semiconductor modules and the coolers are circular. It will be appreciated that the shape of these parts may vary from circular, such as square or hexagonal, without departing from the inventive idea.
[0061] The lamination has been described and shown as being fitted onto the second set of terminals. In other embodiments, the lamination may be fitted inside or outside of the housing of the piece of electrical equipment.
[0062] The central opening provided the conductive sheet for the bus bar has been described as being is substantially larger than the diameter of the bus bar itself in order to achieve electrical insulation. This insulation can also be achieved by other means, such as by sealing, for example with electrically insulating glue.
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A semiconductor assembly includes a stack with a semiconductor module and a cooler, wherein the semiconductor module is provided in contact with the cooler. A clamping assembly is adapted to exert a force on the two sides of the stack. The stack is provided with a through hole between the two sides thereof and a part of the clamping assembly including an electrically conductive part which extends through the through hole of the stack. Thereby, a compact mechanical arrangement is provided while obtaining improved electrical properties, such as lower inductance and more even current distribution.
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FIELD OF THE INVENTION
[0001] This invention relates to a method for retrieving data from first and second storage medium.
BACKGROUND
[0002] Data on read-only storage media may not be modified. One example of such read-only media are prerecorded discs, e.g. Blu-ray discs (BDP).
[0003] Storage media, particularly optical discs, have usually unique identification labels. It is common that disc players may have integrated harddisk drives (HDD). Within an optical disc player, a Playback Control Engine (PCE) processes the data read from the disc. The data scope of a PCE is the disc. The playback process is controlled by a so-called Movie Module, which via an application interface (API) is connected to the PCE.
[0004] The data on the disc usually structured in a directory tree that is often standardized. E.g. for BDP the directory tree of a particular movie contains one folder for the playlist, one folder with streaming data and one folder for the clipinfo, describing the stream data structure. AV data on a BDP disc are contained in streams, which are multiplexed into a so-called main multiplex.
[0005] In this application, the term “directory tree” is used for a complete directory structure as well as for a particular branch of a directory structure, even hierarchical branches, when referring to rewritable media.
SUMMARY OF THE INVENTION
[0006] For optical disc formats, it is desirable to be able to download content from the studios server to the local player. Basically, there are two applications for downloaded content:
[0007] First, content on the disc shall be replaceable through downloaded content. A typical example is the replacement of an older or out-dated trailer that is stored on the disc through a downloaded trailer, e.g. for a new movie.
[0008] Second, content on the disc shall be completable or upgradable. A typical example is the download of a new subtitle track, e.g. in another language, which is not available on the disc.
[0009] There are two solutions to store downloaded content locally: This can either be realized through equipping the player with a separate local rewritable storage medium, e.g. a HDD, or through some rewritable memory on the disc itself. The first case is preferred, since media for the latter case are more expensive, and players are often equipped with a rewritable local storage medium.
[0010] When separate local storage is applied, i.e. integrated HDD, a mechanism is needed that combines or associates content on local storage with content on a disc. E.g. in case of a downloaded subtitle track, the player needs information to which disc the track belongs, and more specifically, to what content on that disc the track is associated.
[0011] The present invention provides a mechanism to associate off-disc content, e.g. downloaded from the internet and stored on a HDD, with content on the disc, on-disc content.
[0012] The basic idea of the invention is to create a directory tree for each disc on the local storage device (off-disc directory tree). As soon as a disc is inserted into the player, the on-disc directory tree and the associated off-disc directory tree are logically merged. The association is provided through unique disc identifiers or unique content identifiers. Playback of content on the inserted disc involves the merged directory tree. In this way, content on local storage is seamlessly integrated.
[0013] Appropriate merge rules provide the possibility to update on-disc content with off-disc content. Technically, this is achieved through logically replacing an on-disc file with an off-disc file. The invention also allows supplementing on-disc content with off-disc content. This is achieved through logically adding an off-disc file to an on-disc directory. Two modes are possible for determining which on-disc file should be replaced by an off-disc file: either replacement is only done if the file names match exactly, or replacement is done if a particular mapping method is defined for mapping off-disc file names to on-disc file names, e.g. an off-disc file named “b.clpi” may replace an on-disc file named “a.clpi” if in the corresponding directories there is only one file available with the file name extension “clpi”.
[0014] According to the invention, data are retrieved from a first and a second storage medium and combined, or merged, such that a logical directory tree is generated that contains the data of both media. The logical directory tree contains files that are available only in the first or the second directory tree, and for files that are available in both directory trees the version available from the second directory tree.
[0015] Particularly, the disclosed method for retrieving data from first and second storage medium, wherein the data on the first storage medium are stored as files structured in a first directory tree, and the data stored on the second storage medium are stored as files structured in a second directory tree, comprises that the first storage medium has an identification label attached, and a branch of the second directory tree stored on the second storage medium refers to the identification label, further that the branch of the second directory tree is a subset of the first directory tree, or identical with the first directory tree, further that a logical directory tree is constructed from the retrieved data, wherein the structure of the logical directory tree is identical with the structure of the first directory tree, further that files that are available only in the first or the second directory tree are also available in the logical directory tree, and finally that for files that are available in the first and the second directory tree, the version available from the second directory tree is available in the logical directory tree.
[0016] An apparatus that utilizes the method is disclosed in claim 8 .
[0017] Advantageous embodiments of the invention are disclosed in the dependent claims, the following description and the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Exemplary embodiments of the invention are described with reference to the accompanying drawings, which show in
[0019] FIG. 1 the structure of an exemplary directory tree for BDP;
[0020] FIG. 2 the structure of an exemplary local storage directory;
[0021] FIG. 3 an exemplary merge operation;
[0022] FIG. 4 and example for binding information carried in file names;
[0023] FIG. 5 an example for binding information carried in folder names.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Data on optical discs are usually organized in files, which in turn are organized in a standardized directory tree, the on-disc directory tree. The file system provides an abstraction from the underlying storage medium. An exemplary standardized on-disc directory tree is shown in FIG. 1 . It contains for a certain movie object MO a playlist folder PF, a clipinfo folder CF and a data stream folder SF. Each of these folders contains files with file extensions that identify the file type, e.g. “mpls” for playlist files.
[0025] The basic idea of the invention is to create a directory tree for a disc on a rewritable local storage device, so that an off-disc directory tree is created. As soon as a disc is inserted into the player, the on-disc directory tree is merged with the associated off-disc directory tree. In case there is no off-disc directory tree on the local storage device, e.g. when the disc is inserted into the player for the first time, an empty off-disc directory tree is created, according to the employed standard.
[0026] Any disc provides a unique identifier. This can either be a unique disc ID or a unique content ID. There may be several directory trees provided on the local storage device for various discs, e.g. one branch for each disc that was ever inserted into the player. The local storage device holds additional information, which associates one of the directory trees, or rather one branch of the directory tree of the local storage device, with a disc. Preferably, the off-disc directory tree's top-level name is derived from the disc ID. In the simplest case, the name directly corresponds to the ID.
[0027] In general, the structure of the off-disc-tree is arbitrary. Additional rules specify, how each off-disc-folder is merged into the on-disc-tree. Preferably for simplicity and practical reasons, the off-disc directory tree is similarly structured as the on-disc directory tree.
[0028] An option to further speed-up the search for off-disc content is possible through the usage of unique provider identifiers. In addition to the unique disc/content identifier, this unique identifier is also provided with the disc. For each provider, or each provider from which the player ever read a disc, there is a directory created on the local storage device. The corresponding folder name is derived from the provider ID. In the simplest case, the name directly corresponds to the ID. Any off-disc-tree is then created as a subdirectory in the associated provider directory. This grouping has the advantage of speeding up the search process to find off-disc content, as only the provider's directory has to be searched for off-disc content. An exemplary directory structure is shown in FIG. 2 . The data referring to a disc from a certain provider are stored in a disc folder DF which in turn is stored in a provider folder PRF.
[0029] In a scenario where applications need a direct and explicit application programming interface (API) to local storage, this structure has additional advantages. Particularly, the proposed hierarchical structure can easily serve as a basis for access rights management. Simple rules can be established that restrict an applications access to local storage.
[0030] For example, a possible rule could allow an application on a disc labelled XY, published by a provider named Z, to read and write to the associated off-disc directory named XY, and read, but not write, from any other directories within publisher Z's directory tree, while access to any other directories on local storage is forbidden.
[0031] For any downloaded type of content, the storage location on local storage is specified and the player knows where additional downloaded content can be found on the local storage device. When downloading streams, the stream itself and also corresponding information about the stream file is stored.
[0032] Merging the off-disc directory tree with the on-disc directory tree allows the unified handling of off-disc content and on-disc content within the player at playback.
[0033] An exemplary merge operation is shown in FIG. 3 . Data from a directory tree HDD_DT from a HDD and data from a directory tree D_DT from a read-only disc are merged to a logical directory tree L_DT that is used by the PCE of the player. The logical directory tree L_DT is constructed temporarily at run-time.
[0034] The inventive method has the particular advantage that the interface between the Movie Module and the PCE may remain unchanged as compared to today's standard. The merge operation rules are as follows:
[0035] When merging two directories, files in the off-disc directory are added to the files in the on-disc directory. This allows adding content at playback time.
[0036] When merging two directories, and the same file exists in the off-disc directory as well as in the on-disc directory, the file in the off-disc directory takes precedence. This allows replacing content from the disc by other data at playback time, e.g. new subtitles or an enhanced audio stream.
[0037] The application of downloading additional A/V components, e.g. audio or subtitle tracks, requires additional information. Binding information is needed to associate the downloaded track not only with the disc, but also with the corresponding main multiplex on the disc.
[0038] It is assumed that the downloaded off-disc stream and the associated on-disc main multiplex have the same length on the timeline. In other cases additional information needs to be provided that describe where on the timeline the downloaded track is associated with the main multiplex.
[0039] To associate the off-disc component with the main on-disc multiplex, two methods are described in the following:
[0000] Method 1
[0040] The off-disc components file name obey the following rules:
The first part identifies the main multiplex and associates the component with it. It is thus the same for all associated components. The second part, preferably separated from the first part through an underscore, must be unique among all additional components of the main multiplex. Information files are also stored in a separate folder, whose names are derived from the off-disc component.
[0044] An example is shown in FIG. 4 . The first part 0300 of the clipinfo file and the stream file associates the files with the main multiplex, while the second part 001 is unique among the two shown additional components.
[0000] Method 2
[0045] In this method, binding information is provided through the use of appropriate sub-directories
Off-disc components associated with an on-disc multiplex are stored in a separate folder, whose name is derived from the main multiplex on the disc. All off-disc information files are also stored in a separate folder, whose name is derived from the main multiplex on the disc. File names must be unique among all additional components of the main multiplex.
[0049] An example is shown in FIG. 5 . A clipinfo file 001.clpi and a stream data file 001.m2ts are stored in subdirectories 03000 , being subdirectories of the clipinfo folder and the stream folder respectively. The file names 001 are derived from the main multiplex on the disc.
[0050] The inventive method may use any type of rewritable media to add data to any type of read-only media. Examples for rewritable media are magnetic storage devices, such as HDDs, floppies, RAM modules or the like. Examples for read-only media are DVD−R/+R or prerecorded Blu-ray discs (BDP).
[0051] In principle, the disclosed method is also suitable for updating or complementing data stored on a read-only medium by data from another read-only medium.
[0052] As a preferred embodiment, data stored on a BDP may be updated or complemented by data stored on a HDD.
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A method for modifying data read from read-only media during playback time comprises logically merging the on-disc directory tree and an associated off-disc directory tree. A logical directory tree is constructed from the data retrieved from the read-only medium, wherein the structure of the logical directory tree is identical with the structure of the directory tree of the medium. The method allows replacing content on the disc through downloaded content, e.g. replacing an out-dated trailer stored on the disc through a downloaded trailer for a new movie. The method further allows complementing or upgrading content on the disc, e.g. by downloading a new subtitle track from the internet.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of earlier filed U.S. Provisional Patent Application No. 60/760,638, filed Jan. 21, 2006, and having the same title and inventor as above.
FIELD OF THE INVENTION
[0002] The present invention relates to a board or other structure having skate wheels or the like that is self propelled in a forward trajectory by side-to-side movement.
BACKGROUND OF THE INVENTION
[0003] The prior art contains many different types of wheeled recreational devices, including skate boards and a collection of three-wheeled scooters or “cambering vehicles,” the latter being propelled by side-to-side movement.
[0004] Skate boards tend to have a longitudinal axis and travel in a line-of-direction substantially aligned with that longitudinal axis. Forward travel is typically achieved by a push and coast movement, with a user pushing off the ground, placing the push foot on the board, and coasting until slow, then repeating. These types of devices require a user to continually remove their foot from the board and push off of a resistant substrate to attain forward propulsion. These devices tend to be well suited for sidewalk and street travel, but may be less suited for smaller or more restricted spaces.
[0005] The cambering vehicles or the like tend to have three wheels, with a turnable front wheel and a handle bar for steering (similar to a conventional tri-cycle). While these vehicles may be propelled by side to side movement, they include a steering infrastructure, relatively extensive vertical supports and controls, and a limited wheel-base.
[0006] The self-propelled wheeled device of the present invention is compact, relatively lightweight, and physically small in profile. In contrast to a conventional skate board, the present invention achieves forward propulsion in a manner that does not require a user to continually step on and off a board. With the present invention, a user leaves both feet positioned on the board or “platform” and achieves forward propulsion by shifting his or her weight from side to side. The present invention thus provides an alternative transportation method and different recreational outlets.
[0007] Among other features and benefits, the present invention increases recreational opportunities available to youth (and to adults). For example, as we live at higher population densities, there is less space available to children and adults for recreational and/or physical exercise opportunities. Our less active lifestyles are further influenced by automobile travel (not self-propelled) and time in front of a television or computer. This lack of physical movement is deleterious to overall health. The present invention, due to its compact size, low weight and small profile, is well suited for use in or on the hard surfaces and restricted spaces of the urban and suburban landscape, thus providing needed recreational and exercise opportunities to youth (and others) living there.
[0008] The attainment of the foregoing and related advantages and features of the invention should be more readily apparent to those skilled in the art, after review of the following more detailed description of the invention taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIGS. 1-4 are an upside down perspective view, a side elevation view, a detailed cut-away view, and a bottom plan view, respectively, of one embodiment of a side movement propelled wheeled device 10 in accordance with the present invention.
[0010] FIGS. 5-8 are an upside down perspective view, a side elevation view, a detailed cut-away view, and a bottom plan view, respectively, of another embodiment of a side movement propelled wheeled device 10 in accordance with the present invention.
[0011] FIGS. 9-11 are an upside down perspective view, a side elevation view, a detailed cut-away view, and a bottom plan view, respectively, of another embodiment of a side movement propelled wheeled device 10 in accordance with the present invention.
[0012] FIG. 12 is a bottom perspective view of an alternative four wheel side movement propelled device in accordance with the present invention.
[0013] FIG. 13 is a bottom perspective view of a six wheel side movement propelled device in accordance with the present invention.
[0014] FIG. 14 is a bottom perspective view of a eight wheel side movement propelled device in accordance with the present invention.
DETAILED DESCRIPTION
[0015] Referring to FIGS. 1-4 , an upside down perspective view, a side elevation view, a detailed cut-away view, and a bottom plan view, respectively, of a side movement propelled wheeled device 10 in accordance with the present invention is shown.
[0016] Device 10 may include a platform or board 12 that acts as a support structure, receiving a human in a standing position (feet shown in phantom in FIG. 4 ) and supporting the wheels 21 - 24 in a fixed relative position. The wheels (and bearings) may be a conventional skate wheel. Many are known in the art and are available commercially. Wheels 21 - 24 are preferably coupled via casters 31 - 34 , respectively, to platform 12 .
[0017] Referring to FIG. 2 , it can be seen that in device 10 each caster is preferably tilted backwards. The pivot point of caster rotation is located on the backward tilted caster mounting plate 36 - 39 and the pivot or axle 26 - 29 of each wheel 21 - 24 (in a default position) is located rearward of the pivot point of caster rotation. Each caster may be tilted at an angle, α. This angle may be 1-45 degrees and is preferably between 5-35 degrees. In one embodiment, α for the front wheels is approximately 18 degrees while α for the back wheels is approximately 15 degrees. The difference in α is due to the offset of the rear wheels (see discussion below with reference to FIG. 4 ). Since the rear wheels are offset, the height of the platform over the rear wheels would be slightly less than the front wheels if α were the same. Decreasing α a small amount for the rear wheels overcomes the height difference otherwise resulting from the offset.
[0018] The tilt of the caster mounting plate causes each respective wheel to be biased, under weight, towards alignment with a line traversing the lowest and highest points of its respective caster mounting plate. FIG. 2 illustrates that the wheels are generally biased in line with a general line of forward travel of the device, indicated by arrow A. Closer inspection of the rear wheels 23 - 24 shows that they are preferably slightly offset (by an angle, β, discussed below).
[0019] FIG. 4 illustrates that the two front wheels 21 - 22 are substantially aligned in parallel with the “straight ahead” direction of travel of device 10 . The rear wheels are preferably offset from this line by an angle, β. This angle may range from a degree to nearly 90 degrees. In a preferred embodiment the range may be from a few degrees to several dozen or more. In the embodiment of FIG. 4 , the offset is between 5 and 25 degrees, more preferably between 10 and 15 and even more preferably about 12 degrees.
[0020] The front wheels are offset at 0 degrees, yet may be otherwise offset. While the rear wheels preferably have an angle great than 0 degrees, the angle of the rear wheels may be 0 without departing from the present invention.
[0021] In use, device 10 is turned over from the position shown in FIG. 4 and a user stands with a foot located on each side (as roughly indicated by the phantom lines). To achieve initial forward movement, a user may push off the ground with one foot before placing it on the platform, though an initial push off is not necessary.
[0022] From the legs apart or “slightly-straddled” position, a user shifts his or her weight from side to side, effectively pushing off one foot and then the other, in a motion similar to ice skating. This force propels the device forward. Continued operator movement in this side to side, ice-skating manner produces a repeated forward movement thrust that in aggregate propels the device and user ahead at a smooth velocity.
[0023] Turning may be achieved by holding the push-off position on one side (for an increased length of time) or more rapidly by placing a foot outside the front and back wheels on one side and leaning to that side, lifting the opposite wheels off the ground and rotating the platform about the two wheels still contacting the ground, in much the same manner as one rapidly turns a conventional skate board.
[0024] FIGS. 5-8 are an upside down perspective view, a side elevation view, a detailed cut-away view, and a bottom plan view, respectively, of another embodiment of a side movement propelled wheeled device 110 in accordance with the present invention.
[0025] Device 110 of FIGS. 5-8 is similar to device 10 of FIGS. 1-4 . A difference is that the casters 131 - 134 are not biased by tilting, but rather biased by springs 141 - 144 . Springs 141 - 144 may be any suitable coil spring or any other type of spring or other bias device. In essence, they represent mechanical biasing of the wheels by spring or elastic material or other suitable mechanism.
[0026] FIGS. 9-11 are a top perspective view, a side elevation view, and a bottom plan view, respectively, of another embodiment of a side movement propelled wheeled device 310 in accordance with the present invention.
[0027] In device 310 , the platform 312 is comprised of two foot plates 313 - 314 , an adjustable-distance connecting rod 315 and two hubs 316 - 317 . FIG. 11 illustrates that wheels 321 - 324 and casters 331 - 334 are arranged in a manner similar to that disclosed with reference to device 10 of in FIGS. 1-4 .
[0028] Referring to FIG. 12 , a bottom perspective view of an alternative four wheel side movement propelled device 410 in accordance with the present invention is shown. In device 410 , the front wheels are slightly offset in a direction generally opposite that of the rear wheels, i.e., if the rear wheels are angled out, the front wheels are angled in.
[0029] Referring to FIG. 13 , a bottom perspective view of a six wheel side movement propelled device 510 in accordance with the present invention is shown. In device 510 , the front and rear wheels are slightly offset in generally opposite directions (as discussed with reference to FIG. 12 ) and the center wheels are not substantially offset.
[0030] Referring to FIG. 14 , a bottom perspective view of an eight wheel side movement propelled device 610 in accordance with the present invention is shown. In device 610 , the outer front and rear wheels are offset more than the inner front and rear wheels.
[0031] While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification, and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the 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 essential features hereinbefore set forth, and as fall within the scope of the invention and the limits of the appended claims.
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A recreational board propelled by side-to-side movement of a user. The board may be wider than deep, to accommodate a human standing at a slight straddle, and have a plurality of caster wheels mounted to an underside thereof. The wheels are preferably mounted in a biased direction wheel arrangement, the bias being provided by tilting, spring or other mechanism. The orientation of the front wheels may be different from that of the rear wheels. Four, six and eight wheel embodiments are disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an ultrasonic diagnostic apparatus which forms a tomographic image or the like of a test body, and more particularly to a configuration for controlling the waveform of a generated ultrasonic wave.
[0003] 2. Description of the Related Art
[0004] In an ultrasonic diagnostic apparatus, a probe having a single transducer or a plurality of transducers transmits and receives an ultrasonic wave to and from a test body such as the inside of the human body, and a reception signal obtained from the probe is processed so that a tomographic image, blood flow information, or the like of the test body is displayed on a monitor (displaying device) to be observed (for example, see JP-A-2002-034975, JP-A-2002-052025 and JP-A-2002-065671).
[0005] FIGS. 6A and 6B show a transmission signal which is supplied to a single transducer in one ultrasonic scan line, and a reception signal which is received from one reflector. When the transmission signal Sa of FIG. 6A is applied to the transducer, a generated ultrasonic wave is transmitted toward the reflector (test body). An ultrasonic wave which returns from the reflector is received by the same transducer, and the reception signal Ra of FIG. 6B is obtained. In FIG. 6B , the waveform g 1 shows leakage of the transmission signal.
[0006] FIGS. 7A and 7B shows enlarged waveforms of the transmission signal and the reception signal. As shown in FIG. 7A , the transmission signal Sa has a trigger waveform of an amplitude a 0 (about several tens to several hundreds of V) and a pulse width t 0 . As shown in FIG. 7B , the reception signal Ra has a waveform in which the amplitude (maximum amplitude A 0 ) is varied, and which continues for the ultrasonic wave (generation) period H 0 of, for example, 5 to 6 cycles. In the reception signal Ra, as the ultrasonic wave period H 0 is shorter, the distance resolution is higher, and, as the amplitude (wave height) is larger, the sensitivity is higher.
[0007] In an ultrasonic diagnostic apparatus, it is requested to further improve the quality of an ultrasonic image. When the above-mentioned distance resolution and search sensitivity in ultrasonic transmitted and received waves are enhanced more than those in the related art, it is possible to obtain an image which has a high image quality, and which can be easily observed.
SUMMARY OF THE INVENTION
[0008] The invention has been conducted in view of the above-discussed problems. It is an object of the invention to provide an ultrasonic diagnostic apparatus in which the distance resolution and the search sensitivity can be enhanced, and which can obtain an image that has a high image quality, and that is easily observed.
[0009] (1) In order to attain the object, there is provided an ultrasonic diagnostic apparatus comprising a probe, the probe including at least one transducer that generates an ultrasonic wave, so as to form an ultrasonic tomographic image, wherein a plurality of transmission signals are generated to at least one of said at least one transducer in a common scan line period, said plurality of transmission signals including a first transmission signal and at least one second transmission signal subsequent to the first transmission signal, wherein said at least one second transmission signal is generated when a first ultrasonic wave resulting from the first transmission signal is generated, so as to form at least one second ultrasonic wave, and wherein the first ultrasonic wave and said at least one second ultrasonic wave are combined with each other, so as to form a synthesized ultrasonic wave having a controlled waveform.
[0010] (2) There is provided the ultrasonic diagnostic apparatus as set forth in (1), wherein an initial one of said at least one second ultrasonic wave is generated with forming a shift of approximately nT/4 where n is an odd number and T is a cycle of a waveform of the first ultrasonic wave, to control a generation period of the synthesized ultrasonic wave to be shortened as compared with that of the first ultrasonic wave.
[0011] (3) There is provided the ultrasonic diagnostic apparatus as set forth in (1), wherein adjacent ones of a plurality of ultrasonic waves are generated with forming a shift of approximately one cycle, said plurality of ultrasonic waves resulted from said plurality of transmission signals, so as to control an amplitude of the synthesized ultrasonic wave to be increased as compared with that of the first ultrasonic wave.
[0012] According to the configuration of the invention, an ultrasonic wave which is to be transmitted and received in one ultrasonic scan line (one direction) is formed by plural transmission (pulse) signals. When the timings of outputting the transmission signals are adjusted, or the delay amount for the second and subsequent ultrasonic waves with respect to the first ultrasonic wave is controlled, the resulting synthesized ultrasonic waveform can be arbitrarily changed. In the case of (2) above, two ultrasonic waves in which the amplitude (wave height) is made smaller than that in the related art are generated with shifting from each other by, for example, ¼ (or ¾, 5/4, or the like) cycle, and then combined with each other. As a result, the ultrasonic wave generation period is shortened, and hence the distance resolution can be enhanced. In the case of (3) above, for example, two ultrasonic waves which are shifted from each other by one cycle are combined with each other, so that the amplitude is increased. Therefore, the search sensitivity can be enhanced.
[0013] (4) There is provided the ultrasonic diagnostic apparatus as set forth in (1), wherein an amplitude of each of said plurality of transmission signals is variably adjusted.
[0014] (5) There is provided the ultrasonic diagnostic apparatus as set forth in (4), wherein a pulse width of each of said plurality of transmission signals is variably adjusted.
[0015] (6) There is provided the ultrasonic diagnostic apparatus as set forth in (1), wherein a pulse width of each of said plurality of transmission signals is variably adjusted.
[0016] According to the configuration of (4) above, an ultrasonic wave which is to be transmitted and received in one ultrasonic scan line (one direction) is formed by plural transmission (pulse) signals. When the timings of outputting the transmission signals are adjusted, or the delay amount for the second and subsequent ultrasonic waves with respect to the first ultrasonic wave is controlled, and the amplitudes of the transmission signals are adjusted respectively to different values, the resulting synthesized ultrasonic waveform can be arbitrarily changed. When the amplitudes (wave heights) of the ultrasonic waves are adjusted so as to be increased, it is possible to enhance the search sensitivity.
[0017] In the case of (6) above, when the delay amount for the second and subsequent ultrasonic waves with respect to the first ultrasonic wave is controlled, and the pulse widths of the transmission signals are adjusted respectively to different values, the resulting synthesized ultrasonic waveform can be arbitrarily changed. When both the amplitudes and pulse widths of the transmission signals are adjusted as in the case of (5) above, the ultrasonic waveform can be changed to a desired one.
[0018] (7) There is provided an ultrasonic diagnostic apparatus comprising: a probe that includes a transducer generating an ultrasonic wave; a transmitting section that outputs a plurality of transmission signals to the transducer; a receiving section that receives a reception signal from the transducer; a detection section that detects the reception signal, the detection section being connected to the receiving section; an A/D converter that analog/digital-converts an output of the detection circuit; a digital scan converter that applies scan conversion to an output of the A/D converter; a monitor that displays an ultrasonic image based on an output of the digital scan converter; and a control section connected to the transmitting section, wherein the transmitting section comprises: at least one transmitting circuit; and a delaying circuit connected to at least one of said at least one transmitting circuit and to the control section, wherein the control section sends a plurality of transmission triggers to said at least one transmitting circuit, at least one of said plurality of transmission triggers being routed through the delaying circuit, wherein each of said at least one transmitting circuit receives each of said plurality of transmission triggers in the different timing, so as to output each of said plurality of transmission signals in the different timing.
[0019] (8) There is provided the ultrasonic diagnostic apparatus as set forth in (7), wherein the control section sends, to one of said at least one transmitting circuit, one of said plurality of transmission triggers which is not being routed through the delaying circuit, and sends, to the delaying circuit, the other one of said plurality of transmission triggers.
[0020] (9) There is provided the ultrasonic diagnostic apparatus as set forth in (7), further comprising an amplitude control section that variably adjusts an amplitude of each of said plurality of transmission signals.
[0021] (10) There is provided the ultrasonic diagnostic apparatus as set forth in (7), further comprising a pulse width control section that variably adjusts a pulse width of each of said plurality of transmission signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a block diagram showing the whole configuration of an ultrasonic diagnostic apparatus of an embodiment of the invention;
[0023] FIGS. 2A and 2B are block diagrams showing two examples of the configurations of a transmitting section in the first embodiment;
[0024] FIG. 3A is a waveform chart showing a transmission signal in one ultrasonic scan line in the embodiment;
[0025] FIG. 3B is a waveform chart showing a reception signal in one ultrasonic scan line in the embodiment;
[0026] FIGS. 4A to 4 F are enlarged waveform charts illustrating combining of ultrasonic waveforms for enhancing the distance resolution in the first embodiment;
[0027] FIGS. 5A to 5 D are enlarged waveform charts illustrating combining of ultrasonic waveforms for enhancing the search sensitivity in the first embodiment;
[0028] FIG. 6A is a waveform chart showing a transmission signal in one ultrasonic scan line in the related art;
[0029] FIG. 6B is a waveform chart showing a reception signal in one ultrasonic scan line in the related art;
[0030] FIG. 7A is an enlarged waveform chart showing the transmission signal in FIG. 6A ;
[0031] FIG. 7B is an enlarged waveform chart showing the reception signal in FIG. 6B ;
[0032] FIG. 8 is a block diagram showing an example of the configuration of a transmitting section in the second embodiment;
[0033] FIG. 9 is a block diagram showing another example of the configuration of the transmitting section in the second embodiment;
[0034] FIGS. 10A and 10B are waveform charts showing examples in the case where the amplitudes of first and second transmission signals in the second embodiment are set to different values;
[0035] FIGS. 10C and 10D are waveform charts showing examples in the case where the pulse widths of first and second transmission signals in the second embodiment are set to different values;
[0036] FIGS. 11A to 11 F are enlarged waveform charts illustrating combining of ultrasonic waveforms for enhancing the distance resolution in the second embodiment;
[0037] FIGS. 12A and 12B are enlarged waveform charts illustrating another example of combining of ultrasonic waveforms for enhancing the distance resolution in the second embodiment.
[0038] FIGS. 13A to 13 C are waveform charts illustrating combining of ultrasonic waveforms for enhancing the search sensitivity in the second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0039] FIG. 1 shows the whole configuration of an ultrasonic diagnostic apparatus of a first embodiment, and FIGS. 2A and 2B show the configurations of a transmitting section in FIG. 1 . In the ultrasonic diagnostic apparatus shown in FIG. 1 , the transmitting section 12 which performs a transmission process, and a receiving section 13 which performs a reception process are connected to one or more transducers 11 disposed in a probe. A detection circuit 14 which detects a reception signal, an A/D converter 15 which analog/digital-converts an output of the detection circuit 14 , and a digital scan converter (DSC) 16 which applies conversion (scan conversion) from data in a sound ray space to those in a physical space on an output of the A/D converter 15 are connected to the receiving section 13 . In the apparatus, a controlling circuit 17 which controls these circuits, and a monitor 18 which displays an ultrasonic image based on an output of the DSC 16 are further disposed.
[0040] FIGS. 2A and 2B show two configurations of the transmitting section 12 . FIG. 2A shows a configuration in the case where one transmitting circuit outputs a plurality of transmission signals, and FIG. 2B shows a configuration in the case where two transmitting circuits output a plurality of transmission signals. In the transmitting section 12 of FIG. 2A , one transmitting circuit 12 a and a delaying circuit 12 b are disposed. In accordance with a delay amount control signal supplied from the controlling circuit 17 , the delaying circuit 12 b sets the delay amount (time) of second and subsequent transmission (pulse) signals with respect to a first transmission (pulse) signal. Specifically, the delaying circuit 12 b supplies a trigger signal which lags an incoming transmission trigger by a predetermined amount (d), to the transmitting circuit 12 a . The transmitting circuit 12 a first receives the transmission trigger, directly from the controlling circuit 17 , and outputs the first transmission signal. On the basis of the trigger signal supplied from the delaying circuit 12 b , the transmitting circuit then outputs the second transmission signal which is delayed by the predetermined amount (d).
[0041] In the transmitting section 12 of FIG. 2B , a first transmitting circuit 12 c , a second transmitting circuit 12 d , and a delaying circuit 12 e are disposed. In this case, the first transmitting circuit 12 c which receives the transmission trigger from the controlling circuit 17 outputs the first transmission signal. The delaying circuit 12 e forms a trigger signal which lags from the transmission trigger by the predetermined amount (d), and the second transmitting circuit 12 d which receives the trigger signal outputs the second transmission signal which is delayed by the predetermined amount (d). In the case where three or more transmission signals are to be sequentially output, the above-described transmitting circuits ( 12 d ) and delaying circuits ( 12 e ) may be further added, or plural transmission signals may be formed and output by two sets of a transmitting circuit and a delaying circuit.
[0042] In the above, the configuration of the first embodiment has been schematically described. Next, the function in the case where an ultrasonic wave is formed by two transmission signals will be described. FIGS. 3A and 3B show a transmission signal which is supplied to the single transducer, and a reception signal which is received from one reflector. In the embodiment, as shown in FIG. 3A , a first transmission signal S 1 and a second transmission signal S 2 are successively output in the same ultrasonic scan line, and the two transmission signals are given to the transducer 11 . In the transducer 11 , ultrasonic waves which are obtained by the respective transmission signals are combined with each other, and the resulting synthesized ultrasonic wave is transmitted to and received from a test body. The reception signal of the ultrasonic wave reflected by one reflector is obtained as shown by a reception signal R b in FIG. 3B . The waveform g 2 in FIG. 3B shows leakage of the transmission signals.
[0043] In the first embodiment, when the delay amount (time) d between the first transmission signal S 1 and the second transmission signal S 2 in FIG. 3A is variably adjusted, the distance resolution and the sensitivity can be enhanced as shown in FIGS. 4A to 4 F and 5 A to 5 D. FIG. 4 shows waveforms in the case where the distance resolution is to be enhanced. When a transmission signal S 0 of an amplitude a 1 and a pulse width t 1 is used as shown in FIG. 4 A, an ultrasonic (reception) waveform due to the signal S 0 is obtained as a waveform R 1 in an ultrasonic wave generation period H a shown in FIG. 4B . When the transmission signal S 0 is used as a first transmission signal S 01 , and also as a second transmission signal S 02 with forming an interval of, for example, a previously adjusted delay amount d 1 as shown in FIG. 4C , the delay amount (time) D 1 of a second ultrasonic waveform R 2 with respect to a first ultrasonic waveform R 1 which is generated by the transducer 11 is T/4 (T: cycle of the ultrasonic waveform), and an ultrasonic wave (reception wave) of a waveform R 3 which is a combination of these ultrasonic waves (waveforms R 1 and R 2 ) is obtained as shown in FIG. 4D . The ultrasonic waveform R 3 is longer by a period of T/4 than the ultrasonic wave generation period H a , but the amplitude (wave height) is higher than that in the case where an ultrasonic wave is generated by the single transmission signal S 0 .
[0044] It will be seen that, when the amplitude of the ultrasonic wave of FIG. 4D is reduced so as to be lowered to the level shown in FIG. 4B , the ultrasonic wave generation period H b1 becomes shorter than the period H a as indicated by the ultrasonic waveform R b1 in FIG. 4F . In the embodiment, in order to obtain such an ultrasonic waveform, as shown in FIG. 4E , the first and second transmission signals S 1 , S 2 (an amplitude a 2 and a pulse width t 2 ) which is smaller in amplitude (a 2 <a 1 ) and also in pulse width (t 2 <t 1 ) than the transmission signal S 0 of FIG. 4A are used, whereby an ultrasonic wave [ FIG. 4F ] of the shorter ultrasonic wave generation period H b1 is generated so that the distance resolution is enhanced. In FIG. 4F , while the period H b1 is made shorter than that in the related art, the amplitude of the ultrasonic wave may be maintained higher than that in the related art. In this case, also the search sensitivity can be enhanced. Alternatively, the delay amount between ultrasonic waves may be set to a value other than nT/4. In the alternative also, the ultrasonic wave generation period H b1 can be shortened.
[0045] FIGS. 5A to 5 D show waveforms in the case where the search sensitivity is to be enhanced. In this case, an ultrasonic waveform R 1 of FIG. 5B which is generated by a transmission signal S 1 of FIG. 5A is composed with forming a shift of one cycle. As shown in FIG. 5C , namely, a second transmission signal S 2 is output with forming a previously adjusted delay amount d 2 with respect to the first transmission signal S 1 . Therefore, two ultrasonic waveforms R 1 of FIG. 5B are combined with each other with the shift of one cycle, and an ultrasonic waveform R b2 having a high amplitude is obtained as shown in FIG. 5D . The ultrasonic wave generation period H b2 of the ultrasonic waveform R b2 is longer by the degree corresponding to one cycle than the period H a in the case where the combination is not conducted. However, the resulting ultrasonic waveform has a larger amplitude, and hence the search sensitivity can be enhanced.
[0046] FIG. 1 shows the whole configuration of an ultrasonic diagnostic apparatus of a second embodiment, and FIGS. 8 and 9 show the configuration of a transmitting section in FIG. 1 . In the ultrasonic diagnostic apparatus shown in FIG. 1 , the transmitting section 112 which performs a transmission process, and a receiving section 13 which performs a reception process are connected to one or more transducers 11 disposed in a probe. A detection circuit 14 which detects a reception signal, an A/D converter 15 which analog/digital-converts an output of the detection circuit 14 , and a digital scan converter (DSC) 16 which applies conversion (scan conversion) from data in a sound ray space to those in a physical space on an output of the A/D converter 15 are connected to the receiving section 13 . In the apparatus, a controlling circuit 17 which controls these circuits, and a monitor 18 which displays an ultrasonic image based on an output of the DSC 16 are further disposed.
[0047] FIG. 8 shows an example of the configuration of the transmitting section 112 in the case where one transmitting circuit outputs a plurality of transmission signals. In the transmitting section 112 of FIG. 8 , one transmitting circuit 112 a , a delaying circuit 112 b , and an amplitude/pulse width controlling circuit 112 c are disposed. In accordance with a delay amount control signal supplied from the controlling circuit 17 , the delaying circuit 112 b sets the delay amount (time) for second and subsequent transmission (pulse) signals with respect to a first transmission (pulse) signal. The amplitude/pulse width controlling circuit 112 c sets the amplitude or pulse width of each of the first and second (third, . . . ) transmission signals.
[0048] Specifically, the delaying circuit 112 b supplies a trigger signal which lags an incoming transmission trigger by a predetermined amount (d), to the transmitting circuit 112 a . The transmitting circuit 112 a first receives the transmission trigger, directly from the controlling circuit 17 , and forms the first transmission signal. On the basis of the trigger signal supplied from the delaying circuit 112 b , the transmitting circuit then forms the second transmission signal which is delayed by the predetermined amount (d). At the same time, the amplitude/pulse width controlling circuit 112 c is controlled on the basis of the control signal supplied from the controlling circuit 17 , so that the first and second (third, . . . ) transmission signals having different amplitudes or pulse widths (one or both of the amplitude and the pulse width are controlled to different values) are output.
[0049] FIG. 9 shows another example of the configuration of the transmitting section 112 in the case where two transmitting circuits output a plurality of transmission signals. In the transmitting section 112 of FIG. 9 , a first transmitting circuit 112 d which receives a transmission voltage A (transmission voltage control signal) for controlling the amplitude or the like, a second transmitting circuit 112 e which similarly receives a transmission voltage B (transmission voltage control signal), pulse width controlling circuits 112 f , 112 g which receive a pulse width control signal, and a delaying circuit 112 h which is connected to one of the pulse width controlling circuits, or the controlling circuit 112 g are disposed. In this case, on the basis of the transmission trigger supplied from the controlling circuit 17 , the first transmitting circuit 112 d and the pulse width controlling circuit 112 f output a first transmission signal in which the pulse width is controlled. The delaying circuit 112 h forms a trigger signal which lags the transmission trigger signal by the predetermined amount (d). On the basis of the trigger signal, the second transmitting circuit 112 e and the pulse width controlling circuit 112 g output a second transmission signal which lags from the first transmission signal by the predetermined amount (d), and in which the amplitude and the pulse width are controlled to different values. In the case where three or more transmission signals are to be sequentially output, the above-described transmitting circuits ( 112 e ) and delaying circuits ( 112 h ) may be further added, or plural transmission signals may be formed and output by two sets of a transmitting circuit, a pulse width controlling circuit, and a delaying circuit.
[0050] In the above, the configuration of the second embodiment has been schematically described. Next, the function in the case where an ultrasonic wave is formed by two transmission signals will be described. FIGS. 3A and 3B show a transmission signal which is supplied to the single transducer, and a reception signal which is received from one reflector. In the second embodiment, as shown in FIG. 3A , a first transmission signal S 1 and a second transmission signal S 2 are successively output in the same ultrasonic scan line, and the two transmission signals are given to the transducer 11 . In the transducer 11 , ultrasonic waves which are obtained by the respective transmission signals are combined with each other, and the resulting synthesized ultrasonic wave is transmitted to and received from a test body. The reception signal of the ultrasonic wave reflected by one reflector is obtained as shown by a reception signal R b in FIG. 3B . The waveform g 2 in FIG. 3B shows leakage of the transmission signals.
[0051] In the second embodiment, when the delay amount (time) d between the first transmission signal S 1 and the second transmission signal S 2 in FIG. 3A is variably adjusted, and the amplitudes and pulse widths of the transmission signals S 1 , S 2 are variably adjusted as shown in FIGS. 10A to 10 D, the distance resolution and the sensitivity can be enhanced as shown in FIGS. 11A to 11 F to 13 A to 13 C. FIGS. 10A and 10B show examples in the case where the amplitude is changed. As shown in FIG. 10A , for example, a first transmission signal (pulse) S 1 having an amplitude a 1 and a pulse width t 1 , and a second transmission signal (pulse) S 2 having an amplitude a 2 (=a 1 −x) which is smaller than a 1 , and the pulse width t 1 may be used, or, as shown in FIG. 10B , a first transmission signal S 1 having an amplitude a 1 and a pulse width t 1 , and a second transmission signal S 2 having an amplitude a 3 (=a 1 +x) which is larger than a 1 , and the pulse width t 1 may be used.
[0052] FIGS. 10C and 10D show examples in the case where the pulse width is changed. As shown in FIG. 10C , for example, a first transmission signal S 1 having an amplitude a 1 and a pulse width t 1 , and a second transmission signal S 2 having the amplitude a 1 , and a pulse width t 2 (=t 1 −y) which is shorter than t 1 may be used, or, as shown in FIG. 10D , a first transmission signal S 1 having an amplitude a 1 and a pulse width t 1 , and a second transmission signal S 2 having the amplitude a 1 , and a pulse width t 3 (=t 1 +y) which is longer than t 1 may be used. In the first and second transmission signals S 1 , S 2 , alternatively, both the amplitude and the pulse width may be set to different values.
[0053] FIGS. 11A to 11 F show waveforms in composing of ultrasonic waves for enhancing the distance resolution. In the case where a transmission signal S 0 of an amplitude a 1 and a pulse width t 1 is used as shown in FIG. 11A , an ultrasonic (reception) waveform due to the signal S 0 is obtained as a waveform R 1 in an ultrasonic wave generation period H a shown in FIG. 11B . When the transmission signal S 0 is used as a first transmission signal S 01 , and also as a second transmission signal S 02 with forming an interval of, for example, a previously adjusted delay amount d 1 as shown in FIG. 11C , the delay amount (time) D 1 of a second ultrasonic waveform R 2 with respect to a first ultrasonic waveform R 1 which is generated by the transducer 11 is T/4 (T: cycle of the ultrasonic waveform), and an ultrasonic wave (reception wave) of a waveform R 3 which is a combination of these ultrasonic waves (waveforms R 1 and R 2 ) is obtained as shown in FIG. 1D . The ultrasonic waveform R 3 is longer by a period of T/4 than the ultrasonic wave generation period H a , but the wave height (amplitude) is higher than that in the case where an ultrasonic wave is generated by the single transmission signal S 0 .
[0054] It will be seen that, when the amplitude (wave height) of the ultrasonic wave of FIG. 11D is reduced so as to be lowered to the level shown in FIG. 11B , the ultrasonic wave generation period H′ b1 becomes shorter than the period H a as indicated by the ultrasonic waveform R′ b1 in FIG. 11F . In the embodiment, in order to obtain such an ultrasonic waveform, as shown in FIG. 11E , the first transmission signal S 1 having an amplitude a 2 (<a 1 ) and a pulse width t 2 (<t 1 ) which are smaller than those of the transmission signal S 0 of FIG. 11A , and a second transmission signal S 2 having an amplitude a 3 (<a 2 ) which is smaller than a 2 , and a pulse width t 3 (<t 2 ) which is shorter than t 2 are used, whereby an ultrasonic wave [ FIG. 11F ] of the shorter ultrasonic wave generation period H′ b1 is generated so that the distance resolution is enhanced. In FIG. 11F , while the period H′ b1 is made shorter than that in the conventional art, the amplitude of the ultrasonic wave may be maintained higher than that in the conventional art. In this case, also the search sensitivity can be enhanced. Alternatively, the delay amount between ultrasonic waves may be set to nT/4 (n: an odd number), so that the ultrasonic wave generation period H′ b1 can be efficiently shortened and the amplitude can be maintained high.
[0055] FIGS. 12A and 12B show another example of composing of ultrasonic waves for enhancing the distance resolution. When a first transmission signal S 1 such as shown in FIG. 11E and a second transmission signal S 2 which is different in amplitude and pulse width from S 1 are used, an ultrasonic waveform R 4 (solid line) and an ultrasonic waveform R 5 (broken line) can be combined with each other as shown in FIG. 12A . In this case, rear portions of R 4 and R 5 cancel each other, and a synthesized ultrasonic wave R′ b2 of a short generation period H′ b2 is obtained as shown in FIG. 12B . As indicated by r e in FIG. 12B , a small waveform may remain in the tail of the ultrasonic waveform. When the small waveform is low in level, however, the detection is not adversely affected.
[0056] FIGS. 13A to 13 C show waveforms in the case where the search sensitivity is to be enhanced. In this case, as shown in FIG. 13A , a first transmission signal S 1 having an amplitude a 6 and a pulse width t 6 , and a second transmission signal S 2 having an amplitude a 7 (<a 6 ) which is smaller than a 6 , and a pulse width t 7 (<t 6 ) which is shorter than t 6 are used in the same manner as FIGS. 11A to 11 F, whereby an ultrasonic waveform R 7 (broken line) generated by the transmission signal S 2 is combined with an ultrasonic waveform R 6 (solid line) generated by the transmission signal S 1 with a delay amount of about one cycle as shown in FIG. 13B . Namely, the second transmission signal S 2 is output with forming a previously adjusted delay amount d 3 with respect to the first transmission signal S 1 . Therefore, the ultrasonic waveforms R 6 and R 7 are combined with each other with the shift of about one cycle, and an ultrasonic waveform R b3 having a high amplitude is obtained as shown in FIG. 13C . The ultrasonic wave generation period H b3 of the ultrasonic waveform R b3 is slightly longer than the period H a in the case where the combination is not conducted. However, the resulting ultrasonic waveform has a larger amplitude, and hence the search sensitivity can be enhanced.
[0057] In the above, the embodiment in which a synthesized ultrasonic wave is generated by the two transmission signals S 1 , S 2 has been described. In order to further enhance the distance resolution or the sear sensitivity, an ultrasonic wave obtained by combination in which three or more successive transmission (pulse) signals are used may be transmitted and received in the same ultrasonic scan line (directions of transmitting and receiving waves). In the combining of ultrasonic waves, a small waveform may remain in the tail of each ultrasonic wave. When the small waveform is low in level, however, the detection is not adversely affected.
[0058] In the embodiment, in order to enhance the distance resolution or the sear sensitivity, the delay amount and number of the plural ultrasonic wave transmissions, and the amplitudes and pulse widths of the transmission signals are determined according to a probe identification code (the kind of the probe), or a selected or preset frequency of the ultrasonic wave, the transducer, and the like. In an ultrasonic diagnostic apparatus, various probes having different transducer characteristics are used, and there is a case where the frequency of an ultrasonic wave to be generated is selectable. In accordance with such situations, an optimum ultrasonic waveform must be obtained. In the first embodiment, therefore, information indicative of: the delay amount (d) for the second and subsequent transmission signals corresponding to the probe identification code or different ultrasonic wave frequencies; and the number of outputs of the transmission signals is stored and held. When the probe identification code of a connected probe is checked, or when the selected or preset frequency of the ultrasonic wave is checked, therefore, it is possible to control transmission and reception of an ultrasonic wave by the delay amounts and number of transmission signals corresponding to the identification code or the frequency of the ultrasonic wave. In the second embodiment, information indicative of: the delay amount (d) for the second and subsequent transmission signals corresponding to the probe identification code or different ultrasonic wave frequencies; and the number, amplitudes, and pulse widths of outputs of the transmission signals is stored and held. When the probe identification code of a connected probe is checked, or when the selected or preset frequency of the ultrasonic wave is checked, therefore, it is possible to control transmission and reception of an ultrasonic wave by the delay amounts, number, amplitudes, and pulse widths of transmission signals corresponding to the identification code or the frequency of the ultrasonic wave.
[0059] According to the ultrasonic diagnostic apparatus of the invention, the ultrasonic waveform is controlled with changing the delay amount for the second and subsequent ultrasonic waves with respect to the first ultrasonic wave, whereby the distance resolution and the search sensitivity can be enhanced, so that an image which has a high image quality, and which is easily observed can be obtained.
[0060] According to the ultrasonic diagnostic apparatus of the invention, plural transmission signals in each of which the output timing (delay amount) is adjusted are used in order to combine ultrasonic waves, and the amplitudes or pulse widths of the transmission signals are controlled to have different values, so that an arbitrary ultrasonic waveform is formed. As a result, the distance resolution and the search sensitivity can be enhanced, so that an image which has a high image quality, and which is easily observed can be obtained.
[0061] The entire disclosure of each and every foreign patent application from which the benefit of foreign priority has been claimed in the present application is incorporated herein by reference, as if fully set forth.
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An ultrasonic diagnostic apparatus comprising a probe, the probe including at least one transducer that generates an ultrasonic wave, so as to form an ultrasonic tomographic image, wherein a plurality of transmission signals are generated to at least one of said at least one transducer in a common scan line period, said plurality of transmission signals including a first transmission signal and at least one second transmission signal subsequent to the first transmission signal, wherein said at least one second transmission signal is generated when a first ultrasonic wave resulting from the first transmission signal is generated, so as to form at least one second ultrasonic wave, and wherein the first ultrasonic wave and said at least one second ultrasonic wave are combined with each other, so as to form a synthesized ultrasonic wave.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a CVCF (Constant Voltage Constant Frequency) inverter and to a method for controlling the same, and particularly to a CVCF inverter employed in carrying out lap switching with a rotating type power generator.
2. Description of the Prior Art
In a large aircraft in flight, for example, electric power is supplied from a rotating type power generator which is driven by an engine. While on land, on the other hand, the power supply is switched from the power generator on the aircraft to a power supply installed at an airport. In this case, uninterruptible power switching is required because of computers installed in the aircraft. A CVCF inverter is generally used with the power supply installed at the airport.
FIG. 1 shows a conventional power supply system of this type. In FIG. 1, reference numeral 30 designates a rotating type power generator (MG) on the aircraft; 40 designates a CVCF inverter (CVCF); 50 designates apparatuses (loads) on the aircraft to which the power is to be supplied; SW1 and SW2 designates switches; ΔI designates a cross current; and IL designates a load current. The switch SW1 is closed in flight so that the power is supplied from the power generator 30 to the loads 50. After landing, uninterruptible switching is carried out by first closing the switch SW2 so that both switches SW1 and SW2 are closed for a while, and then, by opening the switch SW1 so that the loads 50 are supplied with the power from the CVCF inverter 40 via the switch SW2. Thus, the lap switching operation is performed.
The lap switching operation, however, may sometimes cause a cross current ΔI due to a difference in phases of the voltages supplied from the power generator 30 and the CVCF inverter 40. More specifically, assuming that the output voltage and the output impedance of the CVCF inverter 40 are Asinωt and Z1, and those of the power generator 30 are Asin(ωt+θ) and Z2, a cross current ΔI expressed by equation (1) flows from the power generator 30 to the CVCF inverter 40.
ΔI=A{sin (ωt+θ)-sinωt}/(Z1+Z2)
=2A cos (ωt+θ/2) sin (θ/2)/(Z1+Z2) (1)
Thus, the magnitude of the cross current ΔI is directly proportional to the phase difference θ as long as θ is rather small.
Although the cross current presents little problem as long as the phase difference θ is small, a large phase difference will result in a large current flowing from the power generator 30 to the CVCF inverter 40 or from the CVCF inverter 40 to the power generator 30. For example, when the phase of the power generator 30 leads that of the CVCF inverter 40, the cross current flows from the power generator 30 to the CVCF inverter 40 so that the DC voltage of the CVCF inverter 40 rises, which might cause damage to devices in the inverter in the worst case.
On the other hand, when the phase of the CVCF inverter 40 leads that of the power generator 30, the cross current flows from the CVCF inverter 40 to the power generator 30. In this case, if the output current of the CVCF inverter 40 exceeds a limiting level of an overcurrent, automatic control to limit the output voltage of the CVCF inverter 40 is carried out to protect the inverter 40 from damage. This creates another problem in that sufficient power is not supplied because of the voltage drop at the loads.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a CVCF inverter and method for controlling the same, which protect the inverter by reducing the cross current and which permit the inverter to supply power in a stable and reliable manner.
In a first aspect of the present invention, there is provided a CVCF inverter comprising:
a main circuit for converting a DC input voltage to an AC output voltage;
voltage control means for controlling the output voltage of the main circuit;
frequency control means for controlling a frequency of the output voltage of the main circuit so that the frequency is maintained at a reference frequency;
detecting means for detecting a cross current flowing through the main circuit; and
adjusting means for adjusting the reference frequency in accordance with a detected result of the detecting means.
The detecting means may comprise means for detecting the output voltage of the main circuit, means for detecting an output current of the main circuit, and effective power computing means for computing effective power outputted from or inputted to the main circuit based on the output voltage and the output current of the main circuit, wherein the adjusting means increases the reference frequency when the effective power is flowing into the main circuit and decreases the reference frequency when the effective power is flowing out of the main circuit.
The adjusting means may further comprise comparing means for comparing the output current of the main circuit with a predetermined value, and may change the reference frequency in accordance with the magnitude of the effective power when the output current of the main circuit exceeds the predetermined value.
The adjusting means may comprise a V/F adjuster producing a voltage in accordance with the effective power, and the frequency control means may comprise a V/F oscillator changing its oscillating frequency in response to the voltage outputted from the V/F adjuster.
The adjusting means may further comprise a filter for filtering the output of the V/F adjuster, and a summing point for producing a difference between the output of the filter and the effective power and for supplying the difference to the V/F adjuster.
The detecting means may comprise means for detecting the DC voltage inputted to the main circuit, and the adjusting means may comprise comparing means for comparing the detected DC voltage with a predetermined value, and a voltage adjuster controlling the frequency control means so that the reference frequency is increased by an amount corresponding to the difference between the detected DC voltage and the predetermined value when the detected DC voltage exceeds the predetermined value.
The detecting means may further comprise means for detecting the output voltage of the main circuit, means for detecting an output current of the main circuit, and effective power computing means for computing effective power outputted from or inputted to the main circuit based on the output voltage and the output current of the main circuit, wherein the adjusting means adjusts the reference frequency, when the detected DC voltage is less than the predetermined value, in such a manner that the reference frequency is decreased when the effective power is flowing out of the main circuit and is increased when the effective power is flowing into the main circuit.
The adjusting means may further comprise comparing means for comparing the output current of the main circuit with a predetermined value, and may control the frequency control means so that the reference frequency is changed in accordance with the magnitude of the effective power when the output current of the main circuit exceeds the predetermined value.
The adjusting means may comprise a V/F adjuster producing a voltage in accordance with the effective power, and the frequency control means may comprise a V/F oscillator changing its oscillating frequency in response to the voltage outputted from the V/F adjuster.
The adjusting means may further comprise a filter for filtering the output of the V/F adjuster, and a summing point for producing a difference between the output of the filter and the effective power and supplying the difference to the V/F adjuster.
In a second aspect of the present invention, there is provided a method for controlling a CVCF inverter having a main circuit for converting a DC input voltage to an AC output voltage, the method comprising the steps of:
controlling a frequency of the output voltage of the main circuit so that the frequency is maintained at a reference frequency;
detecting a cross current flowing through the main circuit; and
adjusting the reference frequency in accordance with a detected result.
The step of detecting may comprise the steps of detecting the output voltage of the main circuit, detecting an output current of the main circuit, and computing effective power outputted from or inputted to the main circuit based on the output voltage and the output current of the main circuit, and the step of adjusting may comprise the steps of increasing the reference frequency when the effective power is flowing into the main circuit and decreasing the reference frequency when the effective power is flowing out of the main circuit.
The step of adjusting may comprise the steps of comparing the output current of the main circuit with a predetermined value, and adjusting the reference frequency in accordance with the magnitude of the effective power when the output current of the main circuit exceeds the predetermined value.
The step of adjusting may comprise the step of producing a voltage in accordance with the effective power, and the step of controlling may comprise the step of changing the frequency of the output voltage of the main circuit in response to the voltage.
The step of detecting may comprise the step of detecting the DC voltage inputted to the main circuit, and the step of adjusting may comprise the steps of comparing the detected DC voltage with a predetermined value, and increasing the reference frequency by an amount corresponding to the difference between the detected DC voltage and the predetermined value when the detected DC voltage exceeds the predetermined value.
The step of detecting may comprise the steps of detecting the output voltage of the main circuit, detecting an output current of the main circuit, and computing effective power outputted from or inputted to the main circuit based on the output voltage and the output current of the main circuit, wherein the step of adjusting comprises the step of adjusting the reference frequency, when the detected DC voltage is less than the predetermined value, in such a manner that the reference frequency is decreased when the effective power is flowing out of the main circuit, and is increased when the effective power is flowing into the main circuit.
The step of adjusting may comprise the steps of comparing the output current of the main circuit with a predetermined value, and controlling the reference frequency in accordance with the magnitude of the effective power when the output current of the main circuit exceeds the predetermined value.
The step of adjusting may comprise the step of producing a voltage in accordance with the effective power, and the step of controlling may comprise the step of changing the frequency of the output voltage of the main circuit in response to the voltage.
According to the present invention, the output frequency of the inverter is decreased when the inverter supplies power to an external power supply, and is increased when the inverter receives power from the external power supply. By this, the cross current between the inverter and the external power supply can be reduced. This makes it possible to prevent damage of the components of the inverter, and the voltage drop at the output of the inverter.
In addition, when the DC voltage across a capacitor at the DC side of the inverter exceeds a predetermined value, the output frequency of the inverter is increased so that the effective power is supplied from the inverter to the external power supply, and hence, the DC voltage across the capacitor is reduced. This also makes it possible to protect the components of the inverter.
Furthermore, a combination of the above mentioned two techniques will ensure a more reliable and safe operation.
The above and other objects, effects, features and advantages of the present invention will become more apparent from the following description of the embodiments thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating a lap switching operation of a conventional uninterruptible power switching system;
FIG. 2 is a vector diagram explaining the principle of the present invention;
FIG. 3 is a diagram illustrating waveforms W2 and W2a of a cross current ΔI and the DC voltage of an inverter in accordance with the present invention in comparison with those W1 and W1a of a conventional inverter;
FIG. 4 is a block diagram showing the arrangement of a first embodiment of a CVCF inverter in accordance with the present invention;
FIG. 5 is a block diagram showing the arrangement of a second embodiment of a CVCF inverter in accordance with the present invention; and
FIG. 6 is a block diagram showing the arrangement of a third embodiment of a CVCF inverter in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will now be described with reference to the accompanying drawings.
Before describing embodiments, let us explain the principle of the present invention with reference to FIGS. 2 and 3.
When the phase of the output voltage of the CVCF (Constant Voltage Constant Frequency) inverter 40 leads that of the power generator (MG) 30 as indicated by the arrow A1 of FIG. 2 in an arrangement as shown in FIG. 4, the output frequency of the CVCF inverter 40 is reduced as indicated by the arrow A2 in FIG. 2. On the other hand, when the phase of the output voltage of the CVCF inverter 40 lags behind that of the power generator 30 as indicated by the arrow A3 of FIG. 2, the output frequency of the CVCF inverter 40 is increased as indicated by the arrow A4 so that the phase difference is shrunk. By this control in which the frequency of the inverter is varied, the cross current ΔI flowing between the power generator and the CVCF inverter is gradually reduced as shown at (b) of FIG. 3.
In FIG. 3, (a) illustrates the waveform W1 of the cross current ΔI when this control is not carried out, that is, when the frequency is fixed during the lap switching operation. In this case, since the phase difference θ of equation (1) is kept constant, the magnitude of the cross current ΔI is also kept constant.
On the other hand, when the frequency of the output voltage of the CVCF inverter 40 is controlled as described above, the magnitude of the cross current ΔI varies as shown at (b) of FIG. 3 so that the cross current ΔI is reduced.
The magnitude of the cross current ΔI can be detected in terms of the effective power of the inverter 40. More specifically, assuming that the effective power is ΔP, and the phase difference between the output voltage of the inverter 40 and the cross current ΔI is φ, the following equation holds.
ΔP=K×ΔI×cosφ (2)
where K is a fixed coefficient. Thus, by making the effective power zero, the cross current ΔI also becomes zero as long as cosφ is not zero, which usually holds.
The effective power can be detected not only by directly detecting it at the output side of the inverter, but also by indirectly detecting it in terms of the DC voltage at the input side of the inverter. When the effective power pours into the inverter 40 from the power generator 30, the increase ΔV in the DC voltage of the inverter is expressed as an integral of the effective power. Thus, the following equation is obtained.
ΔV=∫ΔP dt (3)
Accordingly, constant effective power will linearly increase the DC voltage of the inverter. In FIG. 3, (c) illustrates the waveforms of the DC voltages of the inverter, wherein the waveform W1a corresponds to the fixed frequency shown in (a) of FIG. 3, and the waveform W2a corresponds to the variable frequency shown in (b) of FIG. 3.
EMBODIMENT 1
FIG. 4 is a block diagram showing a first embodiment of a CVCF inverter in accordance with the present invention.
In this figure, reference numeral 1 denotes the main circuit of the inverter; 2 denotes an AC reactor; 3 denotes a capacitor; 4 denotes a transformer; 5 denotes a current transformer (CT); 6 denotes a potential transformer (PT); 7 denotes an output contactor; 8 denotes a pulse distributor; 9 denotes a voltage adjuster; 9a denotes a summing point; 10 denotes a voltage setting unit; 11 and 16 denotes AC/DC converters; 12 denotes a V/F (Voltage/Frequency) oscillator; 13 denotes a V/F adjuster; 13a denotes a summing point; 14 denotes a filter; 15 denotes an effective power computing unit; 17 denotes a comparator; 18 denotes a current setting unit; and 19 denotes a switch.
The main circuit 1 inverts a DC voltage to an AC voltage, and its output is shaped into a sinusoidal waveform by a filter comprising the AC reactor 2 and the capacitor 3. The transformer 4 is provided for output voltage matching. The current transformer 5 detects the output current of the inverter, and the potential transformer 6 detects the output voltage of the inverter. The output contactor 7 is turned on when the CVCF inverter starts operation.
A voltage control loop is formed comprising the pulse distributor 8, the voltage adjuster 9, the summing point 9a, the voltage setting unit 10, and the AC/DC converter 11. The voltage control loop functions as follows: First, the converter 11 AC-to-DC converts the output voltage of the potential transformer (PT) 6 so as to output a detected value corresponding to the output voltage of the inverter. The difference between the detected value and the output of the voltage setting unit 10 is inputted from the summing point 9a to the voltage adjuster 9. The voltage adjuster 9 carries out computation based on the difference, and outputs a control voltage. The pulse distributor 8 controls firing of the switching devices of the main circuit 1 in accordance with the control voltage so that the output voltage of the inverter is maintained at the voltage set by the voltage setting unit 10.
On the other hand, the output frequency of the inverter is controlled as follows. First, the AC/DC converter 16 detects the output current of the inverter, and outputs a detected value corresponding to the output current. The comparator 17 compares the detected value with the set value of the output current which is supplied from the current setting unit 18. When the detected value exceeds the set value, the switch 19 is turned on.
The effective power computing unit 15 computes the effective power component of the power which the inverter supplies to the power generator, or the inverter receives from the power generator, on the basis of the signals associated with the output voltage and current of the inverter supplied from the current transformer 5 and the potential transformer 6.
A frequency control loop is formed comprising the V/F oscillator 12, the V/F adjuster 13 and the filter 14. The V/F adjuster 13 supplies the V/F oscillator 12 with a signal that controls the frequency of the V/F oscillator 12 in such a manner that the effective power approaches zero as described before with reference to FIGS. 2 and 3. The output of the V/F adjuster 13 is supplied to the input of the filter 14 so as to be fed back to the input of the V/F adjuster 13 via the filter 14. This serves to prevent unstable operation due to hunting or the like.
With this arrangement, the inverter 1 outputs a constant voltage owing to the control of the voltage control loop, and operates at a constant frequency (a reference frequency) owing to the control of the frequency control loop as long as the output current of the inverter does not exceed the set value.
On the other hand, when the output current of the inverter exceeds the set value, the comparator closes the switch 19 so that the effective power component is supplied to the V/F adjuster 13 via the summing point 13a. The V/F adjuster 13 controls the reference frequency in accordance with the effective power component. Assuming that the effective power component is positive when the power is supplied from the power generator to the inverter, and is negative when the power is supplied from the inverter to the power generator, the reference frequency, that is, the output frequency of the inverter, is increased when the effective power component is positive, whereas it is decreased when the effective power component is negative. Thus, the phase difference between the inverter and the power generator is maintained within a fixed value so that the cross current is reduced.
EMBODIMENT 2
FIG. 5 is a block diagram illustrating a second embodiment of a CVCF inverter in accordance with the present invention.
This embodiment is characterized in that a DC voltage detector 21, a DC voltage adjuster 22, a summing point 22a, and a DC voltage setting unit 23 are provided in addition to the arrangement of FIG. 4, and the AC/DC converter 16, the comparator 17, the current setting unit 18 and the switch 19 are removed therefrom.
The detector 21 detects the DC voltage across the capacitor 20. The detected voltage is inputted to the summing point 22a which outputs the difference between the detected voltage V D and the DC set voltage V S from the voltage setting unit 23. The output of the summing point 22a is fed to the DC voltage adjuster 22 which outputs a voltage proportional to the difference V D -V S . The output of the DC voltage adjuster 22 or that of the V/F adjuster 13 is fed to the V/F oscillator 12 in accordance with the following rule: if V D >V S , the output of the DC voltage adjuster 22 is supplied to the V/F oscillator 12; and if V D <V S the output of the V/F adjuster 13 is applied to the V/F oscillator 12.
The normal control of this embodiment is performed so that the input level of the V/F adjuster 13 is adjusted to zero, and the output frequency of the inverter is regulated at 400 Hz, for example.
If the DC voltage of the inverter across the capacitor 20 increases and the voltage V D exceeds the reference voltage V S , the output of the DC voltage adjuster 22 is supplied to the V/F oscillator 12 instead of the output of the V/F adjuster 13. Even if the cross current is less than a fixed value, the voltage across the capacitor 20 will gradually increase in accordance with equation (3). Thus, when the voltage of the capacitor 20 exceeds a predetermined threshold, that is, the voltage V D exceed V S , the DC voltage adjuster 22 supplies the V/F oscillator 12 with the output so that the output frequency of the inverter will be increased in accordance with the difference V D -V S . If the DC voltage of the inverter drops again and the voltage V D becomes less than V S owing to the increase in the output frequency of the inverter, the control of the V/F oscillator 12 shifts from the DC voltage adjuster 22 to the V/F adjuster 13 again so that the output frequency of the inverter is maintained at 400 Hz. The operation is otherwise similar to that of FIG. 4.
Although the output of an effective power computing unit 15 similar to that of FIG. 4 is applied to the input of the V/F oscillator 12 for stabilizing the operation of the system, the effective power computing unit 15 can be omitted if stable operation is achieved without it.
EMBODIMENT 3
FIG. 6 is a block diagram showing a third embodiment of a CVCF inverter in accordance with the present invention.
As will be seen from this figure, the third embodiment is arranged by combining the arrangements shown in FIGS. 4 and 5. Accordingly, the operation of this embodiment is a combination of these arrangements. More specifically, when the output current of the inverter exceeds a predetermined value, the comparator 17 closes the switch 19, and hence, the effective power component is supplied to the V/F adjuster 13. The V/F adjuster 13 increases or decreases the reference frequency in accordance with the effective power component so that the phase difference between the inverter and the power generator is maintained within a predetermined range. Thus, the cross current is reduced. In addition, when the voltage across the capacitor 20 exceeds the predetermined threshold, the DC voltage adjuster 22 has the V/F oscillator 12 operate to increase the output frequency. Thus, more stable and safe operation is achieved.
Although specific embodiments of a CVCF inverter and a method for controlling the same constructed in accordance with the present invention have been disclosed, it is not intended that the invention be restricted to either the specific configurations or the uses disclosed herein. Modifications may be made in a manner obvious to those skilled in the art. Accordingly, it is intended that the invention be limited only by the scope of the appended claims.
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A CVCF (Constant Voltage Constant Frequency) inverter includes a main circuit, a voltage control loop, and a frequency control loop. In a normal operating mode, constant voltage, constant frequency control is carried out by these loops. In a lap switching operation, if a comparator detects that the output current of the inverter exceeds a predetermined level, a switch is closed so that the effective power component computed by an effective power computing unit is inputted to the frequency control loop. The output frequency of the inverter is controlled by changing a reference frequency in response to the effective power. This reduces the phase difference between the output voltage of the inverter and an external power supply, thus decreasing a cross current. This makes it possible to protect the components of the inverter and to supply power reliably.
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BACKGROUND OF THE INVENTION
As is well known to those versed in the venetian blind art, a variety of tilt rod supports have been used in the past, primarily being of stamped sheet metal and composite metal and plastic, requiring special tools for assembly with a head rail, and forming operations subsequent to assembly with a head rail and tilt rod. Also, the metal edges caused unduly rapid wear of venetian blind cords and ladders.
In addition, the per unit cost of prior tilt rod supports was relatively high, especially by reason of waste material, and multi-stage manufacturing procedures required.
Of the prior art of which applicant is aware, the closest appears in the below listed patents:
______________________________________U.S. Pat. No. NAME______________________________________2,269,434 NELSON2,721,609 RUTLEDGE2,798,546 RICE ET AL2,809,531 MOYER3,333,905 HENNEQUIN3,630,264 DEBS______________________________________
SUMMARY OF THE INVENTION
Accordingly, it is among the important objects of the present invention to provide a tilt rod support for venetian blinds which is capable of manufacture as an integral or one piece plastic molding for effecting substantial savings in costs of manufacture and materials, is capable of assembly with venetian blind head rails by substantially instantaneous finger snap-in without the need for tools, to effect substantial efficiencies in the assembly procedure, and which eliminates any need for material forming operations during or after assembly. It is still another object of the present invention to provide a tilt rod support for venetian blinds having the advantageous characteristics mentioned in the preceeding paragraphs, which effectively protects the tilt rod from wear, and further enhances the useful life of control cords and ladders by eliminating wear against metal edges, and further facilitates operation by natural lubrication of the tilt rod support material engaging moving parts.
Other objects of the present invention will become apparent upon reading the following specification and referring to the accompanying drawings, which form a material part of this disclosure.
The invention accordingly consists in the features of construction, combinations of elements, and arrangements of parts, which will be exemplified in the construction hereinafter described, and of which the scope will be indicated by the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a top perspective view showing a tilt rod support of the present invention apart from a venetian blind.
FIG. 2 is a transverse sectional elevational view taken generally along the line 2--2 of FIG. 1, showing the tilt rod support in operative association with a venetian blind head rail.
FIG. 3 is a sectional elevational view taken generally along the line 3--3 of FIG. 1, but showing the assembly of FIG. 2.
FIG. 4 is a partial sectional view taken generally along the line 4--4 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings, and specifically to FIG. 1 thereof, a tilt rod support is there generally designated 10 and may consist of an integral or one-piece plastic unit, fabricated by injection molding or otherwise, as desired.
The support 10 includes a generally rectangular, substantially flat lower wall or base 11 having a pair of laterally spaced, generally parallel side edges 12, and front and rear edges 13 and 14 extending, respectively, between the front and rear ends of the side edges 12. A central cord opening or hole 16 is formed in the base or plate 11 of the support 10. The through hole 16 may have smoothly curved or radiused corners or edges 17. On opposite sides of the cord hole 16, forwardly and rearwardly thereof, are located laterally elongate, front and rear ladder openings or slots 18 and 19, respectively in adjacent, spaced parallelism with the front and rear base edges 13 and 14.
Depending from the under surface of the generally flat base 11, peripherally bounding the circular cord opening or hole 16 is a circular ridge, rim or rib 21. Also depending from the under side of base 11 is a peripheral rim, rib or ridge 22, bounding the forward ladder opening 18. Similarly, depending from a rearward region of the bottom plate or base 11, extending peripherally about the rear ladder opening 19 is a rib or rim 23.
The forward region of forward depending peripheral rim 22 is provided with a depending extension or wall 25 and provided on its forward side with a downwardly tapering snap catch or retainer 26. The depending wall 25 may be coextensive with the lateral dimension of the depending rim or rib 22, and the snap finger or catch 26 may be laterally coextensive with the depending wall 25. Also, a laterally extending through opening or slot 27 is formed in the bottom wall or base 11 coextensive with the depending retainer wall 25, substantially over the snap retainer 26. This structure is best seen in FIG. 2.
The rearward region of the depending peripheral rim 23 of rear ladder opening 19 is provided with a laterally extending depending extension or wall 30. The lower edge of the depending extension 30, laterally medially thereof, may carry a downwardly tapering, rearwardly projecting snap retainer or finger 31; and, the rearward, laterally medial region of rear edge 14 of base 11 is notched or cut away laterally coextensive with the depending rear wall 30, as by a notch or cut-out 32. As best seen in FIGS. 2 and 3, the retaining catches or fingers 26 and 31 have generally horizontal upper surfaces spaced below the under side of the base or plate 11.
The depending peripheral rims 21, 22 and 23, and the depending extensions or walls 25 and 30, together with horizontally projecting catches 26 and 31, define bosses on the under or nether side of the base plate 11, for conforming engagement with the bottom wall of a venetian blind head rail, as will appear more fully hereinafter.
Upstanding from opposite side edges 12, 12 of base or plate member 11, adjacent to the forward edge 13, are a pair of generally parallel, spaced side or end walls 35. The walls 35 may each upstand from a respective base side edge 12, having a front edge 36 substantially flush with the front base edge 13, and extending rearwardly to a rear edge 37, short of the rear base edge 14. Each side or end wall 35 upstands to a generally horizontal upper edge 38, which may have its forward end notched or cut away, as at 39.
At a location adjacent to and spaced forwardly from its rear edge 37, each wall 35 is formed with a downwardly extending, generally U-shaped notch or cut-out 40. That is, each cut-out or notch 40 extends downwardly through the upper edge 38 of a respective side wall 35 and terminates short of the base plate 11. The notches 40 of the spaced side walls 35 are in alignment with each other laterally of the base plate 11, and in substantial alignment with the central cord opening 16.
Extending forwardly from the rear edge 37 of each side wall 35 is a cut-out or opening 42, which extends in spaced relation beneath the notch or cut-out 40. That is, each opening 42 extends forwardly from the rear wall edge 37, being spaced below the associated cut-out 40 and opening to the bottom wall or base plate 11, the openings 42 terminating at their forward ends in end edges 43 located forwardly of the cut-outs or notches 40.
The side walls 37, in their rearward regions, have upper cut-outs 40 and lower cut-outs 42. In order that these cut-outs do not weaken the rearward wall regions, their is provided reinforcing or thickening of the rear wall regions, as at 44. It will now be appreciated that the downward cut-outs 40 open upwardly to define of the thickened material on opposite sides thereof a pair of forwardly and rearwardly spaced legs, as at 45 and 46.
Further reinforcing the walls 35 are a pair of forwardly and rearwardly spaced gussets or brackets 48 and 49, both extending between the bottom wall or plate 11 and a respective side wall 35, forwardly of its cut-out 42.
One of the side walls 35 may have its upstanding legs 45 and 46 provided on their upper ends with inwardly extending projections 50 and 51. The forward projection 50 may extend rearwardly into cut-out 40, and the rearward projection 51 may extend forwardly into the cut-out, both projections may be offset laterally outwardly beyond the plane of the wall 35. The proportions of the interned projections 50 and 51, and the legs 45 and 46 carrying the projections, are such as to afford a resilient deflectability between the projections for snap engagement thereby of a venetian blind tilt rod such as the rod 52, as best seen in FIG. 3.
One of the side walls 35 may be formed with an upstanding projection, protuberance or stud, as at 55, on the forward edge 36 of the side wall. That is, the locating projection 55 may extend forwardly from the front edge 36 of the associated side wall 35, and upstand therefrom to a level beyond that of the side wall upper edge 38. Specifically, the locating projection 55 may have its upper end rounded, as at 56, for conforming engagement beneath the upper edge curl of a head rail, as will appear presently.
A conventional head rail is generally designated 60, being of channel-like formation including a bottom wall or web 61, and a pair of upstanding, front and rear side walls or flanges 62 and 63. The upper edge portions of the head rail side walls 62 and 63 may be curled inwardly, as at 64 and 65, respectively. Further, the head rail bottom wall 61 is formed at appropriate locations with a generally circular cord opening or hole 66, and front and rear, elongate ladder openings or holes 67 and 68.
In the assembled condition of FIGS. 2-4, a support 10 has been positioned within a head rail 60, and preferably canted to engage the locating projection 55 upward beneath a head rail edge curl 64. Then by simple manipulation, as thumb pressure or the like, the depending boss means 21, 22 and 23 are engaged downwardly through head rail openings 66, 67 and 68. More particularly, the retaining formations 25, 26 and 30, 31 are snap engaged downwardly through front and rear head rail openings 67 and 68 to the position shown in FIGS. 2 and 3. It will there be apparent that the retaining fingers 26 and 31 are engaged beneath the under side of the head rail bottom wall 61 to effectively retain the support 10 in position within the head rail. Also, the peripheral depending rims or ridges 21, 22 and 23 line their respective, receiving head rail openings 66, 67 and 68, to provide smooth, low friction receivers for the control cords and ladders. Similarly, the cord passing openings or passageways 42 are of smooth plastic material, to further minimize cord wear. Advantageously, the plastic material of the support 10 may be an acetal, such as "SELCON", which may include natural or added lubricating qualities to further minimize wear of the cords and tapes.
From the foregoing, it is seen that the present invention provides a venetian blind tilt rod support which is extremely simple in construction, durable and reliable throughout a long useful life, effects substantial savings in manufacture and assembling operations, effectively protects and minimizes wear upon cord and ladder parts, and otherwise fully accomplishes its intended objects.
Although the present invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is understood that certain changes and modifications may be made within the spirit of the invention.
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A support for mounting a tilt rod in the head rail of a venetian blind, including a bottom wall or base for resting on the bottom wall of a head rail with depending retainer means for snap retaining engagement through the bottom of the head rail, a pair of spaced side or end walls upstanding from the base and having aligned cut-outs extending downwardly for rotatably receiving a tilt rod, and resiliently deflectable projections extending into at least one cut-out for snap passage therebetween and releasable retention thereby of a tilt rod in the associated cut out.
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This application claims the benefit of U.S. Provisional Application Ser. No. 60/298,856 filed Jun. 15, 2001, U.S. Provisional Application Ser. No. 60/298,851 filed Jun. 15, 2001, U.S. Provisional Application Ser. No. 60/299,131 filed Jun. 15, 2001, U.S. Provisional Application Ser. No. 60/298,854 filed Jun. 15, 2001, and U.S. Provisional Application Ser. No. 60/298,852 filed Jun. 15, 2001.
FIELD OF THE INVENTION
The present invention relates generally to a method and apparatus for cooling extrusion articles, and more specifically to substantially vaporizing a liquid cryogen and then circulating the vaporized cryogen through a cooling chamber, through a cooling chamber including sizing and/or calibration tools, through a hollow in the article itself or a combination of the aforementioned to cool an extrudate. The invention is particularly useful as an extrusion chiller, and may also be utilized for chilling foods. Additionally, many other applications of the invention will become apparent to those skilled in the art upon a review of the following specification and drawings.
BACKGROUND OF THE INVENTION
Certain continuously extruded materials, e.g., rubber products, plastic products, metal products, wood composites, must be cooled after passing through the extrusion operation in order to prevent deformation. In conventional extrusion operations, the extruded materials, be it hose, pipe, rod, bar or any other shape may deform from its own weight if the temperature was not decreased rapidly after leaving the extruder. Cooling the product rapidly creates at least a minimum amount of rigidity in the extrudate such that the manufacturer can cut, stack or otherwise handle the extrudate without unwanted deformation. If the product is not cooled effectively and quickly, the resultant deformation can lead to excessive rates of rejection of the manufactured or extruded product. Further, the rate at which the extrudate is cooled directly affects the rate at which product may be produced. In other words, the faster an extrudate is cooled, the faster the end product can be produced.
Historically, cooling water systems have been utilized as the primary medium for cooling articles, including extrusions. For example, conventional extrusion chilling systems employ a “cooling” chamber downstream from the extruder. The extrusion is fed through the cooling chamber, wherein the extrusion can be sprayed with water, or partially/fully submerged in water in order to chill the extrusion. Various other components may also be included in such systems, such as a vacuum sizing chamber intermediate the extruder and the cooling chamber. The vacuum sizing chamber can be used for both solid and hollow extrusions and employs an external vacuum pump to create a vacuum to assist the extrusion in maintaining its shape while it cools. Water can also be used in the vacuum chamber to cool the extrusion while the vacuum supports the shape. However, cooling water systems have several drawbacks. Many products are adversely affected if contacted with water. Thus, extra care must be taken to avoid such occurrences. Extrusion speeds are limited because the cooling water generally has a well defined heat transfer capability and thus can only cool the fresh extrudate in accordance therewith. In practice, an optimum cooling temperature of approximately 50° F. is achievable from a cost-effective standpoint, which limits the manufacturer's ability to cool extrusions quickly. Additionally, cooling water systems require excessive floor space and also require treatments or special additive packages to prepare and maintain proper water chemistry, as well as to prevent scaling and bacterial growth, which add significantly to the cost thereof.
Coolant mediums other than water which have been used in cooling processes can be referred to collectively as refrigerants, including cryogens. Cryogens include liquid nitrogen, liquid carbon dioxide, liquid air and other refrigerants having normal boiling points substantially below minus 50° F. (−46° C.). Prior art methods of cooling articles using cryogens disclose the benefits of fully vaporizing a cryogen into a gaseous refrigerant prior to contact with the articles to be cooled. Cryogens due to their extremely low boiling point, naturally and virtually instantaneously expand into gaseous form when dispersed into the air. This results in a radical consumption of heat. The ambient temperature can be reduced to hundreds of degrees below zero (Fahrenheit) in a relatively short time, and much quicker than may be realized with a conventional cooling water system. The extreme difference in vaporized cryogen and the extruded product allows the manufacturer to quickly cool an extrudate.
However, prior methods of cryogenic cooling fail to realize the advantages, both in increased efficiency and in improved system control, that can be achieved by utilizing forced gas convection in combination with nitrogen or any other refrigerant. Some disadvantages of prior art cryogenic cooling systems include lower efficiency and limited options for controlling the cooling process. Such systems generally rely exclusively on the cooling effect of the refrigerant, to lower the ambient temperature and chill the article. Although prior art methods utilize forced convection to ensure complete vaporization of the cryogen, no methods use forced gas convection to control the rate of cooling of the article by controlling the wind chill temperature. Consequently, the only control variable in the prior art methods to adjust (lower) the temperature is the introduction of a liquid cryogen into the system. In contrast, utilization of forced gas convection adds a wide range of variable control to adjust the effective temperature, up or down, by controlling the velocity at which the refrigerant is circulated over/around the article to be cooled. Such a forced gas convection system is disclosed by Thomas in U.S. Pat. No. 6,389,828, incorporated herein in its entirety by reference thereto.
The basis of forced gas convection is the principle that increasing velocity of a refrigerant over a heated surface, such as by blowing, greatly enhances the transfer of heat from that surface. In the context of cold temperatures, this principle is probably better known indirectly from the commonly used phrase “wind chill” temperature, which is frequently reported on TV or radio by weather announcers. In that context, wind chill temperature is what the temperature outside “feels” like, taking into account the ambient temperature and the prevailing velocity of the wind. The stronger (higher velocity) the wind, the lower the temperature “feels,” compared to if there were no wind present. Forced gas convection cooling systems, as disclosed herein, take advantage of this “wind chill” affect in their ability to remove heat from an object faster with a constant temperature of a gas. In other words, if a 400° F. object is placed in a constant 75° F. atmosphere without velocity of the surrounding atmosphere, the transfer of energy from the object to the surrounding atmosphere by convection is much slower than if the atmosphere has a velocity over/around the object. An increase in velocity will increase the rate of energy transfer, even though the temperature of the atmosphere is constant. The rate of cooling can be increased or decreased by manipulating the velocity of the cooling medium as the temperature of the medium remains constant. This principle is advantageously utilized to significantly enhance the cooling efficiency of the system by creating, and controlling, “wind chill” temperature during the cooling process. As a result, the efficiency of the process is increased while simultaneously reducing the size, which is typically the length, of the cooling system.
However, the previous method disclosed by Thomas utilizes only a measurement of the ambient temperature within the cooling chamber to adjust the velocity and discharge of cryogen. An extrudate leaving a cooling chamber does not necessarily need to be cooled to an even temperature throughout, but may rely on “equilibrium cooling.” This principle is advantageously utilized according to the invention to significantly enhance the cooling efficiency of the system by creating and controlling the “wind chill” temperature during the cooling process in relation to a measurement of the temperature of the product after leaving the cooling chamber. The basis for “equilibrium cooling” is that a mass having two different temperature zones, or a temperature gradient, will exchange energy between the two zones until an “equilibrium” temperature is reached. Thus, a manufacturer can reduce cooling time and cooling system length by super-cooling at least 51% of the extrudate mass to form a “skin” having sufficient rigidity such that the extrudate may be handled as needed and then allowing the “equilibrium cooling” effect to take place after the extrudate has left the cooling system.
Another type of prior art cooling system utilizes a device called a “calibrator,” and typically multiple such calibrators, to cool extrusions. A calibrator is a tool which generally has a central opening through which the extrusion is fed, the central opening having a surface which is generally in contact with the surface of the extrusion as it is fed through. As a result of contact with the surface of the extrusion, the calibrator acts as a heat sink and the heat is conducted to the calibrator and away from the extrusion thus cooling the extrusion. Since cooling of the extrudate tends to make the material contract or change shape, a vacuum generated by external vacuum pumps is generally drawn through grooves in the calibrator inner surface making contact with the extrudate. This vacuum assists in maintaining the shape of the extrudate. To enhance the heat transfer from the extrusion, internal passages or circuits are provided in the calibrator through which a coolant is circulated. Typically, the coolant is water, but liquid nitrogen is also known to have been used to some degree. However, circulating liquid nitrogen through the cooling circuits has met with some difficulties regarding contact of the liquid nitrogen with the calibrators. Additionally, cooling water systems include the inherent problems associated therewith as discussed above. The aforementioned U.S. Pat. No. 6,389,828 to Thomas discloses that it is preferable to first vaporize a liquid cryogen, such as liquid nitrogen, and then to circulate the super-cold vapor/refrigerant through the cooling circuits instead of the liquid cryogen, which thus requires a system for vaporizing the liquid cryogen prior to circulation through the cooling circuits of the calibrator. Although such a method is an improvement over the prior art, the system may still require the use of external vacuum pumps as previously stated. The present invention provides for a calibration tooling chamber utilizing forced-gas convection of a cryogenic refrigerant in combination with a calibrator tooling or sizing template having a plurality of fins in an outer surface thereof to allow the extrudate to be cooled at an effective rate. This eliminates the need for internal passages, and thus the additional manufacturing costs associated with the required set-up/connection/break-down of the equipment between different product runs. Further, the present invention, by use of a forced gas convection cooling chamber, provides a means of generating an internally induced vacuum to assist the extrudate without the requirement of a separate external pump. External vacuum pumps are expensive, require continued maintenance and repair, are noisy and they must be replaced often.
Many extruded articles include at least one hollow, such as pipe, hose, etc., or may contain several hollow portions. Prior art cooling systems provide the manufacturer with only the ability to cool an extrudate from an outer surface thereof by contact with a cooler medium (liquid, gas or solid depending on the system). Depending on the product geometry, however, a significant amount of an extrudate's mass may be positioned inward of the outer surface and between several hollow portions. Thus, it is difficult to quickly and effectively cool such an extrudate quickly because the cooling medium does not make contact with those portions. The present invention provides an apparatus and method for cooling an extrudate having at least one hollow by circulating a vaporized cryogen through the hollow, preferably in combination with exterior cooling techniques as disclosed in U.S. Pat. No. 6,389,828 and taught herein. This provides for increased cooling capacity and control, as well as reduced cooling system length requirements.
Accordingly, there is a need for a method and apparatus for cooling articles which can provide improved efficiency, reduce the size of the cooling system, and a cooling system that does not require external vacuum pumps.
SUMMARY OF THE INVENTION
A method and apparatus for cooling articles are provided which can utilize the dispersion of a liquid cryogen into a feed chamber wherein the liquid cryogen is substantially vaporized and then circulated through a cooling chamber containing the article to be cooled. The vaporized cryogen can be further circulated though the cooling chamber at a controllable velocity, over/around the surface of the article to be cooled and/or tooling, in order to regulate the rate of cooling the article by controlling the wind chill temperature, based upon the principles of forced gas convection.
A presently preferred cryogen is liquid nitrogen. The liquid nitrogen can be dispersed into a feed chamber in a controlled manner using a valve, which can be operated by a controller, such as a microprocessor. Since the temperature in the feed chamber is much higher than the boiling point of the liquid nitrogen, a high BTU (British Thermal Unit) and expansion rate is captured thereby producing an extremely effective refrigerant. The feed chamber can be communicated with a cooling chamber into which the vaporized cryogen can be circulated by a fan, or other device for circulating a gas and/or vaporized cryogen. Either the feed chamber or the cooling chamber can be vented to dissipate pressure generated as the liquid nitrogen rapidly expands to gaseous form. The fan can preferably be a variable speed fan, or other variable speed circulation device, for circulating the vaporized cryogen through the system at a controllable velocity to take advantage of principles of forced gas convection. The fan can be located in the feed chamber to aid in substantially vaporizing the liquid cryogen. However, considering the relatively high temperature utilized in the cooling chamber compared to the boiling point of the cryogen, even without the fan, the liquid cryogen will virtually completely and instantaneously vaporize as it is injected into the feed chamber. The fan can be operated by the controller which can regulate the speed of the fan to provide improved temperature control over the system by controlling the wind chill temperature in the cooling chamber. The system can also include a temperature sensor, connected to the controller, for monitoring the temperature in the cooling chamber, and to calculate the wind chill temperature. An additional external temperature sensor is provided and connected to the controller. The external temperature sensor is adapted to monitor the temperature of an article after the article has exited the cooling chamber and relays the output signal to the controller, which can operate the fan and valve to provide improved temperature control over the system by controlling the wind chill temperature in the cooling chamber in relation to the article's exit temperature. A heating device can be provided to increase the temperature in the cooling chamber, if needed. The speed of the fan can be controlled by the microprocessor to circulate the refrigerant at a high volume (CFM) to maximize the cooling efficiency, thereby minimizing cryogen consumption. Essentially, the rate of cooling of the article can be increased for a given amount of cryogen dispersed into the feed chamber by increasing the speed of the fan. Another way to express this concept is to say that the “effective temperature” in the chamber can be reduced by increasing the speed of the fan. The articles to be cooled can be delivered into the cooling chamber by means of a conveyor belt, or various other ways of feeding articles, for example pulling extrusions, through the cooling chambers.
The cooling system can also employ a plurality of cooling chambers, preferably adjacent, each of which can be individually controlled by one or more controllers. The controllers can manage the speed of the fan and the nitrogen injection for each individual cooling chamber, thereby providing for maximum heat exchange rates for efficiency and effectiveness. Each cooling chamber can be equipped with its own temperature sensor, nitrogen injection valve to control the introduction of nitrogen into the cooling chamber, and variable speed fan for circulating refrigerant through the cooling chamber.
In general operation, the temperature sensor detects the temperature in the cooling chamber, or of the circulated refrigerant, and the external temperature sensor detects the temperature of an article that has exited the cooling chamber and each feed the respective information to the controller. The controller can be programmed with a desired temperature to which the temperature inside the cooling chamber is to be regulated or to the desired temperature of the article as it exits the cooling chamber. The controller can also control the nitrogen injection valve and the speed of the fan to cause the temperature in the cooling chamber to correspond to the desired temperature or temperature calculated to cool the article to the desired article temperature. An equation for calculating the “effective temperature,” i.e. wind chill temperature, from the speed of the fan and the ambient temperature in the cooling chamber can be programmed into the microprocessor. The speed of the fan can thus be regulated to increase or decrease the rate of cooling of the article, by adjusting the effective temperature in the cooling chamber, in order to maximize the efficiency of the cooling system. Principles of forced air convection can thus be utilized to increase cooling efficiency while minimizing the consumption of nitrogen. Likewise, principles of forced gas convection can be utilized in combination with principles of “equilibrium” cooling to quickly cool surfaces of an article to produce a “skin” of sufficient rigidity for further handling. A “skin” may be super-cooled (cooled to a temperature below the desired article temperature), but the core remaining at a temperature higher than the desired article temperature. The warmer core regions continue to transfer energy to the cooler “skin” regions after exiting the cooling chamber until the two regions reach an “equilibrium” temperature. Thus, the cooling systems of the present invention can produce the required cooling with less line space. The fan additionally permits improved system control over the effective temperature in the cooling chamber. A method of cooling an article using “equilibrium” cooling according to the invention comprises the following steps: a) introducing liquid cryogen into a feed chamber wherein said liquid cryogen is substantially vaporized; b) circulating said vaporized cryogen from said feed chamber into a separate cooling chamber containing said article to be cooled; c) circulating said vaporized cryogen at a controllable velocity from said feed chamber into said cooling chamber and around said article to create a wind chill temperature in said cooling chamber to increase a rate of cooling of said article; d) sensing the temperature in at least one of said feed chamber and said cooling chamber; e) calculating said wind chill temperature in said cooling chamber, said wind chill temperature being a function of the temperature in said cooling chamber and the velocity at which said vaporized cryogen is circulated through said cooling chamber over said article; f) selecting a desired product temperature; g) sensing the temperature of the article prior to entering said cooling chamber and calculating a difference between said desired product temperature and said temperature of the article prior to entering said cooling chamber; h) calculating an amount of energy that must be removed from said article during the resonance time said article is in said cooling chamber necessary to cool greater than 50% of the mass of said article to a super-cool temperature below the desired product temperature, such that the difference between said super-cool temperature and said desired product temperature is greater than or equal to said difference between the sensed temperature of the article prior to entering the cooling chamber and the desired product temperature, said amount of energy being a function of the heat capacity, thermal conductivity, and resonance time of said article in said cooling chamber; i) calculating a wind chill temperature necessary to remove said amount of energy; and i) controlling said velocity to cause said wind chill temperature to correspond to said wind chill temperature necessary to remove said amount of energy.
Another embodiment of the invention is a cooling system which, utilizing wind chill temperatures, is particularly adapted to vaporize a liquid cryogen and circulate the refrigerant over/pass metal tools for an article within the tool. Specific examples of such tools are a calibrator and a sizing template, which are commonly used to cool extruded articles. The metal tools are provided with a plurality of fins extending from an outer surface thereof that provide for increased external surface area. The metal tools are enclosed within a cooling chamber, or chambers and the metal tools, such as calibrators, through which an extrusion is passed to be cooled, is itself, along with the extrusion, cooled within a cooling chamber. Advantageously, such a system can be vacuum assisted without the need for costly external vacuum pumps. The cooling chamber includes an outlet throat through which refrigerant enters the cooling chamber and an inlet throat through which the refrigerant exits the cooling chamber and is recirculated by a fan. By providing the outlet throat with a cross-sectional area less than the cross-sectional area of the inlet throat, the fan is thus “starved” and a vacuum is induced within the cooling chamber. Preferably, a restrictor plate or other suitable mechanism is provided that can be operated to vary the cross-sectional area of the outlet throat, inlet throat, or both.
Another embodiment of the invention is a cooling system which, utilizing principles of forced gas convection, is particularly adapted to vaporize a liquid cryogen and circulate the vaporized through a hollow within an extrudate. The cooling system includes similar components as previously discussed, except the vaporized cryogen is communicated to the hollow through an inlet bore provided in an extruder die and mandrel. Preferably, the cooling system is “captive” and the vaporized cryogen is recirculated. For example, the vaporized cryogen can exit the hollow within a closed cutting chamber. The cutting chamber communicates with a fan via a return conduit. Operation of the system is the same as previously described. Optionally, the cooling system is used in combination with a cooling system to simultaneously cool the outer surface of the extrudate, such as a metal tool cooling system according to the invention.
Other details, objects, and advantages of the invention will become apparent from the following detailed description and the accompanying drawing figures of certain embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
A more complete understanding of the invention can be obtained by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is perspective view of a simplified representation of a presently preferred embodiment of a forced gas convection cooling system.
FIG. 2 is a perspective view of another presently preferred embodiment of a forced gas convection cooling system 100 in combination with a conventional wet jacketed vacuum calibration cooling system 400 .
FIG. 3 is a perspective view of an embodiment of a forced gas convection cooling system 300 using sizing templates in combination with a forced gas convection calibration cooling system 200 .
FIG. 4 is a perspective view of a calibrator according to the invention.
FIG. 5 is a perspective view of a sizing template according to the invention.
FIG. 6 is a front perspective view of a sizing template assembly.
FIG. 7 is a front perspective view of the sizing template assembly shown in FIG. 6 .
FIG. 8 is schematic representation of the method of inducing an internal vacuum.
FIG. 9 is a perspective view of an extruder die having two mandrels to form an extrudate with two hollows.
FIG. 10 is a section view taken along line 571 — 571 of FIG. 9 .
FIG. 11 is a side view of a schematic representation of a presently preferred embodiment of a forced gas convection system for internally cooling an extrudate having a hollow.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While the present invention will be described fully hereinafter with reference to the accompanying drawings, in which a particular embodiment is shown, it is to be understood at the outset that persons skilled in the art may modify the invention herein described while still achieving the desired result of this invention. Accordingly, the description that follows is to be understood as a broad informative disclosure directed to persons skilled in the appropriate art and not as limitations of the present invention.
A simplified perspective view of a forced gas convection cooling system 10 is shown in FIG. 1, depicting the internal duct work of the cooling system with an external “chamber” 11 shown in phantom lines. The framework and insulation materials have been removed for ease of discussion. Forced gas convection cooling systems are described in U.S. Pat. No. 6,389,828, which is incorporated herein in its entirety. The cooling system 10 includes a variable speed fan 12 or other suitable means for circulating a gas. The fan 12 includes a motor housing 14 and a blade housing 16 , which encloses fan blades 18 . The cooling system 10 includes a back chamber 20 , referred to as a “feed” chamber, and a front chamber 22 , known as the “cooling” chamber, connected by end duct 30 . The end duct 30 includes an extrudate passage 32 , or other opening, through which an extrudate 25 (shown in FIG. 1 after passing through the cooling system for ease of illustration) may enter or exit the cooling system 10 , preferably traveling in a direction shown by arrow 15 . In operation, the fan 12 preferably circulates the gas contained in the system in a direction shown by arrows 13 , although circulation may be in the reverse direction if desired. Gas is drawn into the blade housing 16 , which acts as a return chamber, from the front chamber 22 through an inlet throat 26 and discharged from the fan 12 into the back chamber 20 . The gas enters the front chamber 22 from the end duct 30 through outlet throat 28 , such that the gas travels through the front chamber 22 in the same direction as the extrudate. This process can be repeated as the gas is continuously circulated through the cooling system 10 to cool an extrudate. A liquid cryogen feed line 36 is in communication with a liquid cryogen source (not shown) and is adapted to deliver liquid cryogen, such as nitrogen, to the system 10 . Preferably, the feed line 36 extends into the back chamber 20 and includes a spray bar 38 having a plurality of orifices to evenly inject and distribute liquid cryogen. Preferably, the feed line 36 is placed in communication with the back chamber 20 downstream from the fan 12 to inject or distribute liquid cryogen into the stream of circulated gas, which aids in the vaporization and distribution thereof before it reaches the front chamber 22 containing the extrudate. At the presently preferred operating temperatures of the cooling system 10 , substantially complete and instantaneous vaporization of the liquid cryogen occurs upon release or injection into the back chamber 20 or any other suitable point of entry. However, there may be alternative applications wherein a much lower operating temperature may be utilized, such that there is a greater probability of the liquid cryogen not totally vaporizing. In such applications, a larger feed chamber (not shown) in combination with the fan 12 can provide a region wherein substantially complete vaporization of the liquid cryogen is provided, thereby reducing the likelihood of any liquid cryogen being distributed onto the surface of the extrudate. The liquid cryogen is preferably liquid nitrogen, however, other cryogens such as liquid carbon dioxide, liquid air and other refrigerants having normal boiling points substantially below minus 50° F. (−46° C.) can also be used. The liquid nitrogen expands 700 times its volume in liquid state, capturing a high BTU as it transitions to gaseous form, creating a highly effective refrigerant and rapidly reducing the temperature in the cooling system 10 . The fan 12 can be controlled by a controller 50 to circulate the vaporized cryogen at a variable velocity through the back chamber 20 , end duct 30 , and front chamber 22 where it cools the extrudate. The cooling process continues, including the injection of additional liquid cryogen into the back chamber 20 as needed to obtain, or maintain, a desired temperature in the front chamber 22 . The extrudate enters the cooling system through the extrudate passage 32 and travels through the front chamber 22 where it is cooled by the circulating cryogen gas. An extrudate outlet passage 40 , or other opening, is provided at an end of the front chamber 22 opposite the extrudate passage 32 that allows the extrudate to exit the system 10 . Preferably, both the extrudate inlet passage and outlet passage 32 and 40 are equipped with a sealing means, such as an end template (shown in FIG. 3 ), neoprene gasket or other means known in the art, that prevents or reduces the ingress of air and egress of vaporized cryogen to and from the system. Optionally, the sealing means can be selected or designed to permit excess pressure in the system to vent outside. In such a case, a separate vent may not be needed.
The cooling system 10 can further include a number of other components for controlling, optimizing, and generally automating the cooling process. These other components can include a vent 34 , an internal temperature sensor 42 , and a heating unit 44 . The controller 50 can include a microprocessor, for controlling the operation of the cooling system 10 , either automatically or under the control of an operator. The vent 34 can be provided, for example in the back chamber 20 as shown, to release pressure build up which may be created by the expansion of the liquid nitrogen as it is injected into the cooling system 10 . The vent can simply be a small orifice and is preferably placed upstream of the cryogen feed line 36 and spray bar 38 and downstream of the front chamber 22 (with respect to gas flow as shown by arrows 13 ) to minimize the loss of cooling capacity. By venting after the gas has been circulated over the hot extrudate and before the spray bar 38 distributes fresh liquid cryogen, the vented gas has removed energy from the product and is the warmest portion of gas in the system and therefore does not waste newly delivered liquid cryogen. The temperature sensor 42 can be provided in communication with the gas stream generally at any point, but is preferably in the front chamber 20 , back chamber 22 , or end duct 30 , as shown, to monitor temperature of the vaporized cryogen at a desired point. Alternatively, the temperature sensor could be positioned elsewhere, such as the blade housing 16 in order to detect the temperature of the gas stream coming into the fan 12 . Similarly, additional temperature sensors could be positioned at different locations to detect the temperature of the gas at several points in the cooling system 10 . Output from the temperature sensor 42 , and other sensors, if more are used, can be provided to the controller 50 for use in regulating the speed of the fan 12 and controlling a valve 46 provided in the cryogen feed line 36 to inject liquid cryogen into the back chamber 20 . The temperature sensor 42 can be, for example, a thermocouple. The controller 50 can be programmed with the wind chill equation and can also receive a signal from the fan 12 indicative of the fan's speed. This data can be used to determine the effective temperature in the front chamber 22 . The heating unit 44 , can be a simple heating element and can be located, for example, in the back chamber 20 , as shown in the figure. The heating element can be operated by the controller to increase the temperature in the cooling system 10 , if necessary, to adjust and maintain the desired ambient temperature. Multiple such cooling systems may be placed in series and operated independently or together.
In a preferred embodiment of the present invention, an external temperature sensor 48 , such as an infrared temperature sensor, is provided at a desired point downstream from the extrudate outlet passage 40 to sense the temperature of the extrudate 25 after exiting the front chamber 22 . For example, the external temperature sensor 48 could be placed adjacent the extrudate outlet passage 40 or may be placed further downstream, such as adjacent a cutting assembly or puller. The external temperature sensor 48 senses the surface temperature of the extrudate 25 and relays the output to the controller 50 . The controller 50 utilizes the output from external temperature sensor 48 in addition to temperature sensor 42 (and additional temperatures if provided) in regulating the speed of the fan 12 and controlling the valve 46 provided in the cryogen feed line 36 to inject liquid cryogen into the back chamber 20 .
The controller 50 can control the speed of the fan 12 , the valve 46 to inject the cryogen 37 into the back chamber 20 and the heating unit 44 , and thereby closely regulate the wind chill temperature in the front chamber 22 to correspond to, and be maintained at a desired wind chill temperature to ensure that the extrudate exiting the front chamber 22 has reached an optimum product temperature. The optimum product temperature desired for the extrudate exiting the extrudate outlet passage 40 (or other point depending on where the external temperature sensor 48 is placed) can be input to the controller 50 by an operator. The controller 50 can monitor the speed of the fan 12 (and thus the velocity of the gas stream circulating through the front chamber 22 ) and feedback from the external temperature sensor 48 and temperature sensor 42 to cause the sensed temperature, or calculated wind chill temperature, to increase or decrease depending on the external temperature sensor 48 reading. Thus, the controller can efficiently control the cooling of the extrudate 25 to provide an optimum product temperature (rigidity) for further processing, such as cutting the extrudate 25 .
The cooling efficiency of the system can generally be optimized by using principles of forced air convection. Extraction of heat from an extrudate 25 can be increased by blowing cooler air over a warm surface. The “effective” temperature inside the front chamber 22 , or “cooling” chamber can be calculated from the ambient temperature and the velocity that the gas (cryogen 37 ) is blown over the surface of the article 16 using the following equation for calculating “wind chill” temperature:
T wc =0.0817(3.71 V 0.5 +5.81−0.25 V )( T −91.4)+91.4
More specifically, the efficiency of the cooling system 10 can be optimized, i.e., maximum cooling using a minimum amount of liquid cryogen 37 , by controlling the speed of the fan 12 . In particular, for a given amount of liquid cryogen 37 injected into the back chamber 20 or “feed” chamber, the speed of the fan 12 can be increased in order to increase the rate in cooling of the front chamber 22 without adding more liquid cryogen 37 . Only when the speed of the fan 12 is at its maximum, would it be necessary to inject additional liquid cryogen 37 into the back chamber 20 to further reduce the temperature in the front chamber 22 . Moreover, the temperature in the front chamber 22 can also be regulated to a set point temperature by adjusting the speed of the fan 12 , faster or slower, instead of injecting more liquid cryogen 37 . Output from the external temperature sensor allows the controller 50 to manipulate the “wind chill” within the front chamber 22 to increase or decrease the cooling of the extrudate 25 . In this sense, the cooling system 10 can be optimized based on the optimum product temperature. Thus, minimum necessary cooling using a minimum amount of liquid cryogen 37 is achieved. In contrast, prior art cryogenic cooling systems typically control the temperature solely by controlling the amount of liquid cryogen injected into the system or only monitor the “wind chill.” The efficiency of the system can be further optimized if it becomes necessary to increase the temperature in the cooling chamber by using the heating unit 44 . Prior to expending energy to operate the heating unit, the speed of the fan 12 can be reduced to lower the wind chill temperature, and thus decrease the rate of cooling. If reducing the speed of the fan 12 alone is insufficient, then the heating unit 44 can be operated. By reducing the speed of the fan 12 first, energy can be conserved, thus increasing the efficiency of the cooling system 10 . It should therefore be appreciated that “rate of cooling,” is dependent both on the sensed temperature and the wind chill, i.e., “effective,” temperature. To summarize, increasing the speed of the fan 12 results in lowering the effective temperature in the front chamber 22 , which results in an increase in the rate of cooling of the extrudate 25 . Conversely, reducing the speed of the fan 12 results in an increase in the effective temperature in the front chamber 22 , which results in a decrease in the rate of cooling of the extrudate 25 . Accordingly, it can be appreciated that controlling the speed of the fan 12 and cryogen injection in relation to the extrudate temperature after exiting the “cooling” chamber 22 can be advantageously utilized to control the “effective” temperature in the “cooling” chamber 22 , and thus the rate of cooling of the extrudate 25 . This prevents ineffective or unnecessary “overcooling” of the extrudate, when only the optimum product temperature must be reached.
It also should be understood that the configuration and number of passageways provided to circulate the gas through the cryogenic cooling system, and around the article to be cooled, can be varied to suit different applications and conditions. Consequently, the embodiments illustrated are by way of example only, and are in no way intended to be an exhaustive representation of every possible configuration.
Instead of or in addition to cooling the outer surface of an article, vaporized cryogen can also be used to cool tooling, or articles held therein, by circulating cooling water or vaporized cryogen (as disclosed in U.S. Pat. No. 6,389,828) through internal cooling passageways, e.g., cooling circuits, provided in the tooling. One example applicable to cooling extrusions is tools called calibrators. A prior art type calibrator based cooling system 400 , often referred to as a wet, vacuum-jacketed calibration tooling is shown in FIG. 2 in combination with a downstream cooling system 100 configured similarly to the cooling system 10 shown in FIG. 1 and including a sizing template assembly 180 positioned in front chamber 122 , discussed in more detail below. Cooling system 100 is shown with an external chamber 111 having a top cover 124 in an open position that surrounds the front chamber 122 , back chamber (not shown), end duct (not shown), etc. that is depicted in FIG. 1 with respect to cooling system 10 . A fan 118 is shown positioned near a front end 120 of cooling system 100 , however, the cooling system fan is preferably positioned near the rear end (not shown) as detailed in cooling system 10 illustrated in FIG. 1 . The cooling system 400 includes a calibrator 112 , and such a system can typically utilize several, such as calibrators 112 a-g, positioned at spaced apart locations through which an extrudate 125 is fed and thereby cooled. Water and vacuum conduits (not shown) are connected to a water manifold 114 and vacuum manifold 116 respectively, such that cooling water (or vaporized cryogen) may be circulated through the internal cooling circuits and a vacuum may be applied to the outer surface of the extrudate 125 to assist in maintaining its shape. The extrudate enters system 400 through a calibrator inlet passage 122 , seen in calibrator 112 g. A vacuum is drawn through grooves in the calibrator 112 to maintain contact between the extrudate 125 and an inner face of the calibrator extrudate passage. However, these prior art calibrator-based cooling systems require costly external vacuum pumps to create an assist vacuum and often also come with the disadvantages of using cooling water. The present invention eliminates the need for the external vacuum pumps and the associated vacuum/water conduits associated with the prior art systems.
Referring to FIG. 3, a forced gas convection calibration tooling cooling system 200 is shown in combination with a downstream forced gas convection sizing template cooling system 300 . Cooling system 200 includes a fan 212 and external chamber 211 and top cover 224 that surrounds the remaining elements discussed in reference to cooling system 10 and shown in FIG. 1, including a front chamber 222 . Similarly, cooling system 300 includes a fan (not shown) and external chamber 311 and top cover 324 that surrounds the remaining elements discussed in reference to cooling system 10 and shown in FIG. 1, including a front chamber 322 . An end template 214 is provided on external chamber 211 that includes an extrudate inlet passage 232 and provides a means of sealing against the extrudate (not shown) as previously discussed. Optionally, fan 212 may be used to circulate vaporized cryogen through both cooling system 200 and 300 , however, it is preferred that each cooling system 200 and 300 have an independent fan such that the systems may be controlled separately or separated altogether for different operations. A calibrator assembly 216 is positioned within front chamber 222 . The calibrator assembly 216 includes individual calibrators 218 a-e coupled to guide rail 230 . The number of calibrators used in a calibrator assembly can vary from one to any number, and depending on the requirements of the product. Likewise, the size and shape of the calibrator(s) may vary depending on the specific product to be produced. The vaporized cryogen is circulated thorough front chamber 222 over the extrudate outer surface and the calibrators 218 a-e.
A calibrator 218 for use with cooling system is illustrated in FIG. 4 . The calibrator 218 includes a product passage 220 defining an inner surface 226 that makes contact with, but also provides for the passage of an extrudate. By making contact with the extrudate, the calibrator 218 acts as a heat sink and removes energy from the extrudate through conduction. The calibrator 218 also assists the extrudate in maintaining its extruded shape. The calibrator has an outer surface 232 including a plurality of fins 234 extending outwardly therefrom and running substantially parallel to the center axis of the product passage 220 . The plurality of fins 234 define a plurality of channels 236 there between. Inclusion of the plurality of fins 234 greatly increases the outer surface area of the calibrator 218 . By increasing the outer surface area of the calibrator 218 , greater amounts of energy can be dissipated to the vaporized cryogen circulated in the cooling system 200 . The vaporized cryogen flows over the outer surface of the calibrator removes energy therefrom by forced gas convection. The greater the outer surface area of the calibrator means greater contact with the circulated cryogen and more heat transfer. The plurality of fins 234 also increase the mass of the calibrator 218 which increases the amount of energy (heat) the calibrator can remove from the extrudate. Preferably, vacuum grooves 228 are provided in the inner surface 226 , preferably spaced apart and extending the entire circumference of the product passage 220 . At least one pinhole (not shown) is provided from within each vacuum groove 228 and extending to the outer surface, such that the pressure realized outside of the calibrator 218 is also communicated to the vacuum groove 228 . Preferably, a pinhole is provided at the bottom of each channel 236 such that a single vacuum groove includes a plurality of pinholes in communication with the atmosphere outside the calibrator 218 . Therefore, production of a vacuum within the front chamber 222 is transferred to the vacuum grooves 228 . A vacuum within the vacuum grooves 228 assists in maintaining the extrudate in contact with the calibrator, which in turns ensures a proper shape and advantageous conductive heat transfer. Preferably, the calibrator includes at least one guide slot 238 adapted to provide passage of a guide rail 230 (see FIG. 3) such that the calibrator 218 may be secured in a cooling system. A setscrew 240 allows the calibrator 218 to be tightly secured to the guide rail 230 .
FIG. 5 illustrates a sizing template 318 , another type of tooling that may be used with the present invention, that is similar to the calibrator 218 shown in FIG. 4 . The sizing template 318 includes a product passage 320 defining an inner surface 326 that makes contact with, but also provides for the passage of an extrudate. The sizing template 318 has an outer surface 332 including a plurality of fins 334 extending outwardly therefrom and running substantially parallel to the center axis of the product passage 320 . The plurality of fins 334 define a plurality of channels 336 there between. As previously discussed, inclusion of the plurality of fins 334 greatly increases the outer surface area of the sizing template 318 . Optionally, a circumferential rib 328 is provided in the inner surface 326 . Several such ribs may be incorporated, preferably spaced apart and extending the entire circumference of the product passage 320 . Preferably, the sizing template 318 includes at least one guide slot 338 adapted to provide passage of a guide rail 130 (see FIG. 2) such that the sizing template 318 may be secured in a cooling system (see FIG. 2 ). A setscrew 340 allows the sizing template 318 to be tightly secured to the guide rail 130 .
FIGS. 6 and 7 depict a front perspective and rear perspective, respectively, of a sizing template assembly 182 including an extrudate 225 passing through the product passages in the direction of arrow 186 . Although, the foregoing description is made with respect to a sizing template assembly, a calibrator assembly for use with the present invention may be structure in the same general way. The assembly 182 includes a plurality of sizing templates 318 positioned on four guide rails 184 . Preferably each sizing template 318 is positioned adjacent to a complimentary deflector plate 340 . As best seen in FIG. 6, each deflector plate 340 includes gas flow passages 342 that are adapted to guide the flow of vaporized cryogen over/through the plurality of fins 334 extending from the outer surface of the sizing template 318 . The deflector plate preferably includes a spoiler 344 (FIG. 7) extending from a backside 346 of the deflector plate in a generally downward direction. The spoilers 344 operate to direct the gas flow along the outer surface of the extrudate 225 . The assembly 182 is adapted to be placed within the front or “cooling” chamber of a forced gas convection cooling system.
The forced gas convection calibration cooling system 200 and other forced gas convection cooling systems according to the invention do not require separate external vacuum pumps to provide vacuum assistance to the calibrators and other tools. Advantageously, the cooling system 200 may be operated to internally induce a vacuum within the front chamber 222 or “cooling”/calibration chamber. Referring back to FIG. 1 and cooling system 10 , which illustrates the internal duct-work and system components included in the forced gas convection cooling systems according to the present invention, gas flow enters the front chamber 22 from the end duct 30 via outlet throat 28 and exits the front chamber 22 to the blade housing 16 of fan 12 via inlet throat 26 . A vacuum is generated in the front chamber by operating the fan 12 and restricting the flow of gas into the front chamber 22 . Preferably, this is accomplished by ensuring that the cross-sectional area of the outlet throat 28 is less than the cross-sectional area of the inlet throat 26 . In this manner, the fan 12 is “starved” and produces a vacuum in the front chamber. The vacuum produced in the front chamber can easily reach 15 inches of water, but varies depending on the strength of the fan 12 . Such an internally induced vacuum can be produced with any forced gas convection system having a substantially “captive” system meaning that the gas circulation is a closed loop. Preferably, the outlet throat 28 is of a similar cross-sectional area as the inlet throat 26 but is affixed with a restrictor plate (not shown) which can be mechanically operated (manually or by a solenoid actuator driven by the controller 50 ) to vary the cross-sectional area of the outlet throat 28 . Thus, the controller 50 can manipulate and control the pressure within the front chamber 22 . A pressure sensor may be provided to sense the pressure within the front chamber 22 and send feedback to the controller 50 which then adjusts the cross-sectional area of the outlet throat 28 and hence the pressure. In a reverse scenario, if a positive pressure is required within the front chamber 22 , then the cross-sectional area of the outlet throat 28 should be larger than the cross 0 sectional area of the inlet throat 26 . In this instance, the inlet throat 26 can also be provided with a similar restrictor plate and control or simply designing the outlet throat 28 and restrictor plate such that a cross-sectional area of the outlet throat 28 can vary from an area less than to an area greater than the cross-sectional area of the inlet passage 26 . Referring to FIGS. 1-3, operation of the cooling systems 10 , 100 , 200 and 300 accordingly can provide a reduced pressure or “vacuum” within front chambers 22 , 122 , 222 and 322 respectively. FIG. 8 depicts a schematic representation of the method of creating an internally induced vacuum within the “cooling” chamber of a forced gas convection cooling system. Operation of the fan 3 and maintaining a cross-sectional area of inlet 2 into front chamber 5 less than the cross-sectional area of outlet 4 produces a vacuum in the front chamber 5 .
Another preferred embodiment of the present invention is illustrated by FIGS. 9-11. FIG. 11 shows a simplified version of a forced gas convection cooling system 500 for internally cooling an extrusion having a hollow profile. The components and operation of the cooling system 500 are generally the same as for the cooling systems 10 , 200 and 300 illustrated in FIGS. 1-3, except that an outlet conduit 520 and the extrudate 525 essentially replace the front and back chambers. In particular, a source 509 of liquid cryogen 537 , preferably liquid nitrogen, the injection of which into the cooling system through spray bar 538 can be controlled by a feed valve 546 placed in feed line 536 , which itself can be operated by a controller 550 . As previously discussed, the liquid cryogen 537 substantially instantaneously vaporizes and cools the gas stream circulated by the fan 512 , preferably in a direction shown by arrows 513 . The vaporized cryogen stream is communicated to an extruder die 570 via outlet conduit 520 . Extruder die 570 is shown in more detail in FIGS. 9 and 10. Extruder die 570 includes an inlet bore 572 extending from an outer surface 574 of the extruder die 570 through a mandrel 576 that is adapted to form an extrudate hollow 578 within the extrudate 525 . The inlet bore 572 is adapted to be placed in fluid communication with the outlet conduit 520 and thereby pass vaporized cryogen through the extruder die 570 and mandrel 576 and into the extrudate hollow 578 . Preferably, the inlet bore 572 and outlet conduit are separably coupled such that different dies can be interchanged for different product configurations. Inlet bore 572 terminates at a mandrel outlet 586 where vaporized cryogen may enter the extrudate hollow 578 . Optionally, an outlet extension 580 is provided to ensure that the pressure exerted by the vaporized cryogen as it is introduced into the extrudate hollow 578 is spaced from a leading edge 582 of the die 570 . Optionally, the cooling system 500 is used in combination with an external forced gas convection cooling system, such as described in systems 10 , 100 , 200 and 300 (shown in phantom in FIGS. 10 and 11 ), that are placed substantially adjacent the die 570 , but a small separation 584 may exist. If the outlet extension 580 is not used, then a positive pressure within the extrudate hollow 578 may cause a bubble or distortion within the small separation that is undesirable. Preferably, a forced gas convection calibration cooling system, such as cooling system 200 , is used immediately adjacent the extruder and in combination with cooling system 500 . In this scenario, the outlet extension is selected to have a length such that the vaporized cryogen is released at a point within the length of a calibrator and the distortion problem is thus minimized. Preferably, mandrel outlet 586 and outlet extension 580 are separably coupled, such as with threads 588 , so that different length extensions may be used. The outlet extension 580 includes a nozzle 590 or other means for directing the flow of vaporized cryogen onto an inner surface of the extrudate 525 , as shown by arrows 592 .
FIG. 9 depicts a die 570 a configuration including two mandrels 576 a and 576 b that form extrudate hollows 578 a and 578 b , but do not include outlet extensions. An outlet conduit manifold (not shown) can be provided to provide more than one vaporized cryogen streams to two separate outlet conduits 520 a and 520 b and inlet bores, or an inlet bore manifold (not shown) may be provided to split a single vaporized cryogen stream into any number of inlet bores to provide vaporized cryogen to extrudate hollows. Splitting a single stream ensures that the temperature of the vaporized cryogen streams entering different hollows is substantially the same. However, depending on the profile of an extrudate, it may be desirable to provide each hollow with streams of a different temperature. In this case, each hollow that requires a separate temperature is placed in communication with a separate forced gas convection cooling system as herein disclosed.
Referring again to FIG. 11, temperature sensors 542 a and 542 b can be provided for detecting the ambient temperature in the outlet conduit 520 , preferably at a point downstream from liquid cryogen spray bar 538 , or within cutting chamber 560 and outputting that information to the controller 550 . Additionally, an external temperature sensor 548 , such as an infrared sensor, can be provided that outputs a product temperature reading to the controller 550 as discussed with respect to cooling system 10 illustrated in FIG. 1 . An outlet conduit valve 562 can similarly be operated by the controller 550 . A heating unit 564 can be provided that is operable by the controller to input heat to the system if necessary. A conveyor system 558 can similarly be used to support the extrudate 525 between the extruder and any downstream equipment. The controller 550 can regulate the temperature in the outlet conduit by controlling the fan 512 and the feed valve 546 based upon feedback from the temperature sensor 542 a, the temperature sensor 542 b, the external temperature sensor 548 or all three sensors. The controller 550 is programmed to operate system 500 in a similar manner as disclosed for system 10 to optimize the system's efficiency using principles of forced gas convection. The controller can regulate the speed of the fan 512 , operate feed valve 546 to control release of liquid cryogen 537 into outlet conduit 520 and the heating unit 564 to closely regulate the “wind chill” temperature within the extrudate hollow 578 to correspond to, and be maintained at the desired wind chill temperature which can be input by an operator. Optionally, the controller 550 can also act as the controller for additional cooling systems, such as systems 10 , 100 , 200 and 300 discussed herein, used in combination with cooling system 500 .
Preferably, the cooling system 500 is captive, i.e., closed, such that substantially no outside air enters the vaporized cryogen and the vaporized cryogen is recirculated. The extrudate 525 enters the closed cutting chamber 560 through an inlet portion (not shown) and exits through a similar outlet portion (not shown) provided with appropriate sealing portions as known to those in the art. Cutting chamber 560 includes a means for severing the extrudate 525 into desired lengths for further processing or as the final product. The extrudate 525 enters the cutting chamber 560 through a cutting chamber inlet (not shown) provided with appropriate sealing portions as known to those in the art. A saw (not shown) or other suitable cutting means is housed in the cutting chamber 560 and is operated to periodically cut the extrudate 525 into predetermined lengths. Care should be taken such that during the cutting stroke, the vaporized cryogen is allowed to escape from within the extrudate hollow 578 , such as through a saw blade (not shown) provided with slots. The slots prevent a positive cryogen pressure build-up within the extrudate 525 during the cutting stroke. If a continuous blade is used, even the brief amount of time required for the cutting stroke may cause a blockage of the flow of cryogen through the extrudate hollow 578 , and thus cause bellowing and distortion of the product as well as increased drag on tooling equipment. Return conduit 566 channels the vaporized cryogen back to the variable speed fan 512 . A vent 568 and vent valve 569 are provided to allow pressure in the system to be controlled by the controller 550 . Pressure sensor 567 can give feedback to the controller 550 which then operates the vent valve 569 , fan 512 , feed valve 546 , and outlet conduit valve 562 to vary the pressure within the system. Additional pressure sensors may be included at other points within the system to give feedback to the controller 550 . Optionally, a heat exchanger 568 , e.g., a shell and tube exchanger, is provided to pre-cool the recirculated cryogen and thus reduce the consumption of liquid cryogen 537 . A heating element 50 may be provided in communication with the circulated cryogen 24 , such as in the return conduit 42 as shown, such that heat may be added to the system if necessary.
Advantageously, the present invention allows an extrudate with a hollow profile to be cooled from the outside and from within. The internal and external surfaces of the extrusion can be cooled at equal or variable rates, which allows for extensive process control heretofore unseen. The present invention, by providing cooling from within the extrusion, provides for quicker cooling and shorter cooling chamber lengths. Also, the internal gas flow of cryogen provides a positive pressure against the internal surfaces of the extrusion, which in turn reduces or eliminates the need for an external vacuum on the outer surface of the extrudate to provide a quality product. Since less external vacuum is required, the amount of drag between the product and tooling is reduced, which provides for increased rates of production and smaller downstream, equipment such as pullers.
Various features of the invention have been particularly shown and described in connection with the illustrated embodiments of the invention, however, it must be understood that these particular embodiments merely illustrate and that the invention is to be given its fullest interpretation within the terms of the appended claims.
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A method and apparatus for using a cryogen for cooling articles, particularly having applications for chilling extrusions, food, and similar articles, utilizing dispersion of liquid cryogen into a feed chamber wherein it is substantially vaporized and then circulated through a cooling chamber containing the article to be cooled. A circulation device can circulate the vaporized cryogen through the cooling chamber, or through the article, at a variably controllable velocity to enhance the cooling efficiency using the principle of forced air convection and to provide improved temperature control in the system.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a pen-input panel or a touch panel which is used for input to a personal computer, a word processor, an electronic notepad, etc.
[0003] 2. Description of the Related Art
[0004] A resistance film type touch panel which is used by being placed on a display such as an LCD, a PDP, or a CRT is known. This type touch panel includes a pair of panels, each having a transparent conductive film adhered on a transparent board, which are arranged via electrically insulating spacers so that the conductive films are opposed to each other. Circuits are connected to electrodes which are formed on each of the conductive films, and thereby coordinates can be detected by pushing one of the boards by a pen or finger to allow conduction between the upper and lower panels.
[0005] The touch panel has being used in large quantities in many fields with the development of electronic equipment and, accordingly, a touch panel capable of being produced more simply and having more durability is strongly required.
[0006] For example, for the upper panel and the lower panel of the two transparent panels, a film and a glass, a film and a plastic panel, a film and a film, or the like have been used and, for the conductive film, ITO (indium oxide/tin oxide) or tin oxide (SnO 2 ) is used. However, the conductive film adhered on the board is required to be divided into a desired pattern, and hence prior art touch panels have been formed by eliminating unnecessary portions by etching after adhering a conductive material on the entire surface of the board by sputtering, etc.
[0007] For the etching, photolithography methods and sandblast methods have been used. The photolithography methods are classified into, according to etching material, wet methods using a liquid such as aqua regia or hydrochloric acid, and dry methods using a gas such as hydrofluoric acid (HF) or iodinefluoric acid (HI). The wet method requires many processes such as photosensitive resin coating, drying, exposure development by photomasking, and drying, and requires a significant capital investment for liquid control and waste liquid treatment because dangerous liquid such as aqua regia and hydrochloric acid are used. The dry method also requires a significant capital investment for measures against gas leaks, treatment of exhaust gases, etc. because dangerous gases such as hydrofluoric acid and iodinefluoric acid are used.
[0008] In addition, there is a method of eliminating unnecessary parts by sandblasting. This method has problems in that much process time is required, many man-hours for management are required due to necessity of frequent exchange of the mask covering the necessary parts, and the strength is reduced due to damage to the board. For this reason, a touch panel having a conductive film divided by a simple operation and entailing a small facility cost is strongly required.
[0009] An upper panel and a lower panel of the touch panel can be adhered to each other via a double-faced tape at their perimeters, but they are sometimes damaged by the edge of the double-faced tape when the panel surface is pushed. For this reason, a durable touch panel which does not suffer such damage is required.
[0010] In addition, an optical material is often adhered on the surface of the touch panel via an adhesive layer, but these are sometimes peeled off from each other for adhering them again when foreign materials or bubbles enter therebetween during the adhering work. The touch panel and/or the optical material are sometimes damaged, so that they cannot be used again. For this reason, a touch panel having an optical material so adhered thereto that they can be used again after peeling them off from each other.
SUMMARY OF THE INVENTION
[0011] It is a main object of the present invention to provide a touch panel wherein a conductive film adhered on a board is divided in a simple manner.
[0012] It is another object of the present invention to provide a touch panel wherein a conductive film is not damaged by a double-faced tape.
[0013] It is another object of the present invention to provide a touch panel wherein an optical material is adhered thereto so that they can be used again after peeling them off from each other.
[0014] According to one aspect of the present invention, there is provided a touch panel including a pair of panels, each having a transparent conductive film adhered on a transparent board, which are arranged via electrically insulating spacers so that the conductive films are opposed to each other, characterized in that the conductive film is divided into a plurality of regions of desired form with the channels formed by laser etching.
[0015] Preferably, a plurality of electrode circuits connected to different external conductive wires are provided on the conductive film, and boundary lines are formed with narrow channels so that a plurality of said electrode circuits are not short-circuited.
[0016] Preferably, the conductive film is divided into at least the same number of regions as the electrode circuits.
[0017] Preferably, closed channels are formed along the periphery so that regions having the electrode circuits are not exposed to the side edge, and thereby short-circuits at the side edge are prevented.
[0018] Preferably, wherein the diameter of the laser spot for the etching is 0.1 mm to 2.0 mm.
[0019] Preferably, the wavelength of the laser light for the etching is 900 nm or more and is in the infrared ray region.
[0020] Preferably, the pulse width of the laser light for the etching is 1 ns or less.
[0021] Preferably, a pair of panels are joined at their perimeters via a double-faced tape, and a conductive film damage preventing element, made of an elastic material, to prevent damage, by the edge of the double-faced tape, to the conductive film of the moving-side panel which receives input pressure, is attached to the board of the moving-side panel or the double-faced tape,
[0022] or further an insulating layer extending to the inside of the edge of the double-faced tape is arranged between the fixed-side panel opposed to the moving-side panel and the double-faced tape, and the conductive film damage preventing element extends to the inside of the edge of the insulation layer.
[0023] or further the elastic material is rubber resin.
[0024] Preferably, an optical material is adhered, via a reusable adhesive layer, on the surface having no conductive film of one or both of a pair of panels, and 90-degree peel off power of the reusable adhesive layer to the board surface is 5 g to 500 g/25 mm,
[0025] or further, the main component of the re-usable adhesive layer is any of an ethylene-vinyl alcohol adhesive, a polyacrylester adhesive, a polymethacrylester adhesive or a silicon adhesive,
[0026] or further, the optical device is any of a polarization board, a circular-polarization board or a phase difference board.
[0027] According to one aspect of the present invention, there is provided a touch panel including a pair of panels, each having a transparent conductive film adhered on a transparent board, which are arranged via electrically insulating spacers so that the conductive films are opposed to each other, characterized in that a pair of panels are joined at their perimeters via a double-faced tape, and a conductive film damage preventing element made of elastic material to prevent damage, by the edge of the double-faced tape, to the conductive film of the moving-side panel which receive input pressure, is mounted on the board of the moving-side panel or the double-faced tape.
[0028] Preferably, a insulation layer extending to the inside of the edge of the double-faced tape is arranged between the fixed-side panel opposed to the moving-side panel and the double-faced tape, and the conductive film damage preventing element extends to the inside of the edge of the insulation layer.
[0029] Preferably, the elastic material is rubber resin.
[0030] According to one aspect of the present invention, there is provided a touch panel including a pair of panels, each having a transparent conductive film adhered on a transparent board, which are arranged via electrically insulating spacers so that the conductive films are opposed to each other, characterized in that an optical material is adhered with a re-usable adhesive layer, on the surface having no conductive film of one or both of a pair of panels, and 90-degree peel off power of the re-usable adhesive layer to the board surface is 5 g to 500 g/25 mm.
[0031] Preferably, the main component of the re-usable adhesive layer is any of an ethylene-vinyl alcohol adhesive, a polyacrylester adhesive, a polymethacrylester adhesive or a silicon adhesive.
[0032] Preferably, the optical device is any of a polarization board, a circular-polarization board or a phase difference board.
[0033] The present invention may be more fully understood from the description of preferred embodiments of the invention set forth below, together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] [0034]FIG. 1 is a drawing showing the fixing-side panel of the first embodiment of the invention.
[0035] [0035]FIG. 2 is a drawing showing the moving-side panel of the first embodiment of the invention.
[0036] [0036]FIG. 3 is a drawing showing the double-faced tape placed between the fixing-side panel and the moving-side panel of the first embodiment of the invention.
[0037] [0037]FIG. 4 is A-A section view showing that the fixing-side panel shown in FIG. 1 and the moving-side panel are joined via a double-faced tape, in the first embodiment of the invention.
[0038] [0038]FIG. 5 is a drawing showing the region to be eliminated on the conductive film of the fixing-side panel for a prior art touch panel.
[0039] [0039]FIG. 6 is A′-A′ section view showing that the fixing-side panel wherein the conductive film, eliminated as shown in FIG. 5, is joined to the moving-side panel via a double-faced tape.
[0040] [0040]FIG. 7 is a drawing showing the fixing-side panel in the first variation of the first embodiment.
[0041] [0041]FIG. 8 is A″-A″ section view showing that the fixing-side panel, shown in FIG. 7, is joined to the moving-side panel via a double-faced tape.
[0042] [0042]FIG. 9 is a drawing showing an advantage of the second embodiment.
[0043] [0043]FIG. 10 is a drawing showing an advantage of the first variation of the second embodiment.
[0044] [0044]FIG. 11 is a drawing showing an advantage of the second variation of the second embodiment.
[0045] [0045]FIG. 12 is a drawing showing an advantage of the third variation of the second embodiment.
[0046] [0046]FIG. 13 is a drawing showing the third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Referring to the drawings, preferred embodiments of the present invention are described below.
[0048] In the following descriptions, the moving-side panel is the board far from the display to be pushed with a pen or finger, and the fixing-side panel is the board near the display, and “front” means “input side”, and “back” means “display side”.
[0049] [0049]FIG. 1 shows a front view of a fixing-side panel 100 for a touch panel of the present invention. The fixing-side panel 100 is formed in the manner that a ITO conductive film 120 (refer to FIG. 4) is attached to the front face of a glass board 110 (refer to FIG. 4) by sputtering, then channels 131 , 132 , 133 , 134 , and 135 (shown with thick solid lines) are formed by laser etching, and after that dot spacers 140 are added by screen-printing, and the silver electrode circuits 151 , 152 , 153 , 155 , 156 , and 156 are added by printing. The channels 131 to 135 are so formed that the region of the conductive film 120 connecting the electrode circuits 151 , 152 , 153 , 154 , 155 , and 156 is divided as desired.
[0050] [0050]FIG. 2 is a front view of a moving-side panel which is formed in the manner that a ITO conductive film 220 (refer to FIG. 4) is attached to the back face of a transparent resin film board 210 (refer to FIG. 4) by sputtering, then the silver electrode circuits 251 and 252 are added by printing.
[0051] [0051]FIG. 3 is a front view of a double-faced tape 300 which is placed between the fixing-side panel 100 and the moving-side panel 200 , and joins the fixing-side panel 100 and the moving-side panel. The fixing-side panel 100 and the moving-side panel 200 shown in FIGS. 1 and 2 respectively are joined via this double-faced tape 300 . Symbols 301 and 302 indicate holes to which conductive adhesive is attached, which allows conductivity between the electrode circuit 156 on the fixing-side panel 100 and the electrode circuit 252 on the moving-side panel 200 , and conductivity between the electrode circuits 152 , 153 on the fixing-side panel and the electrode circuit 252 on the moving-side panel 200 .
[0052] [0052]FIG. 4 is a A-A section view showing that the fixing-side panel 100 in FIG. 1 and the moving-side panel are joined via the double-faced tape 300 . The double-faced tape is a thin film both faces of which are coated with adhesive, not shown. The electrode circuits 152 and 153 sunk in the soft adhesive.
[0053] In the first embodiment of the invention, the fixing-side panel 100 is formed as stated above, and the conductive film 120 of the fixing-side panel 100 is divided by the channels 131 to 135 formed by a laser, and thereby the touch panel of the first embodiment may be produced in a very short time and simply, and the facility cost for dividing the conductive film is significant low compared to the prior art touch panel produced with a photolithography method because one set of laser devices is enough for this purpose. In addition, the touch panel of the first embodiment may be produced safely because a dangerous liquid or gas is not used, and thereby no man-hours or facility is required for the control and treatment of a dangerous liquid or gas.
[0054] In the photolithography method, a photolithographic mask is utilized, and it is necessary to prepare a different photolithographic mask after a modification of division pattern. In the present invention using a laser, the modification of a division pattern requires only modification of the software to control the laser movement, and may be carried out in short time without requiring many man-hours.
[0055] In the prior art touch panel, it is not possible to remove the conductive film finely, and thereby it is necessary to remove the conductive film widely as shown in a hatch pattern by dashed lines in FIG. 5, and the fixing-side panel 100 and the moving-side panel 200 are consequently joined as shown in FIG. 6.
[0056] For the etching in this embodiment, a YAG laser is used, but a YLF laser, a YVO laser, a CO2 laser, or another laser may also be used. For the laser light, the preferable wave length is 900 nm or more in the infrared ray region, and the preferable pulse width is less than 1 ns, so as not to leave a heat-metamorphic layer in the conductive film. A preferable laser spot diameter is 0.1 mm to 2.0 mm, because a larger spot diameter may form the conductive film 120 more securely but a laser of too large a spot diameter may not allow sharp etching due to energy distribution.
[0057] To the fixing-side panel 100 of the touch panel completed as above, a power receiving connector (not shown) is fitted at a position shown by mark B in FIG. 1, and voltages of 0 volt, 5 volt, 0 volt, and 5 volt, for example, are applied to the electrode circuits 153 , 154 , 155 , and 156 respectively. when the front face of the moving-side panel 200 is pushed, the resistance is measured via the electrodes, and coordinates are detected and input to the control device (not shown) as input information. An explanation of the control device is omitted since it has no relation to the present invention.
[0058] A variation of the first embodiment is described below. The variation is so configured that the conductive film 120 of the fixing-side panel 100 and the conductive film 220 of the moving-side panel 200 are not shorted at their ends via foreign materials adhered at their ends so as to bridge the conductive film 120 and the conductive film 220 which are extend to the end of the perimeter.
[0059] [0059]FIG. 7 is a drawing showing the fixing-side panel 100 of the variation of the first embodiment. A channel 136 close to the perimeter is added to the fixing-side panel of the first embodiment. FIG. 8 is a A″-A″ section view of the touch panel shown in FIG. 7. In this touch panel, there is no conductivity between the region including the edge and the region in which power circuits are arranged, and thereby short circuits, as aforementioned, will not arise.
[0060] Up to this point, it has been stated that channels made by laser etching are formed on the conductive film 120 adhered on the glass board 110 of the fixing-side panel. Channels made by laser etching may also be formed on a board formed from a film as the board 210 of the moving-side panel.
[0061] The second embodiment is described below. The touch panel of the second embodiment is so configured that the conductive film 220 of the moving-side panel 200 is not damaged by the double-faced tape 300 . Since the adhesive of the double-faced tape 300 is soft, what damages the moving-side panel is the film (not shown) onto which adhesive is coated.
[0062] [0062]FIG. 9 is a drawing showing an advantage of the second embodiment. A rubber elastic device 500 is attached to the moving-side panel 200 so as to cover the area of the moving-side panel 200 with which an edge of the double-faced tape contacts. Thereby, it may be prevented that the edge of the double-faced tape 300 contacts the conductive film 220 of the moving-side panel 200 and that the conductive film is damaged.
[0063] [0063]FIG. 10 is a drawing showing the first variation of the second embodiment, wherein a insulation layer 400 is provided between the fixing-side panel 100 and the double-faced tape 300 , and the elastic device 500 extends inside, and thereby it may be prevented that the edge of the insulation layer 400 contacts the conductive film 220 of the moving-side panel.
[0064] [0064]FIG. 11 is a drawing showing a second variation of the second embodiment, wherein a elastic device 500 is not fitted on the moving-side panel 200 but is fitted on the double-faced tape 300 . FIG. 12 is a drawing showing the third variation of the second embodiment, wherein the insulation layer 400 is provided and a elastic device 500 is fitted on the double-faced tape 300 . As described above, the elasticity device not attached on the moving-side panel 200 but attached on the double-faced tape 300 may also prevent damage to the conductive film 220 .
[0065] In the second embodiment and its variations, the conductive film is divided by the channels formed by laser etching as the first embodiment. However, since the advantage of the second embodiment is its configuration as mentioned above, it is understood easily that the second embodiment is not limited to case that the conductive film is divided by laser etching as the first embodiment, but may also be applied to the case that the conductive film is divided by the method such as a photolithography method and a sandblast method as in the prior art touch panel.
[0066] Before descriptions of the third embodiment, the background is explained in detail.
[0067] In order to prevent reflection at the surface of a touch panel and improve visibility of the touch panel, an optical device such as a polarization board, a phase difference board, and a circular polarization board is often adhered on the front face of a moving-side panel 200 or the back face of a fixing-side panel 100 . During this adhering work, foreign materials or bubbles may enter, and in such a case the optical device is sometimes removed to repeat the adhering work. If adhesive power of the adhesive layer is inadequate, residue may be present on the surface of the optical device, the moving-side panel 200 , or the fixing-side panel 100 , and thereby the optical device, the moving-side panel 200 , or the fixing-side panel 100 may be damaged when removing the optical device, which may not allow the reuse and result in a low yield.
[0068] The third embodiment of the present invention provides solutions to such problems, wherein the adhesive layer is a re-exfoliative adhesive layer having adequate adhesive power which may not cause the problems described above.
[0069] [0069]FIG. 13 is a section view of a touch panel of the third embodiment, wherein an optical device 700 a consisting of a quarter wave length board 710 and a polarization board 720 is adhered on the front face of the moving-side panel 200 via a re-exfoliative adhesive layer 600 a , and an optical device 700 b comprising a quarter wave length board 710 is adhered on the back face of a fixing-side panel via a re-exfoliative adhesive layer 600 b.
[0070] The adhesive layer 600 a has 90-degree exfoliation adhesive power of 5 g to 500 g/25 mm to a resin film board 210 of the moving-side panel 200 . The adhesive layer 600 b has 90-degree peel off power of 5 g to 500 g 25 mm to a glass board 110 of the fixing-side panel 100 . A 90-degree peel off power of 500 g/25 mm means that the power necessary for pulling a 25 mm width tape in a direction at right angles to the adhesive face to remove it is 500 g.
[0071] It is preferable that the re-usable adhesive layer is formed by an adhesive the main component of which is any of an ethylene-vinyl alcohol adhesive, a polyacrylester adhesive, a polymethacrylester adhesive and a silicon adhesive, and that the re-usable adhesive layer has transmittance of 75% or more in the visible light region (JIS Z 8722).
[0072] The re-usable adhesive layer as mentioned above may prevent damage to the optical material 700 a , 700 b , the moving-side panel 200 and the fixing-side panel during removing work, and prevent and of the adhesive to remain, and the yield may be improved accordingly.
[0073] In the third embodiment described above, the conductive film is divided by the channels formed by laser etching as the first embodiment. However, since the advantage of the third embodiment is its configuration as mentioned above, it is understood easily that the third embodiment is not limited to a case where the conductive film is divided by laser etching as the first embodiment, but may also be applied to the case that the conductive film is divided by the method such as a photolithography method and a sandblast method as in the prior art touch panel.
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Laser etching is used to form channels which divides a conductive film adhered on a board of a touch panel into a plurality of regions of desired form. A conductive film damage preventing element is attached on the board of the moving-side panel of a pair of panels or the double-faced tape to join them at their perimeters, to prevent damage by the edge of the double-faced tape. A re-usable adhesive layer having 90-degree peel off power of 5 g to 500 g/25 mm is used to adhere optical material on a surface of the panel.
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TECHNICAL FIELD
The present invention relates to a spool type solenoid valve preferably applied for an oil controlling for an oil pressure device and the like.
BACKGROUND ART
As a conventional solenoid valve, as shown in the following Patent Document 1, there has been provided a solenoid valve wherein a retainer is inserted into a valve body, a portion which the valve body overlapped with the retainer is made as a thin wall, the retainer is fixed by caulking the thin wall portion in a radius direction.
For the solenoid valve having such constitution, the inner circumferential wall of the valve body is sometimes deformed due to the collapse of the valve main body in the radius direction because a force is applied to the radius direction when caulking the retainer. As a result, there is a case to become a cause of increasing hysteresis because smooth operation of a spool sliding to the axial direction at the inside of the valve body is inhibited, the spool will not be moving in the worst case.
Also, for the solenoid valve in the Patent Document 1, a screw cutting is performed in the valve body in order to fix the retainer and it is necessary to perform screw-driving to a predetermined position. Thus, assembling property is insufficient and further, there is a problem that a manufacturing cost becomes higher when performing a threading process because there is a large number of man-hour for producing components.
Prior Art Literatures
Patent Document
Patent Document 1: Japanese Unexamined Patent Publication No. 2000-104847
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
The present invention has been made by considering the above problems, a purpose thereof is to provide a solenoid valve which does not cause a deformation in a valve body when mounting a retainer and which can be easily assembled, and also a method for manufacturing thereof.
Means for Solving the Problem
In order to achieve the above purpose, a solenoid valve according to the present invention comprises
a valve body in which a spool is provided so as to move in an axial direction,
a solenoid portion provided at one axial end of said valve body,
a retainer provided at the other axial end of said valve body, wherein
a caulking portion provided at the axial end of the valve body is caulked from the axial direction so that the retainer is fixed.
By making such constitution, because a pressure force on caulking the retainer acts only in the axial direction (the pressure force does not act in the radius direction of the valve body), the pressure force does not act on a sliding portion of the spool of the valve body, and deformation is not achieved to the sliding portion of the spool in the valve body. Therefore, a sliding motion of the spool at the inside of the valve body is not inhibited, and the spool can be moved smoothly in the axial direction.
In the present invention, preferably, a groove for inserting a caulk receiving jig is formed near said caulking portion in the axial direction.
By making such constitution, the caulk receiving jig can be arranged to the groove when caulking the retainer. Therefore, the pressure force which acts along the axial direction can be applied to the caulk receiving jig when caulking the retainer, and the valve body is not deformed in the axial direction of the valve body. Namely, it preferably enables to prevent the valve body from deforming, and the sliding movement of the spool which is axially movably arranged at the inside of the valve body is not inhibited.
In the present invention, preferably, said retainer is comprised of a cylindrical body, a flange portion projecting to an outer radius direction is formed at one opening end of the axial direction of said cylindrical body, the caulking portion of said valve body is comprised of a caulking piece projecting from the other axial end of said valve body.
By making such constitution, it enables to caulk the flange portion as covered by the caulking pieces according to contacting the flange portion of the retainer at the inside of the radial direction of caulking pieces in the valve body. Therefore, a process for a solenoid valve assembly can be simplified and it becomes more efficient, because it is not necessary to perform a screw cutting to the valve body and the retainer can be fixed to the valve body.
Also, in order to achieve the above purpose, a method for manufacturing solenoid valve of the present invention comprises steps of,
providing a caulking portion at the axial end portion of a valve body,
forming a groove for inserting a caulk receiving jig near said caulking portion in the axial direction,
arranging a spool as axially movably at the inside of the valve body,
mounting a solenoid portion at one axial end of said valve body,
arranging said caulk receiving jig at said groove, and
mounting the retainer at the other axial end of said valve body by caulking said caulking portion from the axial direction to the retainer.
By the method for manufacturing solenoid valve having such constitution, the valve body is not deformed in the radius direction of the valve body, because a pressure force acts only in the axial direction when caulking the retainer (the pressure force does not act in the radius direction of the valve body) and also the pressure force can be produced to the caulk receiving jig when caulking the retainer. Therefore, a sliding motion of the spool which is arranged axially movably at the inside of the valve body is not inhibited.
Also, it is not necessary to perform a screw cutting to the valve body, because the retainer can be fixed to the valve body by caulking from the axial direction with the caulking portion. Therefore, the process for a solenoid valve assembly can be simplified and it becomes more efficient.
Effects of the Invention
According to the present invention, it is possible to provide a solenoid valve which is configured such that the valve body is not deformed when a retainer is mounted and which can be easily assembled, and also a method for manufacturing thereof.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a cross sectional view of a solenoid valve according to one embodiment of the present invention;
FIG. 2A is a main portion cross sectional view of a retainer in the solenoid valve shown in FIG. 1 before caulking;
FIG. 2B is a main portion cross sectional view of a retainer in the solenoid valve shown in FIG. 1 when caulking; and
FIG. 3 is a main portion enlarged view of FIG. 2B .
DETAILED DESCRIPTION
Hereinafter, the present invention will be explained on the basis of embodiments shown in drawings. FIG. 1 is a cross sectional view of a solenoid valve according to one embodiment of the present invention, FIG. 2A is a main portion cross sectional view of a retainer in the solenoid valve shown in FIG. 1 before caulking, FIG. 2B is a main portion cross sectional view of a retainer in the solenoid valve shown in FIG. 1 when caulking, FIG. 3 is a main portion enlarged view of FIG. 2B .
As shown in FIG. 1 , a solenoid valve 10 according to an embodiment of the present invention is a spool type solenoid valve to control an oil pressure of, for example, an automatic transmission of vehicle.
The solenoid valve 10 comprises a solenoid portion (linear solenoid) 20 as an electromagnetic drive portion, a valve body 40 as a valve portion and a retainer 45 . The solenoid portion 20 is mounted at one end along the axial direction Z of the valve body 40 , and the retainer 45 is mounted at the other end along the axial direction Z of the valve body 40 .
The solenoid portion 20 comprises a rod 24 , a plunger 23 and a coil 22 at the inside of a case 21 .
The case 21 is configured with a cylindrical body having a bottom, and the rod 24 is arranged at roughly at center of the case 21 along the axial direction Z. The rod 24 contacts with a spool 60 at one end of the axial direction Z, the spool 60 is arranged at the inside of the valve body 40 .
The plunger 23 which is integrally movable with the rod 24 , is arranged at an outer circumferential surface of the rod 24 . Also, the coil 22 is arranged at an outer circumferential side of the plunger 23 , and the coil 22 generates a magnetic field in a desired direction with a desired strength according to a controlling current provided from a control circuit (not shown). Although a material of the case 21 is not particularly limited, it is manufactured by using a magnetic material, for example, SPCC, SPCE, SUY and the like.
The valve body 40 comprises a spring 42 and the spool 60 at the inside of a valve sleeve 41 .
The valve sleeve 41 is configured with a cylindrical body, the spring 42 and the spool 60 are arranged at roughly at center of the valve sleeve 41 along the axial direction Z. The spool 60 contacts with the spring 42 at one end of the axial direction Z, and contacts with the rod 24 at the other end of the axial direction Z.
As openings penetrating a circumferential wall of the valve sleeve 41 , an inlet port 51 , an outlet port 52 , a feedback port 53 and a first drain port 54 are formed on the valve sleeve 41 . Note that, the inlet port 51 , the outlet port 52 , the feedback port 53 and the first drain port 54 are formed as a plural respectively, toward a circumferential direction.
The inlet port 51 is a port to which a controlling fluid (for example, hydraulic oil) provided by a pump from a tank which are not shown.
The outlet port 52 is a port supplying a fluid which is controlled by a desired pressure to a requested fluid portion (load) of an automatic converter which is not shown.
The outlet port 52 and the feedback port 53 are communicating through at an external portion of the solenoid valve 10 , and some part of the controlling fluid flown from the outlet port 52 flows into the feedback port 53 .
The first drain port 54 is a port which outlets the controlling fluid at the outlet port 52 side to a drain.
The spring 42 is mounted between the spool 60 and an inner circumferential surface of a retainer 45 which is mentioned below along the axial direction Z, and presses the spool 60 in the axial direction Z.
The spool 60 is movably arranged at roughly at center of the valve sleeve 41 along the axial direction Z, and is constituted by a spool axis 61 and a first to third lands 63 to 65 which are formed as cylindrically.
The first to third lands 63 to 65 are formed integrally with the spool axis 61 from an end portion of the spring 42 side of the spool 60 along the axial direction Z with predetermined spaces sequentially.
Outer diameters of the first to third lands 63 to 65 are larger than an outer diameter of the spool axis 61 . Also, although the outer diameters of the fist land 63 and the second land 64 are about the same, the outer diameter of the third land 65 is smaller compared to the outer diameters of the first land 63 and the second land 64 .
A feedback chamber 67 is formed between the second land 64 and the third land 65 at the inside of the valve sleeve 41 . Because there is an outer diameter difference between the second land 64 and the third land 65 , the areas to which the controlling fluid fed back by the feedback chamber 67 that acting to the spool 60 are different. As a result, a desired output pressure Pc can be obtained by a balance of three forces which are a feedback force generated by the difference of the area (outer diameter difference between the land 64 and the land 65 ), a spring force by the spring 42 and an electromagnetic force which changes by the volume of current. For example, in case the controlling valve is the type that an output pressure decreases as an electric current supplied to the solenoid portion 20 is increased, the balance of three forces can be shown by the following formula (1);
[spring force]=[output pressure(=feedback force generated at outer diameter difference of lands)]+[electromagnetic force] (1).
Also, in case the controlling valve is the type that an output pressure increases as an electric current supplied to the solenoid portion 20 is decreased, the balance of three forces can be shown by the following formula (2);
[spring force]+[output pressure(=feedback force generated at outer diameter difference of lands)]=[electromagnetic force] (2).
Along the axial direction Z, one end of the spool 60 contacts with the spring 42 and the other end of the spool 60 contacts with the rod 24 . As a result, as well as a pressure force of the controlling fluid in the feedback chamber 67 (feedback force), a pressure force of the spring 42 (spring force) and a pressure force (electromagnetic force) by the movement of the plunger 23 via the rod 24 are transmitted to the spool 60 . The spool 60 slides at the inside of the valve sleeve 41 in the axial direction Z by these pressure forces.
In the solenoid valve 10 having such constitution, the spool 60 rests at a position where a pressure force (spring force) generated by the spring 42 , a pressure force (electromagnetic force) which the plunger 23 presses the spool 60 with a magnetic suction force of a magnetic field generated by an electric current supplied to the coil 22 and a pressure force (feedback force) generated by a pressure force of the controlling fluid in the feedback chamber 67 are balanced. Precisely, although it is balanced at a statically balanced position, it is practically controlled by opening and shutting the inlet port 51 and the first drain port 54 frequently.
A position of the spool 60 in the valve sleeve 41 is controlled by the above mentioned force, and the inlet port 51 and/or the first drain port 54 are opened and shut as desired status.
Also, the amount of the controlling fluid which flows from the inlet port 51 to the outlet port 52 is determined by an opening amount of the inlet port 51 . The opening amount of the inlet port 51 is determined by a position of the spool 60 at the inside of the valve sleeve 41 .
The amount of the controlling fluid which flows from the inlet port 51 to the outlet port 52 is increased by changing a position of the spool 60 at the inside of the valve sleeve 41 and enlarging the opening amount of the inlet port 51 . Also, the amount of the controlling fluid which flows from the inlet port 51 to the outlet port 52 is decreased by reducing the opening amount of the inlet port 51 .
Similarly, the amount of the controlling fluid which flows from the outlet port 52 to the fist drain port 54 is determined by the opening amount of the first drain port 54 . The amount of the controlling fluid which flows from the outlet port 52 to the first drain port 54 is increased by changing a position of the spool 60 at the inside of the valve sleeve 41 and enlarging the opening amount of the first drain port 54 . Also, the amount of the controlling fluid which flows from the outlet port 52 to the first drain port 54 is decreased by reducing the opening amount of the first drain port 54 .
Namely, in the solenoid valve 10 of the present embodiment, in case that the output pressure Pc (=feedback force generated by outer diameter difference of the land) is smaller than a desired pressure, the spool 60 moves to the solenoid portion 20 side along the axial direction Z to open the inlet port 51 . As a result, an inlet pressure Po is provided to the inside of the valve body 40 through the inlet port 51 . On the other hand, in case that the outlet pressure Pc is larger than a desired pressure, the spool 60 moves to the spring 42 side along the axial direction Z and the first drain port 54 is caused to open so that the pressure force Pc is emitted through the first drain port 54 .
A caulking portion 70 is formed at the end of a retainer side along the axial direction Z of the valve sleeve 41 . The caulking portion 70 comprises a caulking piece 71 which extends along the axial direction Z from the valve sleeve 41 , and a groove 72 is formed near the axial direction Z of the caulking portion 70 .
The caulking piece 71 may be formed on the whole circumference along a circumferential direction of the valve sleeve 41 , or may be formed as intermittently at predetermined spaces along the circumferential direction of the valve sleeve 41 . Also, it may be formed as intermittently at irregularly spaces along the circumferential direction of the valve sleeve 41 .
The groove 72 may be formed on the whole circumference along the circumferential direction of the valve sleeve 41 , or may be formed at predetermined spaces along the circumferential direction of the valve sleeve 41 . Also, it may be formed as intermittently at irregularly spaces along the circumferential direction of the valve sleeve 41 .
As shown in FIG. 2A , although a width W 1 along the axial direction Z of the caulking piece 71 is not particularly limited, 0.5 to 3.0 mm is preferable and 1.5 to 2.0 mm is further preferable.
Also, a width W 2 of the axial direction Z from the groove 72 to the caulking piece 71 is preferably 0.5 mm or more, and 1.0 to 4.0 mm is particularly preferable.
Also, a width W 3 along the axial direction Z of the groove 72 is preferably 1.5 mm or more, and 2.0 to 3.0 mm is particularly preferable.
Also, for a depth D 1 along the inside of a radius direction of the groove 72 from the outer diameter of the caulking piece 71 , a depth which is available to receive a pressure force certainly that acts only in the axial direction Z when calking the retainer 45 is preferable, and 1.0 to 3.0 mm is particularly preferable.
Also, a width W 4 of the axial direction Z from the groove 72 to the first drain port 54 is not particularly limited.
Although a material of the valve sleeve 41 is not particularly limited, it is manufactured by using, for example, aluminum and the like.
The retainer 45 is configured with a cylindrical body having a bottom, a flange portion 45 F which projects to the outside of a radius direction is formed at one opening end along the axial direction Z of the cylindrical body. Also, a second drain port 55 is formed at the other end portion (bottom portion) along the axial direction Z of the cylindrical body. The spring 42 is mounted between the other end portion (bottom portion) along the axial direction Z of the cylindrical body and the spool 60 , and the spring 42 presses the spool 60 .
The flange portion 45 F may be formed on the whole circumference along the circumferential direction of the retainer 45 , or may be formed at predetermined spaces along the circumferential direction of the retainer 45 . Also, it may be formed as intermittently at irregularly spaces along the circumferential direction of the retainer 45 .
Although a material of the retainer 45 is not particularly limited, it is manufactured by using, for example, iron and the like.
As shown in FIG. 2B , when caulking the retainer 45 , the flange portion 45 F is caused to contact with the inner side of the radius direction of the caulking piece 71 . After this, a caulk receiving jig 76 is arranged to the groove 72 , and the flange portion 45 F is caulked to be covered by the caulking piece 71 by applying a force from the axial direction Z to the caulking piece 71 with use of caulking tool 75 so that the retainer 45 is fixed to the valve sleeve 41 .
The calking tool 75 is configured with a cylindrical body having a bottom, a tapered surface 77 is formed at the inside of the radius direction of one opening end along the axial direction Z of the cylindrical body. The retainer 45 is fitted to the inner surface 78 of a cylindrical body of the caulking tool 75 , and the caulking piece 71 is bent to the inner side of the radius direction along the tapered surface 77 by pressing the caulking tool 75 to the axial direction Z so that the caulking piece 71 contacts with the tapered surface 77 . Deformation of the valve sleeve 41 is prevented, because a pressing force of the caulking tool 75 is received effectively by the caulk receiving jig 76 .
Also, as shown in FIG. 3 , the pressing force of the caulking tool 75 acts to a position where the flange portion 45 F contacts to the caulking piece 71 . In order for receiving the pressing force effectively, it is preferable to make the depth D 1 along the inside of the radius direction of the groove 72 deeper than the position where the flange portion 45 F contacts with the caulking piece 71 .
In the solenoid valve 10 configured like this, the coil 22 generates a magnetic field having desired strength and desired direction by being supplied an electric current from a controlling circuit which is not shown in the drawings to the coil 22 of the solenoid portion 20 , and the plunger 23 is moved by the magnetic suction force of the magnetic field.
The spool 60 moves to the spring 42 side in the valve sleeve 41 of the valve body 40 by increasing the amount of the electric current supplied to the coil 22 and making a large magnetic suction force acts on the plunger 23 .
When the spool 60 moves to the spring 42 side in the valve sleeve 41 , the inlet port 51 closes and the first drain port 54 is caused to open. Therefore, the controlling fluid does not flow from the inlet port 51 to the outlet port 52 , and the controlling fluid flows from the outlet port 52 to the first drain port 54 . As a result, the pressure force Pc of the controlling fluid flown out from the outlet port 52 is decreased.
On the other hand, the spool 60 moves to the solenoid portion 20 side in the valve sleeve 41 by reducing the amount of the electric current supplied to the coil 22 and making the magnetic suction force which acts to the plunger 23 decreases.
When the spool 60 moves to the solenoid portion 20 side in the valve sleeve 41 , the first drain port 54 closes and the inlet port 51 is caused to open. Accordingly, the controlling fluid flows from the inlet port 51 to the outlet port 52 , and the controlling fluid does not flow from the outlet port 52 to the first drain port 54 . As a result, the pressure force Pc of the controlling fluid flown out from the outlet port 52 is increased.
Namely, in the solenoid valve 10 of the present embodiment, the pressure force Pc of the controlling fluid which is output from the outlet port 52 decreases as the electric current supplied to the coil 22 is increased, and the pressure force Pc of the controlling fluid which is output from the outlet port 52 increases as the electric current supplied to the coil 22 is decreased.
In the solenoid valve 10 having such constitution, by controlling the electric value supplied to the coil 22 , the pressure force of the controlling fluid flown out from the outlet port 52 is controlled according to the adjustment of the pressing force of the solenoid portion 20 to the spool 60 and the adjustment of a valve open-shut of the valve body 40 .
Note that, the present invention is not limited to the above mentioned embodiment, it can be modified variously within the scope of the present invention. For example, arrangement for the inlet port 51 , the outlet port 52 , the feedback port 53 and the first drain port 54 in the valve body 40 are not limited to the example shown in FIG. 1 , it may be a solenoid valve wherein the outlet port 52 and the feedback port 53 are changed.
In the solenoid valve having such constitution, a relation of the electric current supplied to the coil of the solenoid portion and a pressure force of the controlling fluid becomes opposite to the above mentioned solenoid valve 10 . Namely, in this solenoid valve, the pressure force Pc of the controlling fluid which is output from the outlet port increases as the electric current supplied to the coil 22 is increased, and the pressure force Pc of the controlling fluid which is output from the outlet port decreases as the electric current supplied to the coil is decreased. Briefly, the solenoid valve is different from the solenoid valve 10 shown in FIG. 1 and has an opposite characteristic.
Also, in the above mentioned embodiment, the retainer 45 is caulked after arranging the caulk receiving jig 76 to the groove 72 , however, the retainer 45 may be caulked without arranging the caulk receiving jig 76 to the groove 72 .
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Provided are a solenoid valve which is configured such that the valve body is not deformed when a retainer is mounted and which can be easily assembled, and a method of manufacturing the solenoid valve. A solenoid valve is provided with a valve body inside which a spool is provided so as to move in an axial direction, a solenoid section which is mounted to one end of the valve body in the axial direction thereof, and a retainer which is mounted to the other end of the valve body in the axial direction thereof. The retainer is fixed by a staking section which is provided to an end of the valve body in the axial direction thereof and staked in the axial direction.
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BACKGROUND OF THE INVENTION
This invention relates to elevator controls and, in particular, to the car and hall call buttons activated for requesting elevator service.
The contactless touch button, consisting of a cold cathode gas tube, is a popular and widely used type of button, particularly because it has no moving parts. It is the subject of U.S. Pat. Nos. 2,525,767, 2,525,768 and 2,525,769. The button is activated in response to the capacitance between a metallic coating on the cold cathode tube and the user's finger. In installations using this button, a D.C. voltage is applied across the anode and cathode while, at the same time, it is floated on an A.C. voltage to enhance the capacitive coupling response needed to fire the tube. Typically, the D.C. voltage is about 135 volts and the A.C. float voltage is about 200 volts r.m.s. When activated, the tube conducts a D.C. current, which is used to generate a signal to activate the elevator controls located in a remote control room, while at the same time, it glows to provide a visual indication of a service request.
When the requested elevator service is supplied, an A.C. signal is transmitted to the button and where it is used to bias the tube into its nonconductive state. The tube thereupon ceases to glow, indicating that the requested service has been supplied.
Power for the tube is derived from the control room and is carried over three conductors. One conductor carries the positive D.C. voltage; a second provides a D.C. return and the third carries the reset signal and the D.C. control signal. In installations having several call buttons on a floor or in a car, known as multiriser systems, the buttons are connected in parallel so that activation of one button will activate the others.
In certain applications there is a need, however, to replace the touch type button with a mechanical type. It is desired, however, that the replacement use the existing wiring and, naturally, require little if any modification to the power supplies in the control room. This "retrofit" unit also needs to provide a visual indication of a request and also have about the same performance characteristics as the gas tube unit.
There are two particularly important constraints imposed upon the retrofit unit. First, it should generate essentially the same D.C. control signal, when activated, and respond to the same type of reset signal, so that modifications are not necessary to the control circuitry. Second, it should be usable in the multiriser systems, and provide the same performance in those installations.
SUMMARY OF THE INVENTION
Thus an object of the present invention is to provide a retrofit elevator control button having the same performance characteristics as the cold gas tube type button.
A related object is to provide a retrofit, mechanical type button which requires little if any modification to the existing circuitry and power systems, and, in particular, which is compatible with the existing reset and control signals.
In accordance with the present invention, a mechanical switch is connected to the existing D.C. power supply lines and is activated to provide a momentary pulse to a solid-state switch which is then placed in a high conductance state. The solid-state switch includes an output transistor which is coupled to the existing positive voltage and driven into saturation. The transistor provides connection to the existing reset and signal line and when driven into saturation applies substantially the same D.C. control signal to the reset line as the gas tube. The output transistor, thus, essentially duplicates the active state condition of the replaced gas tube. The D.C. signal on the reset and signal line is used to activate a solid-state latch unit which provides a signal to the switch input causing it to latch in this activated state. Once activated, the output transistor in the solid-state switch applies substantially the supply D.C. voltage to at least one neon indicator light, causing it to glow.
A reset signal, which consists of half wave rectified pulses, is applied to the reset-signal line. A capacitor is coupled to the input of the solid-state switch, and charges to substantially the peak level of the pulses causing the switch to deactivate. Due to its polarity, the reset signal tends to maintain the latch unit in a condition supplying an input signal to the solid-state switch that would hold the switch in the activated state, after each pulse. The capacitor prevents this, however, by maintaining the deactivating voltage on the switch input until the latch also goes off when the pulse drops below the voltage needed to turn it on.
DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of a multiriser elevator button control, showing the connection of three buttons to the existing control room over the existing lines;
FIG. 2 is a simplified schematic diagram of the control room circuitry;
FIG. 3 is a block diagram of a button embracing the present invention;
FIG. 4 is a schematic of the button circuit of FIG. 3;
FIG. 5 is a common time base diagram of the waveforms for the output pulse from the mechanical switch in the button; the resulting input voltage that activates the solid-state switch and the corresponding ON-OFF states for the transistors in the mechanical and solid-state switches;
FIG. 6 is a common time base diagram of the waveforms for the reset signal, and the input voltage to the solid-state switch, and a plot of the activation states for the latch and solid-state switch.
DETAILED DESCRIPTION
FIG. 1 is a block diagram of a three-riser installation. Three buttons 10, 12, 14 are connected to the control room 16 over a V+ line 18, an R/S line 20 and an R line 22. The three buttons 10, 12, 14 are identical and each can be seen to include a switch 23 and an indicator 24. The V+ line 18 provides the positive voltage supply to the switch 23 in each button; the R line 22 provides a return for the V+ line 18; and the R/S line 20 provides the signal path for the reset signal transmitted from the control room 16 and the D.C. signal produced when any one of the buttons is activated upon a service or call request.
The V+ line 18, R/S line 20, R line 22 and the control room 16 represent the preexisting elevator equipment associated with the replaced gas tube button. The buttons 10, 12, 14 connect directly to lines 18, 20 and 22.
FIG. 2 is a comparatively simplified schematic diagram of the power supply for the buttons contained in the control room 16. A transformer T1 is powered from an A.C. source 25 and provides approximately 200 v.a.c. float to the D.C. power supply 26 connected to the V+ line 18 and the R line 22. This 200 volt float, as mentioned earlier, enhances operation of the gas tube type switch. The transformer T1 is tapped so as to produce a smaller A.C. voltage which is supplied to the diode D1. The switch S1, typically a suitable relay contact, provides a controlled connection between the cathode of the diode D1 and the R/S line 20 and is activated to produce the half wave reset signal of FIG. 6 transmitted over the R/S line to the buttons 10, 12, 14. The unit 44 generally depicts the control circuit connected to the R/S line which is responsive to the D.C. signal placed on the line when a service request is made. The details of the control unit 44 are not germane to an understanding of the present invention and are not described.
FIG. 3 is a block diagram button 10, which is identical to the buttons 12, 14 of FIG. 1. The V+ line 18 is connected through an optional temperature responsive fuse 27 to a switch unit 28. This switch is mechanically actuated by a caller and causes pulse generator 30 to generate a single short pulse which is supplied to the input 36 of the signal and indicator S/I unit 32. The S/I unit is connected to the V+ line 18 through the fuse 27 and when activated supplies power to the indicator 24, which as set forth below, consists of an illuminating device, such as a neon bulb. When the S/I unit 32 is activated it also produces a D.C. signal which is applied to the R/S line 20. The latch unit 34 is connected to the R/S line and in response to the D.C. signal applies a signal to the input 36 of the S/I unit 32 so as to latch it in the activated state with the indicator 24 remaining in an activated condition and the D.C. signal continuously applied to the R/S line and the latch 34.
The previously mentioned optional fuse 27 would be included in the hall buttons so that in the event of a fire, all power to the buttons would be removed thereby preventing unintended activation of the buttons, which could undesirably result in calling an elevator to a floor where a fire is present.
The half wave rectified pulses, shown in FIG. 6, are transmitted on the R/S line to reset the button. The pulses are applied to the reset unit 38 which applies an additional signal to the S/I input 36 that negates the output from the latch 34 so as to deactivate the S/I unit. This removes the D.C. signal on the R/S line 20 and simultaneously deactivates indicator 24.
In the anticipated retrofit application for existing touch type buttons, the half wave pulses are of the same polarity as the D.C. signal on the R/S line and therefore they tend to reinforce latch 34 in a condition at which it continues to apply an activating signal to input 36. That could activate the S/I unit as the output of the reset unit 38 decreases each time the reset pulses go to zero, thereby preventing deactivation of the button by the reset signal. However, as outlined in greater detail after, the reset unit holds the deactivating voltage for substantially the complete duration of at least one pulse which allows the output of the latch unit 34 to go off before a pulse goes to zero, thereby assuring that the signal indicator unit 32 is completely deactivated by the reset signal.
FIG. 4 is a schematic of the button 10. The incoming R/S line 20 is connected to the R/S terminal 19 included in the button. Similarly, the V+ line 18 is connected to the included V+ terminal 21 and the R line 22 connects to the R terminal 29. In addition, a VR terminal 39 is provided and is connected to the R line through the diode D2. The VR terminal 39 provides the D.C. voltage return from the V+ terminal 21 in the button. All circuit connections in the button to the R/S line 20, R line 22 and V+ line 18 are made to these terminals 19, 21, 29, which enables connection of the button to the existing lines by simply connecting each line to its corresponding terminal.
The switch unit 28 includes resistors R1 and R2 and a mechanical type switch S2. When switch S2 is closed, the circuit is completed from the V+ terminal 21 to the VR terminal through resistors R1 and R2, thereby producing a voltage across resistor R2. This voltage is applied to the input of pulse generator 30 through a capacitor C1 and instantaneously passes through capacitor C1 and appears across resistors R3 and R4. Capacitor C1 and resistors R3 and R4 function as a differentiator circuit in producing a pulse P1 across resistor R3 having the characteristics shown in the waveform of FIG. 5. The time duration of pulse P1 is determined by the time constant associated with capacitor C1 and resistors R3 and R4. The specific operational parameters for determining a time constant, of course, depends on the particular installation.
Pulse P1 is applied across the base of the transistor T2 which is thereby driven into an active state of conduction. The resulting collector current in transistor T2 produces a voltage drop across the resistor R6 in the S/I unit 32 that connects the base and emitter of transistor T3. This voltage drop, when exceeding at least 0.6 volts, turns transistor T3 on and its resulting collector current produces a voltage drop across the resistor R8 that connects the base and emitter of the transistor T4. The collector of the transistor T4 is connected to the V+ terminal 21. The transistor T4 is driven into near saturation by transistor T3 and, as a result, the emitter of the transistor T4 is substantially at its collector voltage, V+. The emitter of the transistor T4 is connected to the indicator unit 24, which as shown, consists of two neon lights 40. These neon lights require at least 120 volts to glow and, consequently, if the V+ terminal is about 135 volts, when transistor T4 is near saturation, at least 120 volts is applied across the lamps 40, thereby ensuring their activation.
When transistor T4 is in the conductive state, its emitter current flows through a diode D3 and a resistor R9 that connects the emitter of transistor T4 to the R/S terminal 19. A resistor R10 across the R/S and R terminals 19, 29 represents an external load in the machine room or button fixture and the emitter current flows through the resistor 10 from the R/S terminal to produce a D.C. voltage on the R/S line 19. The value of R10 determines the level of the D.C. voltage appearing on the R/S line and this D.C. voltage provides the required call signal for unit 44 in the control room (FIG. 2). This D.C. voltage, at the same time, biases a transistor T5 in latch unit 34 into conduction by establishing a suitable voltage across a resistor R12 that connects its base and emitter. The resulting current in transistor T5 flows from the V+ terminal 21 through the resistor R6. This latches transistor T3 on to hold transistor T4 in its activated near saturation state, with lamps 40 glowing and the D.C. voltage on the R/S line 19 continuously being present. This constitutes the activated state for latch 34 and S/I unit 32.
The reset unit 38 contains a storage capacitor C2 having one electrode connected to the V+ terminal and its other terminal connected to the input 36 of S/I unit 32 through a resistor R11. A diode D4 connects the R/S terminal and the input 36. Prior to activation of switch S2, capacitor C2 has substantially no voltage across it and therefore input 36 is substantially at the voltage of the V+ terminal (V+), which keeps transistor T3 off. When switch S2 is closed, however, it is necessary to bring the input 36 down to a voltage low enough so as to forward bias the emitter base junction of transistor T3 to turn it on. The specific level required, of course, depends on the particular level of the V+ terminal and the required operating parameters for the semiconductors used, although, in general, the base of transistor T3 should be at least 0.6 volts negative with respect to the emitter to assure full turn on of transistor T3. It should be noted, however, that since the voltage on capacitor C2 cannot instantly change, there will be a time lag from the time t2 is rendered conductive until input 36 drops below the level allowing transistor T3 to turn on. It is therefore necessary that the time constant associated with the differentiator in the pulse generator 30 (capacitor C1, resistors R3 and R4) be long enough so that transistor T2 remains on long enough for input 36 to drop at least 0.6 volts below V+. A table is set forth in a latter portion of this description showing the respective resistor and capacitor levels for a specific retrofit installation utilizing a 135 volt supply and neon lamps 40 in accordance with these guidelines.
As mentioned previously, when the switch S1 in control room 16 is closed (FIG. 2), the reset signal is generated on the R/S line 20. This signal is supplied from diode D1 and consists of the positive half wave pulses P2, as shown in FIG. 6. If the peak value VP of each pulse P2 is greater than the voltage level of input 36 when transistor T5 is on, then diode D4 will conduct, and, as a result, the capacitor C2 will charge towards VP at a rate determined by its time constant. If VP is at least equal to V+, D4 will conduct and when the input 36 reaches V+, transistor T3 will be turned off because its base-emitter junction will no longer be forward biased. However, to assure that the transistor is turned off, the peak level VP of the pulses should be somewhat greater than V+ so that the voltage level on capacitor C2 will produce a significant back bias upon the base-emitter junction of transistor T3.
An important aspect to be noted is that the positive reset pulses P2, although being of the polarity and magnitude which turns transistor T3 and T4 off, nonetheless are of a polarity that drives transistor T5 into further conduction, even with transistor T4 off. Consequently, capacitor C2 must hold VIN at input 36 at or above the turn off voltage of transistor T3 until transistor T5 goes completely off after the reset P2 pulse ceases at the end of the half cycle.
The diode D4 couples the reset signal to the input 36 and capacitor C2 while effectively creating an open circuit from the base of transistor T3 through the R/S line 20 and resistor R10 to the R line 22. Without it, the button would permanently latch up as soon as power is supplied on the V+ line. The diode D3 protects transistor T4 and the balance of the S/I unit 32 from the positive pulses P2 on the R/S line 19.
Referring to FIG. 1 and FIG. 4, in a multiriser system, activation of any one button 10, 12, 14 will activate the remaining buttons also connected to the same R/S line. This occurs because the D.C. voltage placed on the R/S line 20, when a button is actuated, will activate the transistor T5 in each unit and discharge the related capacitor C2, whereupon the related transistors T3 and T4 are driven into conduction and the neon lamps 40 are activated. In the multiriser system, the resistor R10 associated with each button 10, 12, 14 is in parallel with the corresponding associated resistor for the other buttons. Thus, when the one button is actuated, the current from the transistor T4 in that button flows essentially through a resistance equal to one-third of resistor R10 and, therefore, the D.C. level on the R/S line will be one-third of the required level. However, after a brief interval of time, determined essentially by the time constant of capacitor C2, the remaining buttons will become activated. Thus, with all the buttons on, the net current is three times higher which brings the voltage on the R/S line 20 up to the normal, required level. The time interval for this duration is virtually imperceptible, and of little or no significance to the operation of the elevator system. In this way, the button of the present invention performs the same as the gas tube of the prior art. Moreover, in multiriser systems, the R/S line is given identical use: it provides interconnection between corresponding buttons so that activation of any one simultaneously activates the others causing their respective indicators to be activated; and it provides a common reset linkage for related buttons.
As set forth earlier, the present invention has particular utility in a retrofit installation for the touch type gas tube elevator buttons. In these installations there is usually a 135 volt V+ supply which floats on a 200 volt A.C. supply. Referring to FIG. 2, in that instance the V+ line 18 would be at 135 volts and both the V+ line and R line 22 would float on a 200 volt A.C. level. In these installations the R/S line is usually taken off transformer T1 so as to produce a 100 volt half wave pulse on the output of diode D1. However, to assure that transistor T3 is turned off by the reset signal, transformer T1 should be tapped so pulses P2 have a peak value equal to approximately 160 volts. With the input 36 at this voltage level T3 will be heavily back biased. The following table represents the resistor and capacitor values considered important to the operation of the retrofit button in a specific installation of this type.
______________________________________C1 = .15 mmf R3 = 330 k R8 = 2.2 k R14 = 100 kC2 = .39 mmf R4 = 12 k R9 = 3.9 k R18 = 100 kR1 = 10 k R5 = 130 k R10 = 3.3 k V+ = 135 v.d.c.R2 = 560 k R6 = 4.3 k R11 = 470 P2 = 160 peak, 60 Hz.______________________________________
Utilizing these values, the time constant for the capacitor C1 is determined ostensively by the product of the value of the capacitor and the resistor R3. The resistor R4 is shunted by the transistor T2 when the transistor conducts. The resistor R1 is substantially smaller than resistor R3. Consequently, for present purposes, the resistors R1 and R4 can be discounted in the computation of the time constant, which is approximately 50 m.s.
The time constant for the capacitor C1 is determined under two distinct operating conditions. The first condition is when the capacitor is forced to a voltage less than V+ so as to turn transistor T3 on when transistor T2 is turned on by the switch S2. Under this condition, the time constant is determined essentially by the product of the value of the capacitor C2 and the combined, effective resistance of the resistor R1 plus the parallel resistance of the resistors R5 and R14. The resulting time constant under this condition is approximately 23 m.s. Under the second condition, the transistor T2 is off; the reset signal is applied to R/S line and the capacitor C2 is charged towards the peak level of the reset pulses. The capacitor C2 is charged, during this sequence, through the resistor R11 and consequently the time constant is approximately 0.2 m.s. Since the half wave pulses that comprise the reset signal occur at a frequency of 60 Hz., each pulse is approximately 8 m.s. long. Therefore the voltage on the capacitor C2 follows the pulses. After the capacitor C2 has charged to the peak level of the reset pulse, the discharge path for the capacitor is quite different and comparatively complex, since, at that time, the transistor T5 is still conductive, and remains so, until the reset pulses go substantially to zero. The discharge path is ostensively through the resistors R5, R14 and R18 and the resulting time constant, using known circuit analysis techniques, is approximately 32 m.s.
The significance of these time constants is simply to demonstrate how the capacitor C2 holds a voltage greater than V+ following the peak level of the reset pulse and thereby holds the input voltage VIN at input 36, above V+ so as to hold the transistors T3 and T4 in an off condition while the pulse goes to zero, which also turns transistor T5 off.
The time constant associated with the capacitor C1 demonstrates how the transistor T2 stays on sufficiently long to allow the voltage on the capacitor C2 to drop below the level of V+ so as to allow the VIN, at input 36, to drop below this level to turn the transistor T3 on. In particular, when the switch S2 is closed, the instantaneous voltage between the terminal 39 and the junction of capacitor C1 and resistor R3 is at least 110 volts. Since the required voltage at this junction to cause the transistor T2 to conduct is no more than 30 volts, the transistor T2 actually remains in a conductive state for more than one time constant of the capacitor C1, until this junction voltage decays to less than 30 volts. This assures that the requisite interrelation between the conductive state of the transistor T2 and the charging of the capacitor C2 is satisfied.
Referring to FIG. 5, at time t1, the switch S2 is momentarily closed, producing the pulse P1. As a result, the transistor T2 is turned on at time t1. In the manner set forth previously, the voltage VIN at input 36 drops from V+ to VIN, ON, at the time t2. At that time both of the transistors T3 and T4 are turned on. The transistor T2 remains on until the time t3. Although the time constant associated with the pulse P1 is shown to be considerably longer than the time constant associated with VIN, it is important to realize that the time constant together with the peak level of the pulse P1 assures that the transistor T2 will remain in a conductive state for a period of time greater than is needed for VIN to drop from V+ to VIN, ON. Simply having a longer time constant would not suffice if the peak level was close to the turn on voltage for transistor T2, because the pulse P1 would quickly drop below the voltage turning transistor T2 on and thereby never allow VIN to drop to VIN-ON. Likewise, even if the peak voltage of the pulse P1 is much greater than the voltage needed to turn the transistor T2 on, an extremely short time constant associated with the capacitor C1 will allow the pulse to drop below the activating level before VIN reaches VIN-ON. Thus proper operation requires consideration of both of these parameters. The foregoing selected values meet these requirements.
Referring now to FIG. 6, the reset pulse P2 is applied at time t1 and as a result the voltage VIN, at input terminal 36, shown by the dotted line, begins to rise towards VP, the peak voltage of the pulse P2. If the time constant for the capacitor C2 is sufficiently short, as it is in the case of the previously set forth values, VIN will essentially follow the pulse P2 and reach VP at time t2. Nonetheless, for purposes of waveform clarity, a longer time constant is assumed and hence VIN does not necessarily reach VP in a single pulse, but instead charges to an intermediate voltage between V+ and VP between times t1 and t2. Following time t2, the capacitor discharges at an extremely slow rate, due to the longer discharge time constant, and as a result, at time t4 VIN is still above V+. The importance of this is that following time t2, VIN is held above V+ and in particular as long as the reset pulses P2 are applied. As a result, transistors T3 and T4 are turned off and remain off following time t2. However, because the polarity of the reset pulse P2 maintains transistor T5 on, only when the reset pulse goes substantially to zero, for example between times t3 and t4 and at an after time t6, is the transistor T5 turned off. In the case of a single reset pulse P2, it can be seen that the transistors T3, T4 and T5 are off following time t3, this being a button reset condition. However in the event of successive reset pulses, it also can be seen that at time t4 the transistor T5 is again turned on even though the transistors T3 and T4 remain off, due to the holding action of the capacitor C2. However, at time t6 the transistor T5 is again turned off, in effect repeating the previous button reset condition that occurred at the time t3. Consequently, once the transistors T3 and T4 are turned off they cannot be turned on by transistor T5 but only by actuation of the switch S2.
The foregoing is a description of the preferred embodiment of the present invention. Specific component values have been set forth where deemed appropriate to an understanding of the operation of the button embracing the invention. Nevertheless, it is anticipated that there are numerous possible modifications and variations which nevertheless embrace the full scope and spirit of the invention, and therefore the claims which follow are intended to cover all such modifications and variations.
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A switch is closed to generate a short duration pulse. The pulse activates a semiconductor switch which powers an indicator lamp and generates a D.C. control signal on a single conductor. A latching unit responds to the D.C. signal on the conductor to latch the switch in the activated state. A reset signal consisting of half wave pulses is transmitted over the conductor. These pulses charge a capacitor coupled to the switch input to substantially the peak voltage of the half wave pulses, which deactivates the switch. The capacitor holds a voltage of sufficient level to maintain the switch in the deactivated state until the latch unit is deactivated when transmission of the reset signal stops.
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The present invention relates to apparatus for detection of small amounts of vapors or gases in an atmosphere of air or other gas. Specifically, the invention relates to an improvement in a drift tube type ionization sensor.
In a drift tube, vapors or gases are subjected to ionizing radiation and the resulting ions are placed in an electric field, causing the ions to migrate in a predetermined direction. The different types of ions can be separated, detected, and measured by virtue of the difference of velocity or mobility of the ions in an electric field. Ion shutters or gates are provided for segregating the ions in accordance with their drift time.
The construction of drift tubes can take several forms. In certain applications, two or more drift tubes are combined to increase selectivity and sensitivity. For example, U.S. Pat. No. 4,238,678 shows an apparatus where two drift tubes are combined in series. In one of the tubes, electric grids are provided and energized with constant potentials. The grids operate to capture lighter, higher mobility ions, while allowing a greater number of heavier, lower mobility ions to pass through. The second drift tube contains electric grids which are energized by electric potentials which are modulated. Through the application of the modulated potentials, the grids act as electric shutters, allowing packets to pass through at specified times, while blocking the passage of ions at other times.
Alternatively, the selectivity of vapors or gases can be improved by combining the features of a drift tube with that of an ionization cell, as illustrated in U.S. Pat. No. 4,119,851. The apparatus can take form in two basic configurations. In one configuration, the ionization cell operates as a pre-selector or pre-filter which eliminates or reduces the effects of the great majority of possible interfering ion species while allowing a significant fraction of the ions of interest to pass through. The drift tube then receives the selected ions and further classifies the ions on the basis of their mobility. In an alternate configuration, the drift tube is positioned upstream of the ionization cell.
The presence of particular ions in the vapor or gas is detected by appearance of an electric signal at the collector. The time separation or delay between the introduction of a packet of ions into a drift region and the detection of a signal at the collector provides the identifying information as to the ion type.
A problem encountered with the prior art drift tubes is caused by the fact that a shift occurs in the output signal with changes in atmospheric pressure. As the atmosphere pressure is decreased, the time delay between the introduction of a packet of ions into the drift region and its detection is reduced. The dependence of drift tube response on atmospheric pressure introduces ambiguity into the drift tube output signal information.
In accordance with the present invention, the high voltage electric field in the drift tube is varied as a function of atmospheric pressure. Such variation of the electric field provides good compensation for the effects produced by changes in atmospheric pressure. As a result, the identification of a particular compound at different altitudes or barometric pressures is greatly simplified.
It is therefore an object of the present invention to provide an improved drift tube with compensation for changes in atmospheric pressure. A more specific object of the present invention is to provide an ionization sensor which is capable of unambiguously identifying a particular compound under conditions of different atmospheric pressures. A further object of the present invention is to provide an improved ionization sensor capable of being operated at any altitude, with automatic compensation for variations in atmospheric pressure due to changes in altitude.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 of the drawings illustrate a preferred embodiment of the present invention;
FIG. 2 illustrates an alternate embodiment of the present invention;
FIG. 3 is a graphical representation of the changes in signals generated by cells such as shown in FIGS. 1 and 2 as a function of changes in altitude and voltage; and
FIG. 4 is a schematic diagram of a power supply whose voltage output varies with changes in atmospheric pressure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawing, a preferred embodiment of the present invention is shown having a housing 10 constructed of non-conductive material, such as Teflon or constructed of a conductive material, such as aluminum, lined or coated with a non-conductive material. Mounted within housing 10, at a first end, is a radiation emitting source 14, which consists of a metal screen to which is affixed a radiation emitting foil. The gas sample to be detected is received from the direction shown by arrow 17. A conductive plate 20, having a central opening 21, separates radiation source 14 from a drift region 30. The other end of drift region 30 (the downstream end) is defined by a region 35 wherein the sample gas stream combines with the flow of clean air or gas from the direction indicated by arrow 18.
A plurality of conductive rings 22, 23, 24, 25, and 26 are mounted within drift region 30 and are connected to an electric potential source 45 via a voltage divider network 40. Electric potential source 45, in conjunction with voltage divider network 40, establishes a linear electric field between plate 20 at the upstream end and conductive ring 26 at the downstream end of drift region 30. The intensity of the linear electric field is varied as a function of atmospheric pressure to compensate for the effects produced in the output signal due to pressure change. Electric potential source 45 is a pressure controlled high voltage power supply, such as shown in FIG. 4.
An electrically conductive grid 31 is positioned in a plane normal to the gas flow between guard rings 22 and 23 near the upstream end of drift region 30. Grid 31 is comprised of a plurality of electric conductors, the alternate of which are connected to each other such that a different voltage can be applied to alternate conductors in each grid at terminals 31a and 31b, respectively.
A second drift region identified with numeral 50 is located downstream from drift region 30. In drift region 50, electrically conductive guard rings 51, 52, 53, 54, and 55 are mounted about the periphery of the drift region in the manner shown. A collector electrode 70 is mounted in a plane perpendicular to the direction of gas flow at the downstream end of drift region 50. A voltage divider network 60 connects guard rings 51 through 55 and collector electrode 70 to electric potential source 45 via voltage divider network 40. Electric potential source 45, together with divider network 40, establishes a linear electric field in drift region 50 between guard ring 51 and collector 70.
A counter flow of clean air flows continuously in the direction shown by arrow 18 and serves to prevent ion-molecule reactions from occurring in drift region 50. The two streams of gas combine in region 35 and the resulting gas mixture is pumped out through port 19 in the direction shown by arrow 17a. In an alternate and equally effective mode of operation, the gas sample can be introduced through port 19 in a direction opposite arrow 17a and the two gas streams (17a reversed and 18) will combine and be pumped out from the left side of housing 10 in a direction opposite arrow 17.
A grid 61 is positioned in drift region 50 between guard rings 51 and 52 in a plane normal to the direction of gas flow. As in the case of grid 31 in drift region 30, grid 61 has alternate conductors electrically connected to each other such that the alternate conductors can be energized with different voltage at terminals 61a and 61b, respectively.
Collector electrode 70 is connected to the input of an amplifier 68, which has an output 69.
In the preferred embodiment of the invention shown in the drawing, the gas sample is received from the direction of arrow 17 and is directed past radioactive source 14 into drift region 30. The gas sample becomes ionized near the radioactive source 14 by a charge transfer process. The resulting ions move under the influence of a constant potential established in region 30. A further much lesser influence on the motion of the ions is the constant flow of the gas through the tube. Grid 31 is operated as a co-planar electrical shutter. By applying appropriate constant potentials to terminals 31a and 31b of grid 31, the shutter is biased partially open to allow only ions of lower mobility to enter into drift region 30. Grid 31, with the difference potentials between the alternate conductors, acts very much like the recombination region of an ionization cell such as shown in U.S. Pat. No. 3,835,328, to Harris, et al. issued on Sept. 10, 1974. That is, the grid operates as an electrical analog to baffles, providing a means for capturing the lighter, higher mobility ions, while allowing a greater number of heavier, lower mobility ions to pass through to the second drift tube. A major advantage of using grid 31 in the manner described, as opposed to passing ions through a recombination region, is that a much greater concentration of ions survive and reach grid 61. The sensitivity and stability of the cell are thereby improved.
The ions emerging from drive region 30 enter drift region 50. As stated previously, a linear electric field is established in drift region 50 by electric potential source 45 through divider networks 40 and 60, connected to guard rings 51 through 55 and collector 70. The alternate conductors in grid 61 are energized such that a different potential can briefly exist between adjacent conductors, while the average potential of each grid is equal to the linear drift potential at the location of the respective grid. The ions emerging from drift region 30 and passing through region 35 (wherein the gas streams combine) reach grid 61 in a steady stream. By applying appropriate potentials to terminals 61a and 61b of grid 61, the shutter opens briefly to allow a discrete packet of ions to enter drift region 50. Each ion species drifts at a speed which is characteristic of its mobility. Therefore, when several ion species are present they can be separately detected by their different arrival times at collector 70.
Collector 70 is connected to the input of an amplifier 68, whose output 69 will provide the signal indicating the presence of particular ions in the gas sample. The amplitude of the signal is a function of the number of ions detected.
In the operation of the preferred embodiment described above, grid 31 in recombination region 30 was energized with constant potentials, while grid 61 of recombination region 50 was energized with modulated potentials. The invention operates satisfactorily with the functions of the two drift cells reversed, i.e. by energizing grid 31 with modulated potentials and applying constant potentials to grid 61.
While in the preferred embodiment of the present invention drift regions 30 and 50 are shown to be of about the same size, the invention works equally well with drift regions of different sizes, both in length and diameter. The placement of grid 31 and the constant potentials applied thereto can be selected to obtain a particular desired effect on the ion species produced and transmitted through region 30.
FIG. 3 is a graphical representation of the variations in the signals appearing at the outputs of the cells of FIGS. 1 and 2 as a function of changes in voltage and altitude. The upper curve of the graph shows the response to dimethyl methyl phosphonate (DMMP) at sea level with the high voltage at the output of power supply 45 at 2000 volts. The second curve from the top shows the response to DMMP at 15,000 feet altitude (about 0.6 sea level pressure) at 2000 volts. It should be noted that all spectral peaks move, but not equally. The lower curve of FIG. 3 shows the response to DMMP at 15,000 feet altitude but with the voltage reduced to approximately 1200 volts. The resulting response is virtually identical to sea level response at 2000 volts. Thus, using the compensation technique of the present invention, DMMP can be reliably identified at different altitudes.
FIG. 2 illustrates an alternate preferred embodiment of the present invention. It includes a housing 76 constructed of non-conductive material, such as Teflon. Mounted within housing 76, at a first end, is a radiation emitting source 84, which consists of a metal screen to which is affixed a radiation emitting foil. A conductive plate 90, having a central opening 91, separates radiation source 84 from a drift region 80. The other end of drift region 80 (the downstream end) is defined by a manifold 86, which also defines the upstream end of a recombination region. A plurality of conductive rings 92, 93, 94, and 95 are mounted within drift region 80 and are connected to a source of a pressure controlled high voltage power supply 45 via voltage divider network 71 to establish a linear electric field between plate 90 and manifold 86. Electrically conductive grids 79 and 78 act as electrical shutters which, upon receiving an appropriate signal from pulse signal generator 75 allow only ions of a specific mobility to pass through the drift region and into the recombination region beyond manifold 86.
The voltage supplied to rings 92 through 95 from power supply 45 is varied with changes in atmospheric pressure to provide compensation for such changes in pressure. Power supply 45 can be of the type shown in FIG. 4 and described below.
The selected ions which are allowed to pass through drift region 80 are then further acted upon in the recombination region by interaction with surfaces created by washers 103 and baffles 104 and 102 and manifold 86.
The ions exiting drift region 80 generate a signal at collector 98 which is received at the input of amplifier 100. The ions passing through the recombination region and reaching collector 105 at the downstream end of the recombination region generate a signal which is applied to the input of amplifier 101. The amplified signals from amplifiers 100 and 101 may be used individually as an indication of the presence of specific ions in the gas sample, or these signals can be logically combined for increased sensitivity.
The schematic of a pressure controlled high voltage power supply used in the preferred embodiment of the present invention is illustrated in FIG. 4. The input voltage to the power supply is applied between input terminals 401 and 402. Normally, the input voltage is derived from a source such as a battery operating between 20 and 36 volts. The power supply converts this relatively low input voltage into a high voltage output in the range of 2000 volts, appearing between output terminals 461 and 462.
A PWM (pulse width modulator) 400 drives a VMOS switch 410 connected in series with a primary winding 425 of a transformer 420. Transformer 420 has a secondary winding 426 which has a turns ratio of about 20 to 1 as compared to primary winding 425. Resistor 421 and capacitor 422, connected across primary winding 425, form what is commonly referred to as a snubber circuit. Its function is to limit the voltage across winding 425 during the "flyback" action. A small resistor 428 is connected between winding 425 and VMOS switch 410. Its function is to act as a fuze in case of excessive current flow, to prevent damage to VMOS switch 410 or zener diode 411. A zener diode 411 is connected across VMOS switch 410 to keep the voltage across VMOS 410 from rising above 75 volts and prevent voltage breakdown of the switch.
The amplified voltage appearing across secondary winding 426 is further stepped up through a diode/capacitor voltage multiplier network 430 comprised of diodes 431 through 434 and capacitors 435 through 438.
Pulse width modulator 400 in the preferred embodiment is an integrated circuit TL494 manufactured by Texas Instruments. Other equivalent circuits available on the market could be used for this purpose.
The power to PWM 400 is applied between pins 7 and 12, pin 12 being connected through resistor 406 to the positive potential terminal 401 and pin 7 being connected to the reference potential terminal 402. Resistor 403 and capacitor 404, connected between pins 6 and 5, respectively, and the ground potential terminal 402, set the operating frequency of PWM 400.
A capacitor 407 connected between input terminals 401 and 402 provides localized filtering to supply transient current for the switching circuit and absorb voltage transients generated by it. Resistor 406 and a capacitor 405 form a decoupling circuit.
The output of PWM 400, which is applied to the base electrode of VMOS switch 410, is provided at pin 10.
Pin 1 of pulse width modulator 400 is connected to a junction point between resistor 474 having its other end connected to output terminal 461 and resistor 475 having its other end connected to output terminal 462. The signal received by pin 1, which is a function of the output voltage appearing between output terminals 461 and 462, is compared internally in circuit 400 with a reference voltage signal applied at pin 2. The difference in the voltages received at pins 1 and 2 controls the duty cycle of PWM 400, which in turn controls the amplitude of the output voltage between terminals 461 and 462 through the operation of VMOS switch 410. Via a switch 445, pin 2 of PWM 400 can be connected to either receive a manually selected reference voltage from a variable voltage divider 470 or a pressure controlled voltage generated by pressure transducer 440. A zener diode 471 sets the voltage across voltage divider 470. A second zener diode 473 is connected across resistor 474 to provide over voltage protection for PWM 400 input.
In the preferred embodiment, pressure transducer 440 is a piezoresistive type manufactured by National Semiconductor and identified by LX0503A. Other comparable pressure transducers are available on the market. Pressure transducer 440 has constructed internally a resistive bridge comprised of piezoresistive elements. The output voltage signal appearing between pins 5 and 6 of transducer 440 is a differential signal indicative of the bridge unbalance produced by changes in pressure. The signal from the output of transducer 440 is applied between input terminals of a differential amplifier 441, where it is amplified and then applied to the input of a second amplifier 442. The signal from the output of amplifier 442 is a pressure responsive voltage signal which can be applied to pin 2 of PWM 400 through switch 445. When switch 445 is moved into the position connecting the output of amplifier 442 to pin 2 of PWM 400, the duty cycle of PWM 400 will be controlled as a function of atmospheric pressure.
Pressure transducer 440 is connected to receive input power between pin 3 connected to a positive potential source through resistor 446 and pin 8 connected to ground. The input voltage between pins 3 and 8 is accurately controlled by adjustable precision shunt regulator 450, which in the preferred embodiment is a TL431 type manufactured by Texas Instruments. Resistors 451 and 452 are selected to control the voltage at pin 3 at approximately 6.5 volts.
A variable resistor 443 is connected between the output of amplifier 442 and the ground terminal for calibrating the pressure variable reference voltage applied to pin 2 of PWM 400. In the preferred embodiment, variable resistor 20 is adjusted such that at a pressure of 1 atmosphere the power supply generates 2000 volts between output terminals 461 and 462.
A unique and improved apparatus for sensing and measuring gaseous impurities has been shown and described in the foregoing specification. Various modifications of the inventive concepts will be obvious to those skilled in the art, without departing from the spirit of the invention. It is intended that the scope of the invention be limited only by the following claims.
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An improved drift tube wherein the high voltage electric field is generated as a function of atmospheric pressure. Such variation of the electric field provides good compensation for the effects produced by changes in atmospheric pressure. As a result, the identification of a particular compound at different altitudes is greatly simplified.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a substitute application of our earlier application Ser. No. 602,331, filed Aug. 6, 1975, and abandoned Oct. 23, 1976.
BACKGROUND OF THE INVENTION
The compound 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[ b,f][1,4]oxazepine is a known compound having therapeutic effects on the central nervous system. U.S. Pat. No. 3,546,226 specifically discloses 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine, its nontoxic pharamaceutically acceptable acid addition salts, their parenteral administration and their utility as central nervous system agents. U.S. Pat. 3,663,696 discloses a parenteral solution composed of 2-chloro-11-(1-piperazinyl)-dibenz[ b,f][1,4]oxazepine and certain acid addition salts thereof, in a mixture of propylene glycol, water and ascorbic acid. U.S. Pat. No. 3,412,193 discloses the oral administration of 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]-oxazepine in propylene glycol for the purpose of testing anti-fertility efficacy.
Problems have existed with preparations containing 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine. Due to the compound's low solubility in water, it is difficult to formulate in conventional pharmaceutical forms such as parenteral and oral liquid preparations employing, for example, water for injection. Another problem which makes the compound difficult to prepare in liquid dosage forms in its low solubility in liquids having a basic or near neutral pH. A still further problem associated with the compounds is that one of its hydrolysis products, namely, 2-chloro-dibenz[b,f][1,4]oxazepin-11(10H)-one, is extremely insoluable in water. Aqueous solutions of 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine have proven unstable and unsuitable primarily because of the precipitation of the above hydrolysis product which forms in trace amounts long before the potency of the solution has dropped below acceptable levels. Although the hydrolysis product is nontoxic, its precipitation is, of course, unacceptable in an injectable solution of the active oxazepine. All of the above problems can be overcome by the application of the instant invention.
The oxazepine of this invention and its acid addition salts can be prepared as illustrated in U.S. Pat. No. 3,663,696.
SUMMARY OF THE INVENTION
This invention is concerned with stable oral concentrates and parenteral solutions of 2-chloro-11-(4-methyl-1-piperazinyl)dibenz[b,f][1,4]oxazepine base and its non-toxic pharmaceutically acceptable acid addition salts.
The invention is specifically concerned with an improved solubilized, stabilized solution comprising as the main active ingredient 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[ b,f][1,4]oxazepine base or pharmaceutically acceptable acid addition salts thereof dissolved in about 50% to about 80% (preferably about 70% v/v) aqueous solution of propylene glycol having a pH of from about 5.0 to about 7.0 (preferably about 6.0), and, optionally, containing from about 2% to about 10% (preferably about 5%) polysorbate 80. The invention is specifically concerned with parenteral solutions and oral concentrates in accordance with the above.
The invention is further specifically concerned with a method of solubilizing and stabilizing 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine which comprises dissolving the compound in about 50% to 80% (preferably 70% v/v) aqueous solutions of propylene glycol, adjusting the pH to about 5.0 to about 7.0 (preferably about 6.0 pH) with a dilute mineral acid such as dilute hydrochloric or sulfuric acid (e.g., 10%); optionally, adding from about 2% to about 10% (preferably about 5%) polysorbate 80; and adding water to the desired volume (water for injection in the case of parenterals). Such a procedure has the advantages of providing a stable, pharmaceutically acceptable solution of the active oxazepine, wherein: solution is complete and remains so for prolonged periods; the pH is conductive to maintaining solution and is not incompatible for either oral or parenteral administration; the stability is good; and traces of the noted hydrolysis product remain in solution.
The addition of Polysorbate 80 at a level of about 2% to about 10%, although not absolutely necessary, provides an additional advantage for both the parenteral solution and oral concentrate. Because 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine crystallizes from neutral or basic media, the oxazepine exhibits a tendency to crystallize when parenterally administered to body fluids (pH about 7.0). The addition of Polysorbate 80 raises the solubility level of the oxazepine in the 70% aqueous propylene glycol and eliminates the crystallization during intramuscular administration. The addition of Polysorbate 80 to the oral concentrate is advantageous when it is desired to add the concentrate to non-acidic foods or beverages because the oxazepine precipitates on dilution with such foods unless polysorbate 80 is present.
The compound 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine may be employed in the solutions of this invention either in the form of its free base or its non-toxic, pharmaceutically acceptable acid addition salts, preferably the succinate salt. Other non-toxic pharmaceutically acceptable acid addition salts deemed suitable in addition to the succinate included the hydrochloride, sulfate, phosphate, citrate, tartrate, maleate, fumarate, heptanoate, pamoate, etc.
DETAILED DESCRIPTION OF THE INVENTION
A parenteral solution of the invention may be prepared as follows. The concentrations of ingredients are based on the final volume unless otherwise defined. 2-Chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine in an amount sufficient to provide a final weight percent/volume of 0.5% to 5% (5 mg/cc to 50 mg/cc) is dissolved in 50% to 80% v/v of propylene glycol U.S.P. The solution is adjusted to pH 5.0 to 7.0 with a dilute mineral acid, diluted to 100% with water for injection U.S.P. and then sterile filtered. If desired, Polysorbate 80 U.S.P. at 2% to 10% may be added to the propylene glycol solution before diluting to final volume with water for injection.
A oral concentrate of the invention may be prepared in the same manner as above except that sterilization is not needed and distilled water may be substituted for water for injection.
The oral concentrate can be added to foods for the purpose of producing a palatable form of the oxazepine or for concealing its presence, e.g., for administration to patients who may reject the drug if aware of it. Such patients include mentally disturbed persons, as in mental hospitals; children; senile persons; etc. Although a variety of foods can be used for these purposes, liquid foods are especially adaptable and particularly fruit juices, such as orange juice and related beverages. Oral concentrates containing about 10-50 mg of drug per ml of concentrate may be used with about 25 mg/ml being preferred. The oral concentrate may be added to foods in amounts of up to 2 ml of concentrate per ounce of food with about 0.5-1.0 ml/ounce being preferred. The total amount of concentrate will of course depend on the nature of the illness and on the patient, but, in general, from one half to 6 ml of concentrate, containing for example 25 mg/ml, may be used per day, with a preferred range of 2 to 4 ml. Such amount may be given in one dose or divided into 2, 3 or 4 doses which are given at appropriate intervals.
EXAMPLE 1
Preparation of Parenteral Solution of 2-Chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine Base
A 63.0 gm portion of 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine base is added to 2100 ml of propylene glycol U.S.P. grade and mixed. An 800 ml portion of water for injection is added and mixed. The pH is adjusted to 6.2 with 10% hydrochloric acid, mixed and heated to 60° C. for 30 minutes. The pH is adjusted to 6.0 with 10% hydrochloric acid (making the total volume of hydrochloric acid used 51 ml). The mixture is diluted to 3000 ml with water for injection and sterile filtered through a 293 mm Selas filter or its equivalent having a 0.22μ membrane. The final solution has a potency of 2.0% active ingredient.
The formulation is filled into ampoules or vials each containing 2.0 ml (representing 40 mg of drug).
EXAMPLE 2
Preparation of Parenteral Solution of 2-Chloro-11-4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine Base
A 105.63 gm portion of 2-chloro-11-(4-methyl-1-piperazinyl)-debenz[b,f][1,4]oxazepine base is added to a mixture of 1400 ml of propylene glycol U.S.P. and 400 ml of water for injection and mixed. The pH is adjusted to 6.0 with 10% hydrochloric acid. A 100 gm portion of Polysorbate 80 U.S.P. is added. The pH is readjusted to 6.0 with 10% hydrochloric acid and the solution is diluted to 2000 ml with water for injection. The solution is filtered through a Millipore AP20 pad and then Selas 0.2μ silver membrane or its equivalent. The final solution has a potency of 5.0% active ingredient.
The formulation is filled into ampoules or vials each containing 2.0 m. (representing 100 mg of drug).
EXAMPLE 3
Preparation of an Oral Concentrate of 2-Chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine Base
A 12,600 ml portion of propylene glycol U.S.P. is placed in a 25 liter stainless steel pot. A 4 liter portion of water is added and mixed. A 474 gm portion of 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine base is added and mixed. The pH of the solution is adjusted to 6.0 with 10% hydrochloric acid. This solution is diluted to 18,000 ml with water; mixed, the pH is readjusted to 6.0 and then filtered through a Millipore AP 20 pad and 0.45 to 1.2 micron solvent resistant membrane. The potency of the final solution is 2.5% as active ingredient.
EXAMPLE 4
Use of Oral Concentrate of 2-Chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine Base
An oral concentrate containing 2.5% w/v 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine base in 70% aqueous propylene glycol, prepared as in Example 3, was added to grapefruit, orange, or pineapple juice, adding 1 ml of concentrate per ounce of juice (0.83 mg of drug per ml of drink). The taste, appearance, and pH of the drinks were acceptable and the stability was satisfactory for at least 24 hours in the juices named.
EXAMPLE 5
Typical formulations are:
______________________________________ PercentParenteral w/v2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine base 5.25Polysorbate 80 USP Food Additive Grade 5.0Hydrochloric Acid - Reagent q.s. pH 6.0 q.s.Propylene Glycol USP 70.0 (v)Water for injection USP q.s. ad 100.0 (v)Oral2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine base 2.63Hydrochloric Acid - Reagent q.s. pH 6.0 q.s.Propylene Glycol USP 70.0 (v)Water (Distilled) 100.0 (v)______________________________________
Other ingredients which do not adversely affect the parenteral solution or oral concentrate may also be added thereto such as buffers, preservatives, flavors, dyes, sweetening agents, suspending agents, and the like. Also, minor amounts of other active ingredients may be added as long as they do not adversely affect the solution or concentrate.
The efficacy of the solutions of 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine, prepared in accordance with the present invention, may be illustrated by a comparison of their potency with the encapsulated form of this compound. For such a test, male Wistar strain rats are used. Capsule contents comprising 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine succinate and conventional excipients is suspended in a 2% starch vehicle and administered to rats by gavage at the rate of 0.5 ml per 100 gm of body weight. Nine dose levels ranging from 0.06 to 12.0 mg/kg are used with 10 to 15 rats per dose. A parenteral solution comprising 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz-[b,f][1,4]oxazepine base at a concentration of 20 mg/ml in 70% propylene glycol is injected into rats undiluted, intramuscularly in micro liter volumes. Eight dose levels ranging from 0.12 to 12.0 mg/kg are used with 10 to 40 rats per dose.
Each rat is tested for catalepsy, a measure of the neuroleptic activity of the drug, at various times up to 6 hours after drug administration. The criterion for catalepsy is maintenance of paw position on four corks for longer than 10 seconds. The median effective doses, those at which 50% of the animals showed catalepsy, is calculated at various intervals of time after drug administration.
The results appear in Table I.
TABLE I__________________________________________________________________________ Median Effective Dose (ED.sub.50) (95% Confidence Limits)Hours AfterAdministration Capsule Suspension (Succinate) Parenteral Solution Base__________________________________________________________________________0.25 12.0 (6.7-21.6) 7.0 (4.7-10.3)0.5 2.1 (1.4-3.4) 2.8 (2.1-3.8)0.75 0.57(0.36-0.91) 0.97(0.65-1.5)1.0 0.32(0.20-0.52) 0.50(0.40-0.62)1.5 0.21(0.14-0.31) 0.36(0.27-0.48)3.0 0.15(0.09-0.24) 0.19(0.15-0.24)6.0 0.12(0.07-0.20) 0.15(0.11-0.21)__________________________________________________________________________
The above results show that there are no real differences in potency between the oral (capsule) and parenteral (intramuscular) forms at any time period up to 6 hours after drug administration.
The favorable stability of the oral and parenteral solutions of this invention have been established in numerous tests. The criterion of stability being the lack of precipitation of the hydroylsis product 2-chloro-dibenz[b,f][1,4]oxazepin-11(1OH)-one. In general, crystallization of this hydrolysis product does not occur at concentrations below 500 mcg/ml in these new solutions. Three such studies follow:
In the first study a number of 10 mg/ml solutions of 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine base are prepared in 50%, 60% and 70% aqueous propylene glycol at pH 6.0. A 15 month stability study produced the composite results shown in Table II.
TABLE II______________________________________Propylene HydrolysisGlycol Product Potency of Active ComponentContent (mcg/ml) As % of Initial Potency______________________________________50% 120 98.260% 110 98.370% 100 98.5______________________________________
All of the solutions retain acceptable potency levels and none show precipitation of the hydrolysis product.
In the second study a parenteral solution of 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine is prepared at a concentration of 15 mg/ml in 70% v/v propylene glycol in water for injection U.S.P. at a pH of 6.0. A stability study is carried out at various temperatures and for varying lengths of time, as indicated in Table III, to measure the retained potency of the active component as well as the increase in concentration of the hydrolysis product.
TABLE III______________________________________ Hydrolysis Potency Product PhysicalStorage Condition (mg/ml) (mcg/ml) Appearance______________________________________Fresh 16.0 26 ClearRoom Temp. 2 Months 15.4 55 " 4 15.6 67 " 6 15.6 94 " 11 15.4 142 " 13 15.1 144 " 18 14.3 260 "42° C 1 Month 16.0 124 " 2 14.5 192 " 4 15.5 340 "56° C 2 Weeks 15.3 163 " 1 Month 16.0 320 " 2 14.5 580 "70° C 1 Week 15.0 370 Precipitate 2 14.8 467 "______________________________________
In the third test a parenteral solution of the active ingredient at a concentration of 20 mg/ml was prepared as described in the second stability study. The results appear in Table IV.
TABLE IV______________________________________ Hydrolysis Potency Product PhysicalStorage Condition (mg/ml) (mcg/ml) Appearance______________________________________Fresh 21.6 33.0 ClearRoom Temp. 2 Months 21.1 62.7 " 4 22.3 78 " 6 20.8 116 " 11 20.7 160 " 13 20.6 184 " 18 20.5 340 "42° C 1 Month 21.8 146 " 2 20.5 232 " 4 20.2 436 "56° C 2 Weeks 21.0 185 " 1 Month 20.6 374 " 2 19.4 732 "70° C 1 Week 20.7 480 Precipitate 2 20.6 623 "______________________________________
As can be seen from the second and third stability studies, the solutions of this invention show excellent stability even under accelerated conditions.
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Stable, soluble solutions of 2-chloro-11-(4-methyl-1-piperazinyl)-dibenz[b,f][1,4]oxazepine are described, some of which are suitable for oral and others for parenteral administration.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/293,083, filed Nov. 9, 2011, which is a continuation of U.S. patent application Ser. No. 12/720,538, filed Mar. 9, 2010, which is a continuation application of U.S. patent application Ser. No. 11/530,394, filed Sep. 8, 2006, entitled SYSTEMS AND METHODS FOR EXPORTING, PUBLISHING, BROWING AND INSTALLING ON-DEMAND APPLICATION IN A MULTI-TENANT DATA BASE ENVIRONMENT, with David Brooks, Lewis Wiley Tucker, Benji Jasik, Timothy Mason, Eric David Bezar, Simon Wong, Douglas Chasman, Tien Tzuo, Scott Hansma, Adam Gross and Steven Tamm listed as inventors, which claims priority to U.S. Provisional Application No. 60/715,749, filed Sep. 9, 2005, entitled SYSTEMS AND METHODS FOR EXPORTING, PUBLISHING, BROWING AND INSTALLING ON-DEMAND APPLICATION IN A MULTI-TENANT DATA BASE ENVIRONMENT with David Brooks, Benji Jasik, Eric D. Bezar, Douglas Chasman, Scott Hansma, Lewis Wiley Tucker, Timothy Mason, Simon Wong, Tien Tzuo and Adam Gross listed as inventors. The disclosures of the aforementioned patent applications are being incorporated by reference herein.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The present invention relates generally to databases, and more particularly to systems and methods for creating and exchanging customized applications in a multitenant and/or multi-application database system.
BACKGROUND
Not too long after inventing numbers and a writing system, early humans realized that they had inadvertently created information. With the creation of information came a problem that would vex humankind for the next several millennia: how to store and manage the information.
Fortunately, the amount of information created by early humans was relatively small and could be tracked using ten fingers and ten toes. Stone or clay tablets were employed to track information when a more permanent record was desired. One early well known example of this mechanism was used by Moses, who stored a body of Ten Commandments on two such stone tablets. These mechanisms were limited, however, to write-once, read-many implementations and were tightly constrained in capacity.
With the advent of the Gutenberg printing press, came the ability to store larger quantities of information as well as to produce copies of stored information in volume. While, these mechanisms also were limited to write-once, read-many implementations, they facilitated the widespread dissemination of knowledge, which in turn accelerated the advance of technical progress. A few centuries later, the computer and database software systems appeared. The computer database provided large capacity, write-read storage in a readily available package. For awhile, it appeared that humankind's age old information storage and management problem had finally been solved.
Computer databases, however, are plagued by numerous problems. Each organization, business or agency, installs its own copy of the database. It was not long, however, before users wished to add their own custom objects and applications to their database in addition to the standard objects and standard applications already provided. The desire for customization lead to disparate schema, an organization of the types of information being stored in the database, as well as applications relying upon that schema being implemented by different users. Disparate schema, in turn blocked any hope of users in different organizations of sharing information or applications among one another.
BRIEF SUMMARY
A computer implemented method of developing computer applications, the method comprising providing to multiple users access, over a network, to information on a data center, with a subgroup of the users having access to a sub-portion of the information that is different from the sub-portion accessible by the remaining tenants of the subgroup; and communicating with the data center over the network employing a computer system associated with a user of the sub-group to establish application functionality with the sub-portion that may be accessed, over the network, by additional parties authorized by the user. Also disclosed is a machine-readable medium and a data center, both of which facilitate carrying-out the steps of the method. These and other embodiments are described below.
Reference to the remaining portions of the specification, including the drawings and claims, will realize other features and advantages of the present invention. Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an environment wherein a multitenant database system might be used;
FIG. 2 illustrates elements of FIG. 1 and various interconnections between the elements;
FIG. 3 shows a data model for a Directory of applications in an embodiment;
FIG. 4 shows a definition of a DirectoryEntry object and other objects in an embodiment;
FIG. 5 shows a solutions category hierarchy in an embodiment;
FIG. 6 shows an example of a GUI screen that allows a user to create a package in an embodiment;
FIG. 7 shows an example of a GUI screenshot showing information, including included items, for a created package in an embodiment; and
FIG. 8 shows an example of a Project data model definition and a Project Member data model definition in an embodiment.
DETAILED DESCRIPTION
In embodiments, the present invention provides systems and methods for creating and exchanging customized applications in a multi-tenant database system.
Customers may wish to add their own custom objects and applications to their database system in addition to the standard objects and standard applications already provided. In a traditional client/server application, where the customer has its own physical database, adding custom objects is typically done via DDL (data definition language) against that database to create new physical schema-tables and columns. In an online multi-tenant database system, this approach may be untenable for various reasons. For example, for a database system with a large population of tenants (e.g., on the order of 1,000 or 10,000 or more tenants), the union of all desired schema would overwhelm the underlying data dictionary catalog (e.g., Oracle dictionary). Additionally, the maintenance of all of these schema objects would be a nearly impossible burden for DBAs (database administrators). Further, current relational databases do not support online DDL (in a highly concurrent transactional system) well enough for organizations to remain logically independent. Specifically, the creation of schema by one organization could lock an application for all other customers causing unacceptable delays.
Many application platforms have the concept of different applications that one can install. WINDOWS®, for example, has applications that can be installed as does Linux and other operating systems. Several websites allow one to browse and select applications for download and installation. For example, CNET has the download.com site that allows one to download PC based applications. Other enterprise software toolkits have the ability to specify a package of meta-data and export it from one environment and import it into another. For example, Peoplesoft has the ability to do this using either importing/exporting over an odbc connection or via a flat file. With flat file and odbc based approaches, there exists the risk of not being able to import packages that were defined or exported using a previous version. Microsoft has an office directory that allows one to download useful spreadsheet or word document templates from their central web site. However, these systems do not allow users to easily and efficiently import and export applications in a multi-tenant environment. These systems also do not preserve the uniqueness of an imported application; one cannot navigate to it as a separate item. Other systems also do not allow one to disable changes to the imported objects in the imported application and uninstall the application in the future.
FIG. 1 illustrates an environment wherein a multitenant database system might be used. As illustrated in FIG. 1 any user systems 12 might interact via a network 14 with a multi-tenant database system (MTS) 16 . The users of those user systems 12 might be users in differing capacities and the capacity of a particular user system 12 might be entirely determined by permissions (permission levels) for the current user. For example, where a salesperson is using a particular user system 12 to interact with MTS 16 , that user system has the capacities allotted to that salesperson. However, while an administrator is using that user system to interact with MTS 16 , that user system has the capacities allotted to that administrator. Thus, different users will have different capabilities with regard to accessing and modifying application and database information, including tab and tab set definition and profile information, depending on a user's permission level.
Network 14 can be a LAN (local area network), WAN (wide area network), wireless network, point-to-point network, star network, token ring network, hub network, or other configuration. As the most common type of network in current use is a TCP/IP (Transfer Control Protocol and Internet Protocol) network such as the global internetwork of networks often referred to as the “Internet” with a capital “I,” that will be used in many of the examples herein. However, it should be understood that the networks that the present invention might use are not so limited, although TCP/IP is the currently preferred protocol.
User systems 12 might communicate with MIS 16 using TCP/IP and, at a higher network level, use other common Internet protocols to communicate, such as HTTP, FTP, AFS, WAP, etc. As an example, where HTTP is used, user system 12 might include an HTTP client commonly referred to as a “browser” for sending and receiving HTTP messages from an HTTP server at MTS 16 . Such HTTP server might be implemented as the sole network interface between MIS 16 and network 14 , but other techniques might be used as well or instead. In some implementations, the interface between MIS 16 and network 14 includes load sharing functionality, such as round-robin HTTP request distributors to balance loads and distribute incoming HTTP requests evenly over a plurality of servers. Each Of the plurality of servers has access to the MTS's data, at least as for the users that are accessing that server.
In one aspect, the system shown in FIG. 1 implements a web-based customer relationship management (CRM) system. For example, in one aspect, MIS 16 can include application servers configured to implement and execute CRM software applications as well as provide related data, code, forms, web pages and other information to and from user systems 12 and to store to, and retrieve from, a database system related data, objects and web page content. With a multi-tenant system, tenant data is preferably arranged so that data of one tenant is kept logically separate from that of other tenants so that one tenant does not have access to another's data, unless such data is expressly shared. In aspects, system 16 implements applications other than, or in addition to, a CRM application. For example, system 16 may provide tenant access to multiple hosted (standard and custom) applications, including a CRM application.
One arrangement for elements of MTS 16 is shown in FIG. 1 , including a network interface 20 , storage 22 for tenant data, storage 24 for system data accessible to MIS 16 and possibly multiple tenants, program code 26 for implementing various functions of MIS 16 , and a process space 28 for executing MTS system processes and tenant-specific processes, such as running applications as part of an application hosting service.
Several elements in the system shown in FIG. 1 include conventional, well-known elements that need not be explained in detail here. For example, each user system 12 could include a desktop personal computer, workstation, laptop, PDA, cell phone, or any WAP-enabled device or any other computing device capable of interfacing directly or indirectly to the Internet or other network connection. User system 12 typically runs an HTTP client, e.g., a browsing program, such as Microsoft's Internet Explorer browser, Netscape's Navigator browser, Opera's browser, or a WAP-enabled browser in the case of a cell phone, PDA or other wireless device, or the like, allowing a user (e.g., subscriber of the multi-tenant database system) of user system 12 to access, process and view information, pages and applications available to it from MTS 16 over network 14 . Each user system 12 also typically includes one or more user interface devices, such as a keyboard, a mouse, touch screen, pen or the like, for interacting with a graphical user interface (GUI) provided by the browser on a display (e.g., monitor screen, LCD display, etc.) in conjunction with pages, forms, applications and other information provided by MTS 16 or other systems or servers. For example, the user interface device can be used to select tabs and tab sets, create and modify applications, and otherwise allow a user to interact with the various GUI pages, for example, as described in U.S. patent application Ser. No. 11/075,546, which is incorporated by reference in its entirety herein.
As discussed above, the present invention is suitable for use with the Internet, which refers to a specific global internetwork of networks. However, it should be understood that other networks can be used instead of the Internet, such as an intranet, an extranet, a virtual private network (VPN), a non-TCP/IP based network, any LAN or WAN or the like.
According to one embodiment, each user system 12 and all of its components are operator configurable using applications, such as a browser, including computer code run using a central processing unit such as an Intel Pentium processor or the like. Similarly, MIS 16 (and additional instances of MIS's, where more than one is present) and all of their components might be operator configurable using application(s) including computer code run using a central processing unit such as an Intel® Pentium processor or the like, or multiple processor units. Computer code for operating and configuring MTS 16 to intercommunicate and to process web pages, applications and other data and media content as described herein is preferably downloaded and stored on a hard disk, but the entire program code, or portions thereof, may also be stored in any other non-transitory computer usable medium or device as is well known, such as a ROM or RAM, a compact disk (CD) medium, digital versatile disk (DVD) medium, a floppy disk, and the like. Additionally, the entire program code, or portions thereof, may be transmitted and downloaded from a software source, e.g., over the Internet, or from another server, as is well known, or transmitted over any other conventional network connection as is well known (e.g., extranet, VPN, LAN, etc.) using any communication medium and protocols (e.g., TCP/IP, HTTP, HTTPS, Ethernet, etc.) as are well known. It will also be appreciated that computer code for implementing aspects of the present invention can be implemented in any programming language that can be executed on a server or server system such as, for example, in C, C++, HTML, any other markup language, Java™ JavaScript, any other scripting language such as VBScript, and many other programming languages as are well known. (Java™ is a trademark of Sun Microsystems, Inc.)
According to one embodiment, each MTS 16 is configured to provide web pages, forms, applications, data and media content to user systems 12 to support the access by user systems 12 as tenants of MTS 16 . As such, MTS 16 provides security mechanisms to keep each tenant's data separate unless the data is shared. If more than one MTS is used, they may be located in close proximity to one another (e.g., in a server farm located in a single building or campus), or they may be distributed at locations remote from one another (e.g., one or more servers located in city A and one or more servers located in city B). As used herein, each MTS could include one or more logically and/or physically connected servers distributed locally or across one or more geographic locations. Additionally, the term “server” is meant to include a computer system, including processing hardware and process space(s), and an associated storage system and database application (e.g., OODBMS or RDBMS) as is well known in the art. It should also be understood that “server system” and “server” are often used interchangeably herein. Similarly, the databases described herein can be implemented as single databases, a distributed database, a collection of distributed databases, a database with redundant online or offline backups or other redundancies, etc., and might include a distributed database or storage network and associated processing intelligence.
FIG. 2 illustrates elements of MTS 16 and various interconnections between these elements in an embodiment. In this example, the network interface is implemented as one or more HTTP application servers 100 . Also shown is system process space 102 including individual tenant process spaces 104 , a system database 106 , tenant database(s) 108 and a tenant management process space 110 . Tenant database 108 might be divided into individual tenant storage areas 112 , which can be either a physical arrangement or a logical arrangement. Within each tenant storage area 112 , user storage 114 might similarly be allocated for each user.
It should also be understood that each application server 100 may be communicably coupled to database systems, e.g., system database 106 and tenant database(s) 108 , via a different network connection. For example, one server 100 1 might be coupled via the Internet 14 , another server 100 N-1 might be coupled via a direct network link, and another server 100 N might be coupled by yet a different network connection. Transfer Control Protocol and Internet Protocol (TCP/IP) are preferred protocols for communicating between servers 100 and the database system, however, it will be apparent to one skilled in the art that other transport protocols may be used to optimize the system depending on the network interconnect used.
In aspects, each application server 100 is configured to handle requests for any user/organization. Because it is desirable to be able to add and remove application servers from the server pool at any time for any reason, there is preferably no server affinity for a user and/or organization to a specific application server 100 . In one embodiment, therefore, an interface system (not shown) implementing a load balancing function (e.g., an F5 Big-IP load balancer) is communicably coupled between the servers 100 and the user systems 12 to distribute requests to the servers 100 . In one aspect, the load balancer uses a least connections algorithm to route user requests to the servers 100 . Other examples of load balancing algorithms, such as round robin and observed response time, also can be used. For example, in certain aspects, three consecutive requests from the same user could hit three different servers, and three requests from different users could hit the same server. In this manner, MTS 16 is multi-tenant, wherein MTS 16 handles storage of, and access to, different objects, data and applications across disparate users and organizations.
As an example of storage, one tenant might be a company that employs a sales force where each salesperson uses MTS 16 to manage their sales process. Thus, a user might maintain contact data, leads data, customer follow-up data, performance data, goals and progress data, etc., all applicable to that user's personal sales process (e.g., in tenant database 108 ). In the preferred MTS arrangement, since all of this data and the applications to access, view, modify, report, transmit, calculate, etc., can be maintained and accessed by a user system having nothing more than network access, the user can manage his or her sales efforts and cycles from any of many different user systems. For example, if a salesperson is visiting a customer and the customer has Internet access in their lobby, the salesperson can obtain critical updates as to that customer while waiting for the customer to arrive in the lobby.
While each user's data might be separate from other users' data regardless of the employers of each user, some data might be organization-wide data shared or accessible by a plurality of users or all of the users for a given organization that is a tenant. Thus, there might be some data structures managed by MTS 16 that are allocated at the tenant level while other data structures might be managed at the user level. Because an MTS might support multiple tenants including possible competitors, the MTS should have security protocols that keep data, applications and application use separate. Also, because many tenants will opt for access, to an MTS rather than maintain their own system, redundancy, up-time and backup are additional critical functions and need to be implemented in the MTS.
In addition to user-specific data and tenant-specific data, MTS 16 might also maintain system level data usable by multiple tenants or other data. Such system level data might include industry reports, news, postings, and the like that are sharable among tenants.
In certain aspects, client systems 12 communicate with application servers 100 to request and update system-level and tenant-level data from MTS 16 that may require one or more queries to database system 106 and/or database system 108 . For example, in one aspect MTS 16 (e.g., an application server 100 in MTS 16 ) generates automatically a SQL query including one or more SQL statements designed to access the desired information.
Each database can generally be viewed as a collection of objects, such as a set of logical tables, containing data placed into predefined categories. A “table” is one representation of a data object, and is used herein to simplify the conceptual description of objects and custom objects according to the present invention. It should be understood that “table” and “object” may be used interchangeably herein. Each table generally contains one or more data categories logically arranged, e.g., as columns or fields in a viewable schema. Each row or record of a table contains an instance of data for each category defined by the fields. For example, a CRM database may include a table that describes a customer with fields for basic contact information such as name, address, phone number, fax number, etc. Another table might describe a purchase order, including fields for information such as customer, product, sale price, date, etc. In some multi-tenant database systems, standard entity tables might be provided for use by all tenants. For CRM database applications, such standard entities might include tables for Account, Contact, Lead and Opportunity data, each containing pre-defined fields.
According to one aspect, a user can design their own custom applications including custom objects, custom tabs, custom fields, and custom page layouts. U.S. patent application Ser. No. 10/817,161, entitled “Custom Entities and Fields in a Multi-Tenant Database System” filed on Apr. 2, 2004, which is herein incorporated by reference in its entirety, discloses systems and methods for creating and customizing objects such as entities and fields. The systems and methods presented therein offer a flexible approach to storing variable schema data in a fixed physical schema. Tabs and tab sets can also be created and customized to define relationships between custom objects and fields, standard objects and fields, and applications and to track related data. U.S. patent application Ser. No. 11/075,546, entitled “Systems and Methods for Implementing Multi-Application Tabs and Tab Sets” filed on Mar. 8, 2005 which is herein incorporated by reference in its entirety, discloses systems and methods for creating and customizing tabs and tab sets in a multi-tenant environment. A brief summary of tabs and tab set creation and functionality as described therein follows.
Custom Tabs and Tab Sets
In embodiments, a tab represents a user interface into an element of an application or into a database object. Selection of a tab provides a user access to the object or element of the application represented by the tab. A tab set is a group of related tabs that work as a unit to provide application functionality. New tabs and tab sets may be defined and tab set views may be customized so that an end user can easily and conveniently switch between the various objects and application elements represented by the defined tabs and tab sets. In one aspect, for example, tabs and tab sets may be used as a means to switch between applications in a multiple application environment, such as an on-demand web-based hosted application environment.
A tab set typically includes a name, a logo, and an ordered list of tabs. A tab set is typically viewed in a graphical user interface (GUI) environment, e.g., using a browser application running on a user's computer system. A standard tab set definition may be provided by a host system, e.g., MTS 16 . Standard tab sets are pre-defined sets of tabs, e.g., imported from a source that provides a capability (e.g., templating capability) that determines which tabs, tab sets and data a tenant or user is initially provisioned with. One example of standard tab sets are provided by the salesforcee.com website through its subscription CRM service. Using these standard tab sets, users are provided access to standard tables or entities such as Account, Contact, Lead and Opportunity entities. As another example, in the salesforce.com service, a user can create custom entities as well as custom fields for standard entities, and a user can create a tab set including tabs representing custom entities and fields.
A user may create custom tab sets and custom tabs. Preferably only administrator level users are provided with tab set creation functionality based on their stored permissions. Additionally, users may customize their view of tab sets, including the order of displayed tabs and which tabs in a tab set are displayed. To allow users to conveniently organize their tabs, each tab may appear in any and all tab sets if desired. Preferably, any user can edit tab combination and order, but cannot rename or replace a logo; tab set naming and logo selection are preferably only administrator level functions. For example, administrators may create new tab sets and customize existing tab sets. For all tab sets, an administrator can specify which tabs are included, and the order that the tabs should be displayed. For organization-specific tab sets, an administrator can also specify the name and provide an optional logo. For standard tab sets provided by the host system, e.g., tab sets provided by salesforce.com, such as Salesforce and Supportforce tab sets, an administrator is barred from changing the name or logo, nor can the administrator delete the standard tab set. Preferably, any user can fully customize their view of all the tab sets they have permission to view. The tabs a user can view (and use) are based on the user's permission level. A profile for each tab set allows an administrator level user to set the profile level viewability of tabs and tab sets, e.g., so that groups of users at certain permission levels may be restricted from viewing (and using) certain tabs or tab sets, and therefore also may be restricted from accessing or viewing certain objects and applications referenced by the restricted tabs or tab sets.
Thus, in one aspect, a tab set can be thought of as a filter that is overlaid on top of an existing profile-level tab visibility definition. An administrator sets the default tabs that are included in each tab set filter, but each user can override as they like—the only thing they preferably cannot change is the tab set name and logo. The net result is that tab sets are quite lightweight and flexible. A particular meaning to a tab set is not enforced; each user can generally use tab sets as they wish.
Creating and Exchanging Applications
In one embodiment, users have the ability to create, post and exchange applications. As used herein, in one aspect, an application is a group or package of multi-tenant database setup data (e.g., metadata) that defines its data model, user interface and business logic. For example, the user may define a tab set, which logically defines the group of metadata that makes up an application. As used herein, a “package” is a metadata object that references the set of metadata objects used in an application in an organization. As used herein, an “organization” can mean a single tenant in a multi-tenant system and/or a set of metadata (both application data and metadata) for a single tenant in a multi-tenant system.
In one embodiment, the present invention refines the concept of a tab set by allowing a user to precisely define a metadata “package” which includes all setup data (e.g., custom object definitions, page layout definitions, workflow rules, etc.) that make up an application. A package may include 0, 1 or more tab sets. The user can then export this package from one “source” organization to a “container” organization that is not associated with any tenant in the database system. An exported package is registered with or listed in an application directory. A user that creates and/or exports a package will be referred to herein as a source user or exporting user. The source user can choose to have the package name and application listed in a public portion of the application directory. Another user can import the package into a separate “target” organization allowing this organization to use the application independently of the creating organization. A user that views and/or imports a package will be referred to herein as a viewing user or importing user.
Upon selecting a package for import, code on the server system takes the metadata from the container organization, selects the appropriate recipient organization, reads the metadata from the container organization, and writes that metadata into the recipient organization. Any conflicting metadata (e.g., object or field names) can be resolved by the importing user, e.g., by aborting or by renaming recipient organization objects, fields, etc. It should be noted that the import process preferably does not overwrite any existing recipient organization fields. Also, an import user can uninstall the imported application.
Embodiments of the package creation process and the export and import processes will now be described.
Package Creation
In the source organization, a source user creates a package definition by selecting the appropriate setup data (metadata). This defines the group of setup data that makes up the application. For example, the source user may select a high level tab set (group of tabs). The system then automatically determines object dependencies for the metadata included in the package. For example, in one aspect, the system automatically executes a dependency finder process (e.g., a process that “spiders” through the object schema and searches for object dependencies) to determine all related objects that are required to use functionality provided by the tab set. In one aspect, this is done in two passes-first top down, then bottom up to determine all inverse relationships between objects in the system and those identified by the tab set. Additionally or alternatively, the source user may explicitly specify the collection of setup data to include in the package.
In one aspect, one or more of the following items (pieces of metadata) can be included in a package:
1. Tab set (this would copy everything referenced by the tab set definition)
2. Custom Object
a. Custom fields b. Relationships (master-detail and Lookup) c. Picklist values, d. Page layouts, e. Search layouts, f. Related list layouts, g. Public list views, h. Custom Links i. Any other items associated with the custom object
3. Custom Tab Definition
4. S-control, which in one aspect is a JavaScript program that performs custom User Interface and business logic processing. A package creator may specify the s-control that runs on a tab or section of a page so that when a user navigates to the tab or page, an application server downloads the JavaScript for execution on a browser. An API is used to save data back to the service when necessary.
5. Custom Report (One Report Folder will be created for each new app.)
6. Dashboard
7. Email Template
8. Document
9. Profile Packages (Including FLS for Custom Objects) (Bundles of permission data associated with profiles, to be defined later)
10. Dependent picklists
11. Workflow rules
12. Record types
Additional metadata items that may be copied may include:
1. Custom fields for Standard objects
2. Mail Merge Templates
3. Business Processes
4. Assignment Rules (A form of workflow)
5. Auto-response rules (A form of workflow)
6. Escalation rules (A form of workflow)
7. Big Deal alerts/Opportunity Reminders
8. Self Service Portal Settings
9. VLO features, which in one aspect includes definitions of different “divisions” within a company or organization. VLO features allow an application to partition data by divisions and thus limit the scope of reports and list views.
10. Delegated Administration settings
11. Home Page Components
FIG. 6 shows an example of a GUI screen that allows a user to create a package, e.g., by selecting “New” with a pointing device, as well as delete and edit existing packages, view a history of installed packages and access a directory from which to install a package. FIG. 7 shows an example of a GUI screenshot showing information, including included items, for a created package. A user is able to edit, delete and publish a package using such a screen.
A user may select to edit a package, e.g., by deleting items or adding items. For example, if a user selects to delete a custom object (or other metadata that is included in a package), the system detects this and alerts the user. If the user wishes to proceed, the metadata is then removed from the package. The next time the user views the package items, the deleted items will be gone. If the package has been exported, the metadata in the exported package is not affected. This feature provides a backup to metadata, but does not provide backup to any records which might have been created, although these records can be saved using a data loader or an Excel plug-in. If a user decides to add new items to a package, a picklist of items available for inclusion may be provided. Any item may be included in more than one package.
When adding an application (e.g., a tab set and/or other metadata items) to a package, the system should add all custom items which are related to this application. This includes the custom tabs, the objects behind the tabs, and any custom objects which are related to these. Ideally, the dependency finder process (e.g., spider process) will also detect any custom objects which are related to any standard tabs which make up the added application as well. Even though these standard objects may not be included in the package, the junction objects and other related objects are part of the functionality embodied in the application. Certain object dependencies should always be included. For example, in certain aspects, all the custom fields on a custom object are included with a custom object, and all page layouts are included with a custom object. In certain aspects, custom object related list layouts (that appear on standard objects) are automatically included as well.
Once the user has finished defining the package, the package is validated. This can be done automatically by the system, e.g., when a user indicates that the package is complete, or it may be done responsive to a user request to validate, e.g., the user selecting a “validate” or similar button on a GUI. This invokes the spidering process that makes sure all required setup data is included in the package definition. This is useful in case a user has changed meta data in the package (e.g., added a relationship, another tab or object, etc.) since metadata items were first added to the package.
In one embodiment, a package is stored in the database as a set of primary keys of the objects included in the package. FIG. 8 shows an example of a Project data model definition and a Project Member data model definition according to one embodiment.
Package Export
After defining the package, the source user can choose to export the package. Exporting the package makes it available for other organizations to import. In one aspect, when exporting a package, the source user is able to specify whether to allow customizations of the application after it has been imported into other organizations. For example, in certain aspects, a flag is set (by the source user) in the package definition to indicate whether customizations to an exported package are subject to upgrade. In certain aspects, a flag is set (by the source user) to indicate whether a particular component/object in the package can be altered at all.
Exporting is implemented, in one aspect, by the system automatically creating a new organization definition, e.g., with an organization of type “container”, that includes a copy of all items (metadata) in the package including dependent object metadata not explicitly included by the export user in the package definition. In one aspect, this container organization shares the same physical database (e.g., Oracle database) schema as all other organizations. However, the container organization could reside in a different, separate database. Further, this type of organization (org) is preferably ignored by standard expiration and billing processes where applicable. In certain aspects, where multiple database instances are present in a database system environment, an exported package is stored to one of the database instances as a container organization. The container organization is replicated to one or more or all of the remaining database instances. The multiple database instances may, for example, be associated with different geographical regions. For example, one database instance might be associated with Europe (EP) and one might be associated with North America (NA). In this manner, staggered and independent upgrading of database instances is facilitated. For example, installs of packages may continue as new releases/upgrades to the database system are implemented in different instances. For example, where the EP instance is upgraded before (e.g., one or two weeks) the NA instance, installs of package X for NA would happen from the NA instance, and installs of package X for EP would happen from the EP instance replicated copy of package X. This ensures installs from like versions would occur.
When the export process completes, the source user receives a URL that includes a unique key of the container organization. Anyone who knows the URL is able to access and import the package in the identified “container” organization into their own organization, e.g., the metadata associated with that package is copied or instantiated into the schema associated with that organization. The source user may send the URL to another user at another company, or the source user may post the URL to a directory as will be described in more detail below.
Once a package is exported, the package remains open in the source organization, and the source user can continue to change it. However, the copy of the package in the container organization is preferably locked from further changes.
A source user can export the same package multiple times, creating multiple container organizations. This allows a source user to create a version history of how the package changes over time.
After the source user creates and exports the package to a container organization, they can optionally create a second new organization object with organization type “demonstration”. The demonstration organization has its own user id(s) and password(s). Any user who knows the id and password can log into the demonstration organization and view the exported package. Once logged in, the viewing user can manually validate that the required objects are present and the application works as expected. If the exporting user specified that sample data be included in the export package, a viewing user can see the sample data when logging into the demonstration organization or they can add their own sample data directly into the demonstration organization. In one aspect, the source user must create a demonstration organization for their package before they publish it to the public directory. This assures that users browsing the directory have a place to “try out” the application before they choose to download or import the package. For example, a package may include a web integration link (WIL)—it is very useful to examine WILs in the demonstration organization to ensure that the services being used by WILs are trusted.
Once a demonstration organization has been created for a package, the source user can “publish” the package to a centralized public directory. Upon publishing, the system notifies the central directory to include the package by sending a message to the directory service. This message, in certain aspects, contains a URL that allows users to navigate from the public directory back to the container organization and import it. The message, in certain aspects, also includes a URL of the demonstration organization. This allows users browsing the public directory to “try it now”—they can log into the demonstration organization and thoroughly inspect the functionality. In certain aspects, the message includes descriptive data about the package (e.g., name, description, etc) and a list of objects included in the package. The directory uses this information to provide detailed information for users browsing the directory looking for packages to import. Additional details about the public directory are described below.
Package Import
To import and install a package into an organization, an import user navigates to the URL that was generated by the package export process, either through the directory, or via a message from the source user. This URL contains a unique key that identifies a particular exported application and package. The import user may have found this URL by browsing the public directory, or the exporting user may have simply emailed the URL to that user. When the import user clicks on the URL they are able to access, view and import the package.
In one aspect, installation is a multi-step process with one or more steps performed in the installation wizard. For example, in one aspect, the steps include providing a display of the package contents for the user to examine and confirm they want to install, configuring the security for the existing profiles in the installer's organization, importing the package contents, and deploying the application to the intended users. An import user may also choose to customize any items in the install package.
In certain aspects, some or all of the following steps may need to be performed or may occur during the package import and install process:
Log into the recipient organization by entering a UserID and Password. This is a user id for the recipient organization into which the package is to be imported.
Optionally, the exporter may have password protected the package. If this is the case, the import user has to enter the package password before they can import it (this is a different password than the user password required to log into the recipient organization).
If object names in the package conflict with setup data in the recipient organization, the import process may fail. The import user may change the object names on conflicting objects within the recipient organization and restart the import process.
During the import process, the recipient organization is locked to prevent inconsistent metadata updates.
The import process checks to make sure the importing user has appropriate organization permissions to import a package.
The import user is asked to define mappings from source organization specific references in the package to values appropriate for the recipient organization. For example, the import user may be prompted to specify a user id, profile or role.
The setup data is copied into the recipient organization in a “development” mode. This allows the import user to verify that the application functions correctly before deploying it to users within the recipient organization.
The import process scans the package for malicious functionality. For example, it can check for any Web Integration Links (WILs) that may post data to third party websites.
If specified in the package definition, the import user is unable to change any of the setup data in the package after it is imported. For example, the import user cannot add or remove fields from a custom object after it is imported if specified in the package definition. This is implemented by the custom object edit screen functionality checking the package definition tables before allowing any edits to an object in the recipient organization.
The import user can optionally “uninstall” a package. This can be implemented because the system keeps track of which metadata objects belong to the package (e.g., through the package database schema).
In certain aspects, packages may be upgraded. For example, if a publisher/export user changes the source package, the import user can choose to pull into their organization the change(s) made by the publisher while preserving any data rows the subscriber had creating since first importing the package. According to certain aspect, one or more flags may be set in the package definition to determine whether and to what extent customizations to a package may be made and upgraded. In one aspect, a “manageable” field is provided to identify whether customizations to a particular object are subject to upgrade. For example, if the package or an object in the package is marked as managed, the user is allowed to customize the package or the object, and these customizations will not be altered upon upgrading of the package. In another aspect, a “control” field is provided to identify whether an object may be modified by the publisher and/or the subscriber. In another aspect, an “immutable” field is provided to identify whether an object can or cannot be altered by anyone. For example, the source user can set the immutable flag so that nobody is able to modify the packages after it has been published. An upgrade process that executes checks each of these fields, where present, to determine the extent that customizations are maintained upon upgrading.
Application Directory
The present invention also provides a central directory of applications; source users can register packages in a central directory. In one aspect, the central directory includes a public portion that includes published packages intended for use by anyone, and a private portion that includes packages not intended for general use (e.g., packages intended for use by import users as selected by the source user). The directory allows other users to browse published applications and choose which ones they want to install into their organization. In one aspect, the central directory is organized by a category hierarchy that allows users to search and browse by category for the types of application they're interested in. In one aspect, the directory allows users to “try it now”—they can look at the demonstration organization containing the package before they install it into their organization. In another aspect, the directory provides an automated approval process that assures submissions are acceptable before they appear in the public directory. In another aspect, the directory includes a ratings system that allows (import) users of an application to vote on an application's usefulness and quality. This voting appears in the public directory for other users to see.
In certain aspects, the directory is built using JSP pages, JSTL, a JSP tag library, JSP tags, and Java classes. In one aspect, data used by the directory is stored in an organization object managed by one or more directory administrators. Source users of applications may use the directory to input and maintain descriptive information held in a DirectoryEntry object for each application. Directory entries have an associated status field and only applications having a status of “published” or “public” are rendered for a visitor. A status of “preview” allows source users and directory administrators to see results as they will appear on the web before they become public. In one aspect, a display of applications according to solution categories is dynamically rendered based on a category picklist of values. An applications is tagged with the categories to which it belongs using a multiple-select picklist. A new value may be added at any time to the picklist and category label to create a new category.
Roles and Publishing Model
Except for visitors browsing the site, almost all other uses of the directory site should require the user to either login or have a valid session id. These users may play different roles and may have different permissions to perform actions according to these roles. For example, three basic roles might include developer, publisher, and importer.
Developers should be able to hand responsibility for publishing the application over to another trusted person through creation of a publisher role and editing permissions. A publisher (which defaults to the developer himself) may be granted permission to create the original directory entry describing the application, modify it at a later date, add other publishers to assist, or even remove the entry from the directory. As used herein a source user can be either or both of a developer and a publisher.
The user id of the person logging into the directory is used to determine the roles and rights the user has in regards to each application. Users should have no real access to the organization in which the directory is kept. User id's are, however, used to uniquely identify users and to retrieve information from their own organizations when necessary.
A developer is an original creator of the application and its package through a setup wizard. One (optional) step in the wizard is to submit the application for publication in the Directory. There, the developer, may either enter information himself or designate others to serve as the publisher and maintainer of the directory entry. A publisher of a given directory entry is a user who is responsible for entering and maintaining descriptive information about the application in the directory. Each application's directory entry has an assigned set of publishers along with permissions granted by the original submitter. These permissions give rights to edit fields, change status, remove the application from the directory or even add others as publishers (e.g., with the same or lesser permissions). An importer is any import user, e.g., system administrator of an organization or tenant, who has initiated the import process of an application for deployment in their own organization. During the import process, a record is created in the database system showing what organizations have which applications imported and by whom. This may be used to show how popular an application is and if it is desirable, to restrict comments and ratings to only those users of organizations that have the application installed. Individuals may participate in multiple roles at different times; i.e., a user may be a developer of one application and an import user for another.
Review of Directory Information
Publishers create an application's directory entry, input associated information such as a description, thumbnail, screenshots, and other information. Prior to becoming public, a publisher may preview this information at any time. When the information is ready to be made publicly available for viewing, the publisher changes the state to “submitted”. In one aspect, this initiates a review of the application by a directory administrator, who may request further information, etc. Once the application has completed review, the directory administrator changes its state to “public”. This makes the application available for public viewing within the directory. Depending upon the business process, the public state may also lock out any further changes by publishers. In this case, should the publisher need to update the directory entry after being made public, a request could be filed with the directory administrator to remove the entry from public view, e.g., by changing the state back to new. If it is desirable to allow publishers to modify entries without requesting permission to change and another round of review, a Modified flag in the directory entry can be used to simply indicate that a public entry has been changed.
Reputation Management Through User Ratings and Comments
In one aspect, to give visitors an idea of what others think about each application, viewing users may assign a rating to the application and provide personal reviews in the form of comments. In one aspect, only users of organizations that have actually installed the application may provide comments and/or ratings. This entitlement could be deduced, for example, by looking at the import records created by system administrators who initiated the application installation.
To keep ratings an honest reflection of how the community rates the application, however, it may be necessary to provide some protection from users gaming the system by making multiple postings. In any case, users may want to change their rating of an application from what they initially rated. In one aspect, this is accomplished by treating the ratings system as one would voting; each user casts a vote for one of five possible star ratings associated with the application and each application keeps a tally of the votes for each of the possible ratings. It then becomes trivial to determine the average rating for each application and also yield a more informative histogram of the votes. Users may change their vote at any time, but no matter how many times they make a rating, they only get to vote once per application. A record is kept for each user of their current rating for applications that they have rated or commented on.
Directory Data Model
FIG. 3 shows a data model for a Directory of applications according to one embodiment. As shown, the Directory data model according to this embodiment includes five main objects: DirectoryEntry, CategoryPage, Publisher, Import and UserReview. It should be appreciated that fewer or more objects may be used.
The DirectoryEntry object holds information pertaining to each individual application submitted for publication. Information is written to this table by the web site during application submission or modification and may be reviewed and modified by the appropriate internal directory support personnel. FIG. 4 shows a definition of a DirectooryEntry object and other objects according to one embodiment.
Associated with each entry in the DirectoryEntry object is a status field indicating the status of the directory record. The values allow coupling the external input and editing functions with an internal process of review and preview. Status values might include:
New: first created with only minimal information
Submitted: entry ready for internal review before publishing
Preview: allows internal site provider personnel to preview information in the context of the site
Public: publishable, ready for public viewing
Inactive: no longer visible in the directory (deleted)
When the state is changed to Public, the developer and other publishers for the application are notified, e.g., by e-mail, and a publish date field or variable is set.
According to one aspect, each entry is associated with a multi-select picklist field representing the solution categories under which the application will be listed. The directory dynamically adapts to categories so they may be added at any time. For readability, in one aspect, the picklist values encode the category and/or subcategory into each name.
The total user votes for a rating, e.g., 1-5 stars, are stored in fields from which the average can be computed. Also, the system can determine and display the ratings for each application, e.g., count how many applications were rated I-star, 2-star, etc.
The CategoryPage object is used to form the category hierarchy driving the Directory's dynamic generation of category pages. This object also holds a title for the page along and a list of several applications to display as featured selections on the page.
The Publisher object holds the user id of a user (e.g., source user) responsible for creating and maintaining the application's directory entry along with their editing permissions. Examples of permission levels include:
Edit: grants someone the right to edit the modifiable fields in the DirectoryEntry
Delete: grants the user the right to delete the DirectoryEntry
AddUser: grants the user the right to add additional users with the same or more restrictive rights.
In one aspect, permission ordering from most-to-least is Delete, AddUser, Edit.
The Import object acts as a record of what imports have been initiated of an application into any particular organization. This object holds ids of the DirectoryEntry (or package id), the system administrator importing the application, the organization affiliation of the system administrator, and the date of import. This object allows ranking of applications based on the number of imports and can be used, if desirable, to limit users to commenting and rating only on those applications that have been imported in their own organizations.
The UserReview object holds comments and ratings made by a specified user of a particular application entry. Restrictions may be imposed on who can add comments and rate applications such as only allowing authenticated users or even restricting only to those users in organizations that have imported the application. An implementation need not have any such restriction.
Implementing Categories Using CategoryPage Objects
A useful user requirement on the Directory is to be able to see a list of applications by solution category. Any application may appear in any number of categories and categories are preferably nested. Additionally, to allow other views of the data, such as by business size or market segment, it is desirable to be list applications accord to different categorization schemes.
According to one aspect, categories are assigned as the application of tags (out of a multi-select picklist) to each application entry. A user working on preparing the directory entry for an application is presented with the current categorization scheme in the form of a set of check boxes to indicate which categories apply to the application. The system will assign the necessary picklist values to the application's directory entry.
To make it easy for a directory administrator to manually make entries and run reports showing which applications are in which categories, in one aspect, each application entry contains a category field containing a multi-select picklist of available categories. For readability, picklist values representing a subcategory should show the path to subcategory, i.e., “Consumer+Games” value would imply the application exists in the subcategory Games under the Consumer category. Multiple values place the application into multiple categories.
Because categories and their hierarchies are created for the purpose of generating category pages, the hierarchical representation of a particular category hierarchy uses a set of Category Page objects. In one aspect, a CategoryPage object exists for each category and/or subcategory available. CategoryPage objects are linked together to form a tree through fields specifying the node's own category and the category of its parent node. Root nodes, are indicated by CategoryPages which have no parent. (See, e.g., FIG. 5 ). Tree traversal is accomplished by query. For example, to find the labels of top level categories of a particular hierarchy, called All-Solutions, a query might look like:
select Label from CategoryPage3 where Parent-Node_c=‘All-Solutions’.
In one aspect, display nodes also carry additional information used by JSP pages rendering the list of applications falling into the specified category. This additional information includes a field for maintaining a count of associated applications, page title label, page body text, and applications to feature on the page.
In summary, directory supported user functions might include: For visitors (viewing and importing users):
View application list filtered and sorted by business area (category), author, date submitted, rating, or other criteria
View full application description (detail page)
View full application specification/profile (such as #of objects, object names, web integration links (WILs), etc.)
View aggregated user ratings of applications
View “highlighted” applications according to business area or overall
View top ranked applications
View most popular applications
Submit/change their rating of individual applications (optional restriction)
Post comments associated with individual applications (optional restriction)
Try out application in app-specific demonstration organization
Import application to their own organization
For developers (export users):
View application packages that the developer developed
Submit application for publication along with associated descriptive information.
Remove applications from the directory
Edit/update application descriptions
Receive email notification when application has been approved by provider review
Delegate responsibility over the management and publication of the application to other users
Upload images, pdfs, and other documents associated with the application as attachments to the DirecctoryEntry
Miscellaneous
In one alternate embodiment, rather than using a new type of organization (e.g., container organization) in the database schema to store an exported package, exported packages are implemented as binary large objects in the database (e.g., Oracle db) or as text or binary data stored in a flat file format. However, upgrade scripts may not work well against flat files. Therefore, in one embodiment, a package is implemented as a separate “hidden” organization within the database system (e.g., salesforce.com service). This advantageously allows release upgrade scripts to upgrade these exported organizations.
In one aspect, storing a foreign key to the unique package id on all setup data included in the package is performed instead of storing a package table including the primary keys of all objects in the package. However, the package table approach is preferred as it makes it more efficient to quickly determine which objects were included in the package at runtime. It may be desirable to determine which objects were included in the package at runtime to differentiate between installed packages from the base system or from each other. For example, in the custom object edit screens, custom objects that were imported as read only cannot be modified while all other custom objects (not imported) can be modified.
While the invention has been described by way of example and in terms of the specific embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A computer implemented method of developing computer applications, the method comprising providing to multiple users access, over a network, to information on a data center, with a subgroup of the users having access to a sub-portion of the information that is different from the sub-portion accessible by the remaining tenants of the subgroup; and communicating with the data center over the network employing a computer system associated with a user of the sub-group to establish application functionality with the sub-portion that may be accessed, over the network, by additional parties authorized by the user. Also disclosed is a machine-readable medium and a data center, both of which facilitate carrying-out the steps of the method.
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RELATED APPLICATIONS
This application claims the benefit of and priority to Chinese Patent Application Nos. 200910057119.1 and 200910057120.4, each filed on Apr. 24, 2009, the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates generally to a method and an apparatus for operating an ultracapacitor powered vehicle.
BACKGROUND
Existing ultracapacitor powered buses or automobiles are driven by electric energy stored in ultracapacitors. The ultracapacitor also supplies power to assisting operating devices. The fundamental principles are similar to those of the trolleybus, as is shown in FIG. 1 . Vehicles powered by ultracapacitors can charge when they are stopped at stations (e.g., bus stations) in a traffic system. When the ultracapacitor needs to charge, it can utilize the existing rectified DC network for trolleybuses as the power source or, after reducing (or lifting) voltage and rectifying, can utilize an AC network as the power source. Because ultracapacitors have high charge acceptance, through rapid charger, the charging process can be finished within tens of seconds while the vehicle or bus stops at the station and loads passengers. Therefore, buses powered by ultracapacitor can be suitable for city public traffic systems that have fixed routes. The system is electric-powered, can have zero-tail-gas-emissions and zero-pollution. It can be used in numerous scenarios including, but not limited to, fixed public traffic routes such as short-distance large passenger-flow routes in downtown areas and/or passenger transport systems for airport, dock, tourist resorts and/or residential districts.
SUMMARY OF THE INVENTION
In currently available technologies, ultracapacitor powered buses are transformed from trolley buses by adding ultracapacitors and AC frequency converter gearing devices. The typical charging voltage range for individual ultracapacitors is 0.9-1.4 Volts. In addition, ultracapacitors can only store a small amount of energy and the full charge endurance is low. Currently available ultracapacitor powered buses do not take full advantage of ultracapacitors storing ability. In some aspects, the invention is directed to curing the deficiency of the currently available ultracapacitor technologies by taking full advantage of ultracapacitor storing ability to increase the full charge endurance and improve the control of the entire bus.
One approach to charging ultracapacitors in an electric vehicle powered by ultracapacitors is to use temperature feedback. The invention, in one aspect, includes an electric vehicle powered by ultracapacitors. The vehicle includes a current collector device for collecting power from an external power source, an electric motor module for providing a driving force to the vehicle, an ultracapacitor module and a charger device. The ultracapacitor module includes one or more ultracapacitors. The ultracapacitor module is coupled to the current collector device for receiving power and is coupled to the electric motor module for providing power. The charger device is connected to the current collector, the ultracapacitor module, and to a temperature signal associated with one or more of the one or more ultracapacitors. The charger device is configured to adjust power supplied to the ultracapacitor module based on the temperature signal.
In another aspect, there is a method for charging an electric vehicle powered by ultracapacitors. The method includes receiving power, via a current collector device, from an external power source. The method also includes measuring one or more temperature values of one or more ultracapacitors in an ultracapacitor module connected to an electric motor. The method also includes charging the one or more ultracapacitors with power received from the external power source, wherein charging the one or more ultracapacitors is based on the one or more temperature values.
In other examples, any of the aspects above can include one or more of the following features. In some embodiments, the vehicle can further include a distributed ultracapacitor monitoring system. The vehicle can further include a controller area network (CAN) device. The CAN device can be configured to communicate using the SAEJ1939 protocol. The vehicle can further include an electric bus pantograph supporting the current collector device. The vehicle can further include a camera positioned to monitor the electric bus pantograph and connected to a controller area network (CAN) device. The ultracapacitor module can further be coupled to one or more additional electric devices for providing power. The charger device can include a IGBT device and a control device. The IGBT device can be connected to the current collector and the ultracapacitor module. The control device can be connected to the temperature signal and the IGBT device. The control device can be configured to adjust the power delivered by the IGBT device to the ultracapacitor module based on the temperature signal. The control device can be configured to decrease, using the IGBT device, an upper limit of charging voltage of the ultracapacitor module when the temperature signal indicates an increase in temperature. The control device can be configured to decrease the upper limit of charging voltage when the temperature signal indicates a temperature higher than 25° C. The control device can be configured to increase, using the IGBT device, an upper limit of charging voltage of the ultracapacitor module when the temperature signal indicates a decrease in temperature. The control device can be configured to increase the upper limit of charging voltage when the temperature signal indicates a temperature lower than 25° C. The upper limit of charging voltage can be between 580 volts and 640 volts.
Other aspects, examples, and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating the principles of the invention by way of example only.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages of the present invention, as well as the invention itself, will be more fully understood from the following description of various embodiments, when read together with the accompanying drawings.
FIG. 1 illustrates a block diagram of typical ultracapacitor powered buses.
FIG. 2 illustrates a block diagram of an ultracapacitor powered bus, according to an illustrative embodiment of the invention.
FIG. 3 illustrates a block diagram of an intelligent charger, according to an illustrative embodiment of the invention.
FIG. 4 illustrates a block diagram of a distributed ultracapacitor monitoring system, according to an illustrative embodiment of the invention.
DETAILED DESCRIPTION
FIG. 2 illustrates a block diagram of an ultracapacitor powered bus 200 , according to an illustrative embodiment of the invention. While FIG. 2 illustrates a bus, other configurations are possible. For example, in some embodiments, ultracapacitors can be used in any vehicle or mobile driven device including, but not limited to, cars, trucks, trains, boats, etc. The bus 200 can include a body structure (not shown), current collector device 210 connected to a pantograph, an intelligent charger module 220 , an ultracapacitor module 230 , additional electric control units 235 , a CAN instrument 240 , a distributed ultracapacitor monitoring system 245 , a camera 250 , and an electric motor and driver module 260 . The current collector device 210 can be raised on a pantograph at, for example, bus stops while passengers unload and load. For example, the drive can manually, via a control interface, raise the pantograph or the bus can automatically detect when it is near a charging station (e.g., via a bluetooth signal) and have the pantograph raised. More generally, current collector device 210 can be any device that can connect to a power source to charge the ultracapacitor bus system 200 . The current collector device 210 can provide electrical power to the ultracapacitor module 230 via current and/or voltage on one or more electrical connections. Two or more elements of the bus system 200 can be connected together using a controller area network (CAN).
In some embodiments, CAN instruments can be based on the SAE J1939 protocol, which can realize real-time communication between every electric control unit (e.g., intelligent charger, distributed ultracapacitor monitoring system, electric motor and driver, etc.) via a CAN-bus. The system can be highly intelligent, precisely measured, highly stable and have the ability of responding in real time. The camera 250 can monitor the bus' pantograph and send video signals to the CAN instrument 240 .
The ultracapacitor module 230 can include one or more ultracapacitors, which provide power to drive the bus. The ultracapacitor module 230 , as the power source, is connected to the electric motor and driver module 260 . In some embodiments, the ultracapacitor module 230 can also provide power to one or more additional electronic units on the bus such as, for example, power steering unit, air conditioner unit, anti-lock braking system, pneumatic brake unit, car lights, wipers, and/or other electrical units.
The ultracapacitor module 230 is connected to the intelligent charger module 220 and can be connected to the distributed ultracapacitor monitoring system 245 .
FIG. 3 illustrates a block diagram 300 of the intelligent charger 220 of FIG. 2 , according to an illustrative embodiment of the invention. An input voltage from the current collector device 210 can be provided to an IGBT device 310 . The IGBT device 310 can chop a power signal and provide one or more outputs to the ultracapacitor module 320 . The IGBT device can also be based on step-down charge technology and use a charging mode of limiting the constant voltage output. The output signal from the IGBT device can be sampled by a sampling device 330 and can be amplified by amplifier 340 . A control device 350 can provide a control signal to the IGBT device 310 that controls the level of charging that the IGBT device 310 provides to the ultracapacitor module 320 . The control device 350 can take as input the amplified signal from the amplifier 340 , an inductive current sampling from the IGBT device 310 , one or more temperature signals from the ultracapacitor module 230 , and/or other control signals from the CAN network. For example, in some embodiments, the control device 350 can operate when it receives a signal from the camera 250 indicating that the current collector device 210 has connected to an external power source.
In some embodiments, the control device 350 can be a digital signal processor (DSP) and/or a programmable logic device (e.g., CPLD). In alternative or supplemental embodiments, the control device 350 can be a proportional-integral-derivative (PID) controller. In yet other embodiments, the control device 350 can be a TMS320LF2812 from Texas Instruments. The control device 350 can control the IGBT device 310 's break-over and shutoff to produce a chopped wave (e.g., it can control one or more of the frequency, duty-cycle, impulse width or other characteristics of the output voltage). The control device 350 produces a control signal based on, for example, the ambient temperature of one or more points in the ultracapacitor module 230 . For example, when the ambient temperature increases, the control device 350 can reduce the upper limit charging voltage of the IGBT device 310 . When the ambient temperature goes down, the control device 350 can increase the upper limit charging voltage of the IGBT device 310 . By reducing the upper limit charging voltage when the temperature increases, the charging calorific value of ultracapacitor can be decreased. At the same time, the charge quantity does not decrease. Similarly, when the temperature goes down, increasing the upper limit charging voltage can increase the calorific value of ultracapacitors and can increase the charge volume of ultracapacitors.
The upper limit of the charging voltage range of an ultracapacitor module can be between 580 and 640 Volts, while the charging current range can be between 30 and 300 Amps. When a temperature sensor detects that the ambient temperature is lower than 25° C., for example, the individual capacitor can be charged to 1.58 Volts. In some embodiments, the entire bus can have 400 capacitors, resulting in a total voltage of 632 Volts. When a temperature sensor detects that the ambient temperature is higher than 25° C., for example, individual capacitor can be charged to 1.52 Volts. If the entire bus has 400 capacitors, then the total voltage will be 600 Volts. Based on the formula E=CU 2 /2, the energy stored in the ultracapacitors will increase by 30-50% and will not influence the normal operation of ultracapacitors. Therefore, the intelligent charger 220 can advantageously automatically adjust the ultracapacitor module 230 's charge voltage and current according to ambient temperature, which can result in more electric energy being stored and/or maximizing the full charge endurance.
The control device 350 can also include a complete failure protection function, a module-level fault diagnosis function, and/or minor fault automatic reset functions. The control device 350 can also use a CAN network interface to connect to a host computer for maintaining a failure log and diagnosis record.
FIG. 4 illustrates a block diagram of a distributed ultracapacitor monitoring system 400 , according to an illustrative embodiment of the invention. The distributed ultracapacitor monitoring system 400 includes a monitoring system master node 410 , one or more distributed capacitance detection child nodes 420 , assisting electronic devices 430 (e.g., fans), a LCD diagnostic device 440 , and/or a CAN meter 450 . In some embodiments, the system 400 can include 30 child nodes 420 . The distributed ultracapacitor monitoring system 400 can based on iCAN protocol, which includes a monitoring control system of host nodes. In some embodiments, being connected to every capacitor child node 420 , the monitoring control system host node 410 can be linked to the vehicle instrument system 450 via CAN bus complying with the SAE J1939 protocol.
The monitored control system host node 410 can have an overall current measuring interface and an overall voltage measuring interface 430 . These two interfaces can be connected to current sensor and voltage sensors, respectively, to measure the overall current and voltage of ultracapacitors in the ultracapacitor module 230 . In some embodiments, the overall voltage measuring interface 430 can include a NCV1-1000V voltage sensor to measure (0-650V±5) volts d.c. In supplemental or alternative embodiments, the overall current measuring interface 430 can include a NT300-S current sensor to measure (rated current 300±3 Amps, maximum measuring range±300 Amps) direct current.
The child nodes 420 can be linked to individual ultracapacitor temperature sensors 425 to measure, for example, its surface temperature. Each child node 420 can be linked through the iCAN communication network with the host node 410 . The CAN control instrument 450 can analyze and process information, give orders, and/or show the working condition of each equipment on the CAN bus. The CAN control instrument 450 can include powerful functions of fault diagnosis and, for example, inform the driver of the reason of breakdown in the first place advantageously increasing traffic safety. Diagnostic information with LCD display 440 can provide for an easy to understand interface with the driver. Through the monitoring camera of the pantograph and meter display, the driver can monitor the pantograph current collector's state to prevent errors and avoid damage caused by malfunction of the pantograph type current collector. In some embodiments, the monitored control system host node can support 320×240 single-color LCD diagnostic equipment. The LCD can be used to display system operating status, inputting alarming threshold parameters. The monitoring control system host node 410 can connect to 2 way relay dry contact output to drive two blowers 430 .
Nodes 410 and 420 can include processing units that are used to process received messages and generate messages to be sent to other devices. In some embodiments, the processing units can communicate (e.g., transmit and/or receive) the messages via one or more physical ports coupled to the processing unit. Communication via the physical ports can be accomplished, for example, according to the processes standardized in a physical layer protocol, data link layer protocol, network layer protocol, hypbrid layer protocol, and/or any combination of protocols thereof (e.g., using one or more of an industrial Ethernet protocol, a SONET/SDH protocol, a CAN protocol, an ATM protocol, and/or other physical and link layer protocols).
The above-described techniques can be implemented in digital and/or analog electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. The implementation can be as a computer program product, i.e., a computer program tangibly embodied in a machine-readable storage device, for execution by, or to control the operation of, a data processing apparatus, e.g., a programmable processor, a computer, and/or multiple computers. A computer program can be written in any form of computer or programming language, including source code, compiled code, interpreted code and/or machine code, and the computer program can be deployed in any form, including as a stand-alone program or as a subroutine, element, or other unit suitable for use in a computing environment. A computer program can be deployed to be executed on one computer or on multiple computers at one or more sites.
Method steps can be performed by one or more processors executing a computer program to perform functions of the invention by operating on input data and/or generating output data. Method steps can also be performed by, and an apparatus can be implemented as, special purpose logic circuitry, e.g., a FPGA (field programmable gate array), a FPAA (field-programmable analog array), a CPLD (complex programmable logic device), a PSoC (Programmable System-on-Chip), ASIP (application-specific instruction-set processor), or an ASIC (application-specific integrated circuit). Subroutines can refer to portions of the computer program and/or the processor/special circuitry that implement one or more functions.
Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital or analog computer. Generally, a processor receives instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and/or data. Memory devices, such as a cache, can be used to temporarily store data. Memory devices can also be used for long-term data storage. Generally, a computer also includes, or is operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. A computer can also be operatively coupled to a communications network in order to receive instructions and/or data from the network and/or to transfer instructions and/or data to the network. Computer-readable storage devices suitable for embodying computer program instructions and data include all forms of volatile and non-volatile memory, including by way of example semiconductor memory devices, e.g., DRAM, SRAM, EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and optical disks, e.g., CD, DVD, HD-DVD, and Blu-ray disks. The processor and the memory can be supplemented by and/or incorporated in special purpose logic circuitry.
To provide for interaction with a user, the above described techniques can be implemented on a computer in communication with a display device, e.g., a CRT (cathode ray tube), plasma, or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse, a trackball, a touchpad, or a motion sensor, by which the user can provide input to the computer (e.g., interact with a user interface element). Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, and/or tactile input.
The computing system can include clients and servers. A client and a server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
The components of the computing system can be interconnected by any form or medium of digital or analog data communication (e.g., a communication network). Examples of communication networks include circuit-based and packet-based networks. Packet-based networks can include, for example, the Internet, a carrier internet protocol (IP) network (e.g., local area network (LAN), wide area network (WAN), campus area network (CAN), metropolitan area network (MAN), home area network (HAN)), a private IP network, an IP private branch exchange (IPBX), a wireless network (e.g., radio access network (RAN), 802.11 network, 802.16 network, general packet radio service (GPRS) network, HiperLAN), and/or other packet-based networks. Circuit-based networks can include, for example, the public switched telephone network (PSTN), a private branch exchange (PBX), a wireless network (e.g., RAN, bluetooth, code-division multiple access (CDMA) network, time division multiple access (TDMA) network, global system for mobile communications (GSM) network), and/or other circuit-based networks.
The power stored in the ultracapacitors can be provided, for example, to power an electric motor module by passing current and/or voltage via one or more electrical wires. An electric motor module can include an electric motor that converts the received current and/or voltage to mechanical energy. Electric motors (e.g., AC, DC, and/or hybrid motors) can operate using well known techniques such as, for example, AC induction, stepper DC techniques, brushless DC techniques, and other electric motor techniques.
One skilled in the art will realize the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting of the invention described herein. Scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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Described are a method and apparatus for charging an electric vehicle powered by ultracapacitors. The vehicle includes a current collector device for collecting power from an external power source, an electric motor module for providing a driving force to the vehicle, an ultracapacitor module, and a charger device. The ultracapacitor module includes one or more ultracapacitors. The ultracapacitor module is coupled to the current collector device for receiving power and is coupled to the electric motor module for providing power. The charger device is connected to the current collector, the ultracapacitor module, and to a temperature signal associated with one or more of the one or more ultracapacitors. The charger device is configured to adjust power supplied to the ultracapacitor module based on the temperature signal.
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BACKGROUND OF THE INVENTION
The present invention relates to a transit seat which is particularly suited for use in a mass transportation vehicle, such as a bus or a rapid transit train.
Plastic shells have been used in transit seats, the principal advantages being in lower costs of maintenance and manufacturing. Also, inserts for plastic shells are known. Examples of such inserts are described in U.S. Pat. Nos. 3,737,198 and 3,797,887. The inserts may be padded for additional comfort so as to provide a somewhat more luxurious seat than a conventional plastic shell while maintaining the basic qualities of durability, economy, and ease of maintenance inherent in the plastic seats. The inserts further provide the ability to design a desired color scheme into the seat. In the event of vandalism to the inserts, which cover the largest exposed portion of the seat, an individual insert which is damaged can be removed and replaced.
The prior art teaches using several screws to secure the inserts to the plastic shell. Accordingly, to replace an insert the screws must be removed and replaced. Furthermore, a longitudinal seat is mounted with the seat back facing either the side walls or the back wall of a transit vehicle thereby requiring removal of the transit seat for access to the inserts securing screws. This may require removal of screws structurally mounting the transit seat to transit vehicle and the removal of adjoining trash shields and similar fittings surrounding the transit seat. Analogously, a transverse seat typically has a back cover secured by a plurality of screws which must be removed to obtain access to the screws holding in the insert. After the insert is replaced the back cover must again be secured by screws. A typical back cover for a two passenger seat has a number of screws exceeding ten. Thus, to remove one insert, a plurality of screws must be unscrewed and rescrewed. Further, the screws holding the back cover are typically self-threading and hold less tightly with successive rescrewings into the same hole. As a result, removal of an insert from either a transverse or longitudinal transit seat presents the possibility of loss of screws and replacement of the insert, the back cover and the seat frame with less than a full complement of screws. Replacement time is obviously related to labor costs and time out-of-service for the bus.
The prior art also includes U.S. Pat. No. 3,948,557 which teaches an elongated insert restraining bar, rotationally secured to the plastic shell, with notches rotated into position to engage studs protruding from the back of the insert. One end of the rectangular bar is engaged with a portion of the chair frame to prevent rotation of the insert restraining bar thereby coupling the insert to the plastic shell. This invention is an improvement of such patented construction.
It has been desirable to provide a fastening means for inserts for plastic shells which provides for correct replacement of the inserts while reducing labor cost and time out-of-service for the bus. The fastening means for inserts desirably restrains the insert when the insert is subjected to an operational environment including twisting and vibrational forces. Furthermore, it has been desirable to be able to use such a fastening means whenever replacement of inserts is desired because of wear, vandalism, a desire to change color schemes or some other reason.
SUMMARY
This invention provides for increased ease of installation by sequentially coupling an insert restraining means to spaced studs protruding from the insert. Thus, an installer's attention and efforts can be directed to a single operation instead of having to perform two simultaneous operations. Also, this invention requires for removing the insert two separate sequential movements of the insert restraining means in directions at an angle to each other. This substantially reduces the chances of accidental uncoupling of the insert due to vibrational and twisting forces. Also the effect of such forces is reduced by the eliminating of the coupling between the seat shell, the insert restraining means and the seat frame. In accordance with this invention, the insert restraining means is coupled only to the insert and the seat shell. Thus, relative motion or twisting of the seat frame with respect to the seat shell cannot cause the insert restraining means to move and cause releasing of the insert. Further, this invention provides for removal of an insert without removing the seat shell, the seat frame, the back cover or any screws for either a longitudinally or transversely mounted vehicle seat. In accordance with an embodiment of this invention, studs protrude from the back of the insert and engage openings in a plastic shell. A first set of openings can be of a keyhole slot type wherein a first set of studs can be inserted into a larger portion and then slid to a narrower portion thereby restraining the stud. A second set of openings permit a second set of studs to pass through the plastic shell and be positively engaged by an elongated insert restraining means. The insert restraining means is an elongated bar which is secured to the plastic shell to permit rotational movement and longitudinal movement and has a pair of notches for engaging the second set of studs and preventing their withdrawal through the second set of openings in the plastic shell.
A first notch in the bar includes a first longitudinal slot spaced from the sides of the rectangular bar and a connected transverse slot for first engaging a first stud of the second set of studs and permitting the stud to pass from the exterior of the rectangular bar to the longitudinal slot. A second notch includes a second longitudinal slot for engaging a second stud of the second set of studs by a longitudinal motion of the bar. As noted, it is of particular significance that the engagement of the first and second studs of the second set by the notches is sequential and an installer can concentrate his efforts on the engagement of a single stud instead of having to engage two studs simultaneously. More specifically, an installer can use one hand to press on the front face of an insert thus providing maximum extension of the stud beyond the shell. Simultaneously, the other hand can be used to position the bar so a notch engages only that stud. The bar can be rotated by a hand slipped behind a seat mounted against a transit vehicle wall and does not require either viewing of the bar or removal of a longitudinally mounted vehicle seat from a mounting adjacent a wall. Further, in accordance with an embodiment of this invention, the back cover of a transversely mounted chair has an opening through which a tool can be inserted to engage an opening in the bar and to rotate the bar. Since the back cover need not be removed, it can be riveted, instead of screwed, into place. Screws are not lost and correct securing of the insert is quickly accomplished. A firmly fastened back cover is desirable to shield a passenger from any insert fastening means. Further, the invention requires a low level of skill for replacing inserts and allows quick replacement thereby resulting in less out-of-service time for the bus and lower labor costs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a frontal perspective view of a seat in accordance with an embodiment of this invention;
FIG. 2 is a rear perspective view of the seat of this invention;
FIG. 3 is a schematic, broken rear elevation view of the interior of a seat back showing the elongated restraining bar for holding the seat insert in place;
FIG. 4 is a partial, cross-sectional view along section line IV--IV of FIG. 3;
FIG. 5 is a partial cross-sectional view of the seat back taken along section line V--V of FIG. 3;
FIG. 6 is a view of the elongated insert restraining element utilized in this invention;
FIG. 7 is a partial cross-sectional view of the element shown in FIGS. 3, 5 and 6 taken along section line VII--VII of FIG. 6;
FIG. 8 is a side view of an insert restraining means in accordance with an embodiment of this invention;
FIG. 9 is a bottom plan view, partially cut away, of a portion of the seat of a chair made in accordance with an embodiment of this invention; and
FIG. 10 is a cross-sectional view taken along section X--X of FIG. 9.
DETAILED DESCRIPTION
Referring to the drawings, a seat 20 includes a one-piece contoured plastic shell 21 mounted on a tubular steel metal frame 26 (FIGS. 9 and 10) and held in place by pop rivets 50 (FIGS. 1 and 2). Such structure is of the type shown in greater detail by U.S. Pat. Nos. 3,737,198, 3,797,887, and 3,948,557, the disclosures of which are herein incorporated by reference. Mounted on shell 21 is a seat insert pad 22 and a back insert pad 23. When seat 20 is mounted longitudinally along the wall of a transit vehicle the back of the shell is typically left uncovered. However, when seat 20 is mounted transversely, the back of the shell is advantageously covered by a back cover 90. Back cover 90 is attached to frame 26 by fastening means 97.
As shown in FIG. 2, seat 20 has back cover 90 with an opening 91 aligned with a handle 108 of bar 70. Accordingly, a tool such as a screw driver or the fingers of a hand can be inserted through opening 91 to grasp handle 108 and longitudinally move and rotate retaining bar 70. Back cover 90 would typically be used when seat 20 is mounted transversely in a transit vehicle.
As best shown in FIG. 4, back insert pad 23 includes a thin metal inner liner 53, a layer of foam material 55, and an upper upholstery panel 56. Alternatively, this insert can be a molded plastic or any equivalent material. Back insert pad 23 also includes studs 10, 12, 14 and 16 protruding from the back of the insert and each having an enlarged head. These studs can be anchored to insert 23 by a weld nut attached to thin metal inner liner 53 or in the case of a plastic insert can be a T-nut having an internally threaded barrel portion. In FIG. 4, a weld nut 18, associated with stud 16, is shown in cross section. In FIG. 5, weld nuts 33 and 34, associated with studs 16 and 14, respectively, are shown.
As shown in FIG. 3, plastic shell 21 has an opening 11 aligned to receive stud 10, an opening 13 aligned to receive stud 12, and opening 15 aligned to receive stud 14, and an opening 17 (visible also in FIG. 4) aligned to receive stud 16. Openings 11 and 13 are key-shaped so that studs 10 and 12 can be inserted into receiving portions 11a and 13a, and then slid over to a narrow portion 11b and 13b, respectively. Once insert 23 is in this position, with studs 10 and 12 inserted, studs 14 and 16 are inserted into openings 15 and 17, respectively. Openings 15 and 17 are not slotted and restrain insert 23 from moving longitudinally so that studs 10 and 12 are thus prevented from being withdrawn through the receiving portions 11a and 13b of openings 11 and 13, until studs 14 and 16 are withdrawn from openings 15 and 17.
To prevent studs 14 and 16 from withdrawing through their respective openings, a retainer bar 70 is positioned around studs 14 and 16. Bar 70 is connected at a longitudinal central slot 100 to plastic shell 21 by pivot 71. Advantageously, pivot 71 includes a rivet 101 (FIG. 5) which is counter sunk into plastic shell 21 and secures a T-shaped shoulder washer 102 through central slot 100. The longitudinal, elongated shape of central slot 100 prevents the shoulder of shoulder washer 102 from passing through central slot 100 thereby securing retainer bar 70 to shell 21 while permitting rotation of retainer bar 70 and longitudinal movement of retainer bar 70 along central slot 100. To show rotation of bar 70, a dotted outline 73 of bar 70 is shown in an offset rotational position in FIG. 3. Bar 70 has an angled shaped notch 74 and a longitudinal notch 75 to engage studs 14 and 16, respectively. It can be appreciated that the distance between insert 23 and the heads of studs 10 and 12 need only be enough to clear the thickness of plastic shell 21. However, the same dimension on studs 14 and 16 must be sufficient to clear the thickness of plastic shell 21 and the thickness of bar 70 when engaged with the studs.
Angled notch 74 as best illustrated by FIGS. 6 and 7 includes a longitudinal slot 103 spaced from the sides of bar 70 and a connected transverse slot 104. Thus, as retainer bar 70 is rotated, stud 14 can be received by transverse slot 104 and the rotation of retaining bar 70 can be continued until stud 14 is aligned in the longitudinal slot 103. Longitudinal notch 75 has only a longitudinal portion and engages stud 16 by longitudinal motion of retaining bar 70. The edges of notch 74 surrounding the sides of transverse slot 104 are inclined at 105a and 105b to provide a ramp which facilitates the sliding of the head of stud 14 therealong as the stud moves through the slot. Longitudinal slot 103 has a taper so the width of longitudinal slot 103 decreases with increasing distance from the end which receives stud 14 and is connected to transverse slot 104 to the opposite end which is adjacent stud 14 when retaining bar 70 is in a secured position. Advantageously, the narrow end of longitudinal slot 103 is sufficient to engage the body and any threads of stud 14 thereby preventing motion due to vibration. The side edges of longitudinal slot 103 are also inclined providing a wedge shaped surface 106 (FIG. 7) along the sides of longitudinal slot 103 which increases in height as stud 14 is moved from the wide to the narrow end of longitudinal slot 103. This wedge shaped surface draws the insert tightly against the seat shell.
Longitudinal notch 75 has a taper similar to longitudinal slot 103 and decreases in width as stud 16 extends into longitudinal notch 75 from the open end of retaining bar 70 along the length of longitudinal notch 75. Also, longitudinal notch 75 has a wedge shaped surface 107 along the edge of longitudinal notch 75. Wedge shape surface 107 is typically formed by embossing and has an increasing height as stud 16 passes to the narrow end of longitudinal notch 75. Further, wedge shaped surface 107 has a transverse change in height and increases in height as distance increases transversely from longitudinal notch 75.
A cross section of retainer bar 70, stud 16 and insert 23 is shown in FIG. 4. As retainer bar 70 is longitudinally moved into position it can be seen that the leading edge of longitudinal notch 75 which is inclined acts as a wedge to positively draw insert 23 against plastic shell 21. The final thickness of retainer bar 70, when it abuts stud 16, should be such so there is a tight fit between stud 16, retainer bar 70, shell 21, and metal sheet 53 of insert 23.
Referring to FIG. 8, retainer bar 70 has an arcuate shape centered about central slot 100 so that the ends of retainer bar 70 are pressed against plastic shell 21 as pivot 71 draws the central portion of retainer bar 70 toward plastic shell 21. Retainer bar 70 is advantageously manufactured of a spring steel such as 16 gauge 1065 steel which is heat treated to Rockwell C. To readily grasp retainer bar 70 so it can be rotated and moved longitudinally, the extremity of retainer bar 70 adjacent angled notch 74 has an angled handle 108 which is typically just an extension of retainer bar 70 bent at a right angle to the remaining portion of retainer bar 70.
To further prevent movement of retainer bar 70 when angled notch 74 is engaging stud 14 a lock spring 109 (FIG. 5) is connected to handle 108 by a rivet 110. Lock spring 109 is resiliently deflected as the head of stud 14 passes toward the narrow end of longitudinal slot 103 and then returns to its original position to resist the backward passage of stud 14. Of course, if it is desired to remove back insert pad 23, sufficient force can be used to overcome the spring bias of lock spring 109. Nevertheless, the typical vibrational forces of a transit vehicle would not be sufficient to overcome the force of lock spring 109 and permit disengagement of retainer bar 70 from the studs of back insert pad 23.
Referring to FIGS. 8 and 9, the retainer bar is adapted to secure a seat insert pad 22 by changing the position and shape of its handle. Frame 26 extends around the front bottom and side bottom of plastic shell 21 to provide support for seat 20 and thus it would normally interfere with handle 108. Therefore, a handle portion 108a of a generally Z-shape is welded to a retainer bar 70a at a point intermediate an angled notch 74a and a central slot 100a. Accordingly, the extremity of retainer bar 70a beyond angled notch 74a is shortened to clear frame 26. Handle 108a is bent to be spaced from and extend parallel to retainer bar 70a toward frame 26. Except for the above changes, the retainer bar 70a is identical to retainer bar 70 previously described and therefore includes angled notch 74a, slot 75a, central slot 100a with the means for rotatably supporting the bar, all as previously described. If desired, a protrusion 111 extends outward from frame 26 to prevent longitudinal movement of handle 108a and retainer bar 70. When it is desired to move retainer bar 70, handle 108a is pulled downwardly out of engagement with protrusion 111 so it clears protrusion 111 and slides across protrusion 111.
OPERATION
An insert can be secured into place by very simple steps. Retainer bar 70 is positioned so notches 74 and 75 are offset from openings 15 and 17, respectively. This can be done by reaching a hand around the top, sides, or bottom of a seat longitudinally mounted along the wall of a transit vehicle. Note that this operation can be performed without being able to see retainer bar 70. If desired, the position and length of central slot 100 can be such that when pivot 71 abuts one end of central slot 100, transverse slot 104 is correctly positioned adjacent opening 15 and in position to receive stud 14. Alternatively, this can be done by inserting a tool or fingers through opening 91 in back 90 and engaging handle 108 of retainer bar 70. Studs 10 and 12, having a body length sufficient just to clear the thickness of shell 21, are inserted into openings 11 and 13, respectively. Insert 23 is slid so the narrow slot portions of openings 11 and 13 receive studs 10 and 12, respectively. Studs 14 and 16 are then aligned with openings 15 and 17, respectively, and are next inserted through shell 21.
With studs 14 and 16 protruding beyond the back of shell 21, retainer bar 70 is rotated so stud 14 enters and passes along transverse slot 104. Once stud 14 has traveled the length of transverse slot 104 longitudinal motion of retainer bar 70 is started and stud 16 approaches the narrow end of longitudinal notch 75 and stud 14 approaches the narrow end of longitudinal slot 103. If a spring lock 109 is part of retainer bar 70 as illustrated for the back in FIG. 5 longitudinal motion is continued until lock spring 109 passes over the head of stud 14 and stud 14 reaches the extremity of longitudinal slot 103. If retainer bar 70 includes a handle 108a as illustrated for the seat in FIGS. 9 and 10, longitudinal motion of retainer bar 70 is continued until handle 108a passes over protrusion 111.
Securing an insert is a particularly easily operation because retainer bar 70 does not have to be seen and studs 14 and 16 are sequentially brought into notches 74 and 75. That is, attention can first be focused on inserting stud 14 into angled notch 74. Typically, this requires applying pressure on back insert pad 23 to extend stud 14 beyond plastic shell 21. Once stud 14 is in transverse slot 104 attention can be focused on extending stud 16 far enough beyond plastic shell 21 so it can be engaged by longitudinal notch 75, which is properly aligned because of the positioning of retainer bar 70.
Removing insert 23 is also a relatively simple process. A person must simply longitudinally move retainer bar 70 by overcoming any retaining force that is used to secure retainer bar 70 against accidental movement caused by such forces as vibration. This frees stud 16. Retainer bar 70 is rotated to free stud 14. Studs 14 and 16 are retracted through openings 15 and 17, respectively, by lifting one side of back insert pad 23. Insert pad 23 is then slid along the slots of openings 11 and 13 until studs 10 and 12 are aligned with the larger portions of openings 11 and 13, respectively. Withdrawal of studs 10 and 12 through their respective openings disengages insert 23 from shell 21.
Various modifications and variations will no doubt occur to those skilled in the various arts to which this invention pertains. For example, elongated fastening means extending from the insert may vary in shape from the studs as described. Also, the retainer bar may be movably mounted by means other than a centrally located pivot. These and all other variations which basically rely on the teachings through which this disclosure has advanced the art are properly considered within the scope of this invention.
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A removable insert for a transit chair shell has a plurality of studs protruding from the back of the insert. A plurality of openings in the chair shell receive the studs. A movable restraining means prevents withdrawal of the studs thereby securely positioning the insert to the chair shell. The restraining means is arranged to be moved longitudinally and rotationally and the insert removed without disassembly of the chair from its operational configuration.
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[0001] This patent is a substitution for U.S. patent application Ser. No. 09/193,937 filed Nov.17, 1998 and abandoned Mar.13, 2001.
FIELD OF THE INVENTION
[0002] This invention relates to a fracturing fluid composition containing an oxidizing breaker retarder and a method for fracturing subterranean reservoirs using such fracturing fluid composition.
BACKGROUND—DESCRIPTION OF PRIOR ART
[0003] Hydraulic fracturing is a technique commonly utilized to stimulate the production of oil and gas from subterranean formations of low permeability. In carrying out such techniques, the fracturing fluid is introduced into the formation under hydraulic pressure to produce one or more fractures in the target formation. The fluid can include proppants that are deposited in the fractures so that when the pressure against the formation is relaxed, the proppants maintain the fracture in an open or propped condition.
[0004] Upon completion of the treatment, it is generally desirable to remove the gelled fracturing fluid from the formation. To effectively remove the fluid, the viscosity of the fluid must be reduced. The reduction of the viscosity of the gelled fluid is referred to as “breaking” the gel. The agent responsible for breaking the gel is referred to as a “gel breaker”. Traditional gel breakers include enzymes and oxidizing breakers. The breaker can comprise substantially any of the well known oxidizing breakers. Examples of oxidizing breakers include ammonium persulfate, sodium persulfate, potassium persulfate, sodium peroxide, sodium chlorite, sodium, lithium or calcium hypochlorite, potassium perphosphate, sodium perborate and the like.
[0005] At formation temperatures of between about 75° F. to about 120° F., and pH ranges of about 4 to 9, enzyme breakers are suitable. At temperatures above 120° F, the enzyme breakers are inadequate and oxidizing breakers are required. Generally, depending upon the temperature of the formation, between about 0.1 and 5.0 pounds of the oxidizing breaker(s) per 1000 gallons of aqueous gel is sufficient to break the gel. However, problems caused by insufficient breaking or the breaking of the fluid too quickly are often experienced with the oxidizing breakers. Ideally, a fracturing fluid has high initial viscosity that remains stable during the well treatment and controlled breaking after the treatment. Heretofore, the control of breaking of the gel has been inadequate resulting in less than desirable treatment results.
[0006] There have been several proposed methods for the delayed breaking of the fracturing fluid that were aimed at eliminating the above problems. U.S. Pat. No. 4,968,442 and U.S. Pat. No. 5,010,954 use various concentrations of ethylenediamine-tetraacetic acid (EDTA) to break gels to a predetermined degree. One advantage claimed in this disclosure is that gels can be broken to different degrees thus controlling the flow-back characteristics of the fracture. U.S. Pat. No. 4,202,795 uses persulfate or fumaric acid or enzyme breaker encapsulated in a prill composed of a hydrolyzable gel to delay the release of said breakers as well as other additives such as demulsifiers that may be included in the prill. U.S. Pat. No. 5,497,830 uses gel breakers coated with a water insoluble wood resin to reduce the rate of release of breaker. U.S. Pat. No. 5,437,331 uses an enzyme encapsulated in a polymeric material such as polymethylmethacrylate (PMMA) to delay the enzymatic breaking of the gel. U.S. Pat. No. 5,393,810 uses sequestering agents such as copolymers of vinylpyrrolidone and acrylic acid to reduce the gel breaking effectiveness of the oxidizer.
[0007] Other delayed oxidizing gel breakers and techniques have been used previously. These include enclosing the breaker within a slowly dissolving or slowly melting capsule. The disadvantages of this approach are 1) the technique is expensive and 2) the melting and dissolving mechanism is dependent on the treatment and formation conditions. If the temperature is not high enough the capsules will not dissolve or melt.
[0008] In spite of all this technology, there still remains a need for a composition and method for the controlled breaking of the fracturing gel that is economical and effective and reduces or eliminates damage to the formation and facilitates well clean up.
[0009] In U.S. Pat. No. 6,617,285, polyols are used to accelerate the enzymatic breaking of borate crosslinked gels. Unexpectedly, as will be shown later, we have found that if these polyols and other polyols are partially esterified they actual serve to retard the breaking process of the oxidizing breaker(s), thus rendering it more controllable.
BRIEF DESCRIPTION OF THE INVENTION
[0010] The present invention relates to fracturing-fluid compositions containing an oxidizing breaker retarder and a method for fracturing subterranean reservoirs using such fracturing fluid compositions.
[0011] The fracturing fluid compositions include gelling agent(s), cross-linker(s), oxidizing breaker(s), pH control agent(s), and other desirable additives that comprise gelled fluids and that are known in the art. In addition the fracturing fluids contain unique oxidizing breaker retarders. The oxidizing breaker retarders are partially esterified, polyalkoxylated polyols that moderate the effect of the oxidizing breaker(s) according to their concentrations, the well treating conditions and also by varying the degree of esterification and the degree of alkoxylation of the partially esterified, polyalkoxylated polyols. By the present invention and the inclusion of partially esterified, polyalkoxylated polyols in aqueous fracturing fluid formulations as oxidizing breaker retarders, the gel breaking time can be controlled.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The composition and method of the present invention is directed to the fracturing of subterranean formations using gelled aqueous fracturing fluids. The present invention includes a partially esterified, polyalkoxylated polyol(s) as the oxidizing breaker retarder in the gelled aqueous fracturing fluid composition.
[0013] The preferred gelled fracturing fluid composition includes a hydratable gelling agent, an aqueous liquid, an oxidizing breaker and partially esterified, polyalkoxylated polyols as oxidizing breaker retarder. Optionally, pH control agents, such as potassium carbonate and the like, may be used to adjust and control the pH. Also crosslinking agents are usually necessary to improve the gel characteristics of the polymer used. Also proppants are usually included to assist in keeping the fractures open.
[0014] The gelling agents include hydratable polymers, which contain, in sufficient concentration and reactive position, cis-hydroxyl, carboxyl, sulfate, sulfonate, amino or amide. Particularly suitable polymers are polysaccharides and derivatives thereof, which contain one or more of the following monosaccharide units: galactose, mannose, glucoside, glucose, xylose, arabinose, fructose, glucuronic acid or pyranosyl sulfate. Natural hydratable polymers containing the foregoing functional groups and units include guar gum and derivatives thereof, locust bean gum, tara, konjak, tamarind, starch, cellulose and derivatives thereof, karaya, xanthan, tragacanth and carrageenan.
[0015] Hydratable synthetic polymers and copolymers which contain the above-mentioned functional groups and which can be utilized in accordance with the present invention include, but are not limited to, polyacrylate, polymethacrylate, polyacrylamide, maleic anhydride methylvinyl ether copolymers, polyvinyl alcohol and polyvinylpyrrolidone.
[0016] The aqueous liquid may include water, a sodium chloride brine solution, a potassium chloride solution, water-alcohol mixtures and the like. The hydratable polymer and aqueous liquid are preferably prepared by combining the polymer with the aqueous liquid in an amount in the range of from about 5 to about 80 pounds of polymer per 1,000 gallons of aqueous liquid.
[0017] Preferably, after combining the aqueous liquid with the gelling agent, the gelling agent may be crosslinked by the addition of sufficient quantities of a crosslinking agent. Typical crosslinking agents include, for example, boron, titanium, antimony, zirconium, and aluminum. The amount of crosslinking agent added to the hydrated gelling agent may depend upon several factors, such as for example, the type and quantity of polymer present in the aqueous liquid, such surface conditions to be encountered by the crosslinked gel system, and the purpose for which the crosslinked gel system is to be used, i.e. gel pad, fracturing, graveling packing, etc. These and other factors are appreciated and well known by those skilled in the art of preparing crosslinked gel systems, and therefore sufficient quantities of crosslinking agent are readily determinable.
[0018] Proppants may be selected from sand, resin coated sand, synthetic ceramics, spherical pellets of glass and the like, as commonly used in the aqueous fracturing processes.
[0019] The breaker can comprise substantially any of the well known oxidizing breakers. Examples of breakers include ammonium persulfate, sodium persulfate, potassium persulfate, sodium peroxide, sodium chlorite, sodium, lithium or calcium hypochlorite, potassium perphosphate, sodium perborate and the like. The breaker generally will be admixed with the gelled aqueous liquid in an amount of from about 0.1 to about 10 pounds per 1000 gallons of aqueous gel and preferably, from about 0.1 to about 0.5 pounds per 1000 gallons of aqueous fluid depending on the preferred gel break time.
[0020] The oxidizing breaker retarder can be any of a number of partially esterified, polyalkoxylated polyols. These include, but are not limit to, mono and higher esters of alkoxylated sorbitol, alkoxylated mono and disaccharides such as glucose, fructose, and sucrose, alkoxylated glycerine, alkoxylated polyglycerine, alkoxylated pentaerythritol, or alkoxylated trimethylolpropane any of which have been alkoxylated with ethylene oxide (POE), propylene oxide (POP) and butylene oxide (POB) or mixtures of one or more POE, POP, POB.
[0021] The amount of oxidizing breaker retarder used is determined by several factors, including the degree of delayed break required, the temperature, the amount of oxidizing breaker present, the nature and the amount of crosslinked polymer present in the aqueous fracturing fluid. Generally the amount of oxidizing breaker retarder used is from about 0.1 to about 20 gallons, and preferably from about 1.0 to about 10 gallons per 1000 gallons.
[0022] In the preferred method, the aqueous fracturing fluid is pumped downhole, under pressure, to cause one or more fractures in the reservoirs. After the fractures have been formed the gel is broken and the aqueous fracturing fluid is withdrawn from the reservoir.
EXAMPLES
[0023] The effectiveness of the partially esterified, polyalkoxylated polyols as oxidizing breaker retarders was determined for a crosslinked guar gum system. The crosslinked gel system contained 40 lbs per 1000 gallons of the guar gum, 10 lbs per 1000 gallons of the potassium carbonate and 1 lb per 1000 gallons of the borate crosslinking agent. 0.125 lbs per 1000 gallons of the Na 2 S 2 O 8 was added to the crosslinked gel as the oxidizing breaker. Different amounts of the POE(30) sorbitol trioleate, which is sorbitol reacted with 30 moles of ethylene oxide and then esterified with 3 moles of oleic acid, were added as the oxidizing breaker retarder.
[0024] The samples were set in a 140° F. oven and the viscosity was measured after 0.5, 1, 2, and 3 hours. The data in Table 1 indicates that the POE(30) Sorbitol Trioleate retards the gel breaking rate of the oxidizing breaker. Using the same oxidizing breaker concentration, the time required for the gel to break is increased by increasing the amount of POE(30) Sorbitol Trioleate. The sample without any oxidizing breaker remained a complex gel after 3 hours at 140° F. The sample with the oxidizing breaker but without any POE(30) Sorbitol Trioleate was reduced from complex gel to 7 cps in 2 hours. Samples containing different amounts of POE(30) Sorbitol Trioleate demonstrated retarded viscosity breaking proportional to the amount of POE(30) Sorbitol Trioleate added
TABLE 1 VISCOSITY (cps) @ 140° F. Sample 0.5 hr 1.0 hr 2.0 hr 3.0 hr 1 C C C C 2 C WC 7 B 3 C C 14 B 4 C C 47 4 5 C C C 35 Note: Sample No. 1: Control, crosslinked guar gum system only Sample No. 2: crosslinked guar gum system + oxidizing gel breaker Sample No. 3: crosslinked guar gum system + oxidizing gel breaker + 2 gal/1000 gal POE(30) Sorbitol Trioleate as oxidizing breaker retarder Sample No. 4: crosslinked guar gum system + oxidizing gel breaker + 5 gal/1000 gal POE(30) Sorbitol Trioleate as oxidizing breaker retarder Sample No. 3: crosslinked guar gum system + oxidizing gel breaker + 10 gal/1000 gal POE(30) Sorbitol Trioleate as oxidizing breaker retarder C = Complexed Gel WC = Weak Complexed Gel B = Broke
[0025] Table 2 shows the effect of the degree of esterification and the degree of ethoxylation on the oxidizing gel breaker retardation. Different samples were prepared using sorbitol reacted with from 20 to 40 moles of ethylene oxide and then esterified with from 0 to 6 moles of oleic acid. The crosslinked gel system contained 40 lbs per 1000 gallons of the guar gum, 10 lbs per 1000 gallons of potassium carbonate, 1 lb per 1000 gallons of the borate crosslinking agent, 0.125 lbs per 1000 gallons of the Na 2 S 2 O 8 , and 2.0 gallons per 1000 gallons of various partially esterified, polyalkoxylated polyols. The viscosity was measured after 1 hour at 140° F. by the visual judgment system as described in U.S. Pat. No. 5,393,810.
TABLE 2 EFFECT OF DEGREE OF ESTERIFICATION/ALKOXYLATION ON OXIDIZING GEL BREAKER RETARDATION Moles Acid/EO 20 24 26 28 30 36 40 0 B B B B B B B 1 B B B WC MC WC B 2 B B WC MC SC MC B 3 B WC MC SC SC MC B 4 B B WC MC SC SC B 5 B B B WC MC MC B 6 B B B B B WC B NOTE: B = Broke WC = Weak Complex MC = Medium Complex SC = Strong Complex
[0026] As shown in Table 2, no gel breaking retardation was observed using oxidizing breaker retarder with less than 20 moles EO or more than 40 moles EO regardless of the degree of esterification. The samples of Sorbitol with 30 moles EO and then esterified with 2-4 moles of oleic acid showed the maximum oxidizing breaker retardation in the crosslinked gel system.
[0027] Similar results to those obtained with oleic acid were found when tall oil fatty acid, lauric acid, and stearic acid were used instead of oleic acid indicating that the fatty acid used to esterify the polyalkoxylated sorbitol was not as critical as the degree of alkoxylation and esterification.
CONCLUSIONS
[0028] The partially esterified, polyalkoxylated polyols can be used as oxidizing breaker retarders in aqueous gelled fracturing systems. They moderate the effect of the oxidizing breaker(s) according to their concentrations, the well treating conditions and also by varying the degree of esterification and the degree of alkoxylation of the product. The inclusion of partially esterified, polyalkoxylated polyols in aqueous fracturing fluid compositions containing an oxidizing breaker and the fracturing of subterranean reservoirs using such formulations can better control the gel breaking time and optimize the treatment results.
[0029] Although the description above contains many specifics these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Various other embodiments and ramifications are possible within it's scope. For example, other acids such as stearic, lauric and tall oil fatty acids may be used. Alkoxylates may be formed using ethylene oxide and propylene oxide, ethylene oxide and butylene oxide or ethylene oxide and both butylene and propylene oxide, in various proportions. Other polyols such as glycerine, polyglycerine, glucose, fructose, sucrose, pentaerythritol, trimethylolpropane, and polymers of ethylene oxide and propylene oxide may be used.
[0030] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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A composition and method for fracturing subterranean reservoirs by including a partially esterified, polyalkoxylated polyols as an oxidizing breaker retarder in the aqueous fracturing fluid to delay its gel breaking properties with the oxidizing breaker. The delayed gel breaking properties will lead to the controlled breaking of the fracturing fluid that reduces or eliminates damage to the formation and facilitates well clean up.
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BACKGROUND OF THE INVENTION
The present invention relates generally to an end use not covered by my prior patent for thwarting suicidal attempts of mentally ill persons using a closet clothes rod, namely, negating suicidal attempts using a door handgrip.
EXAMPLES OF THE PRIOR ART
The problem posed by a closet clothes rod being used for attempted, and actually achieved, suicides at hospital facilities for mentally ill patients is the focus of U.S. Pat. No. 4,643,318 for “Safety Closet Rod System” issued on Feb. 17, 1987 to this inventor, Laurence D. Kopp. The elevated and stationary condition of the clothes rod was used to support a belt in a depending relation terminating in a noose configuration. Equally foreboding is a door handgrip, but the solution of the '318 patent of causing the release of the clothes rod under the body weight of a patient is not available for a door handgrip, because the handgrip mounting on the door must be substantial enough to withstand the normal abuse of use for urging the door in opening and closing movements. In door handgrip technology there is lacking a handgrip construction which negates suicidal attempts.
SUMMARY OF THE INVENTION
Broadly it is an object of the present invention to overcome the foregoing and other shortcomings of the prior art.
More particularly, it is an object to impart a construction to the handgrip which is constrained against an attachment thereto that can be made by the free end of a noose-configurated opposite end of a belt or the like, and nevertheless not impair the door-opening functioning of the handgrip, all as will be better understood as the description proceeds.
The description of the invention which follows, together with the accompanying drawings should not be construed as limiting the invention to the example shown and described, because those skilled in the art to which this invention appertains will be able to devise other forms thereof within the ambit of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of an end use of the door handgrip according to the present invention;
FIG. 2 is an isolated view, in front elevation, of the handgrip;
FIG. 3 is a side elevational view projected from FIG. 2 ; and
FIG. 4 is a partial perspective view illustrating in full line and phantom line perspective an operating mode of the handgrip.
DETAILED DESCRIPTION OF THE INVENTION
In a prior U.S. Pat. No. 4,643,318 entitled “Safety Closet Rod System” there is disclosed “a closet rod which is yieldable [from its support] under a predetermined weight,” it being explained “there are several instances wherein closet rods, mounted in the conventional manner, pose a hazard to the safety and well being of the persons using such facility. For example, mentally ill persons have been known to use such rods to hang themselves in an attempt at suicide.” This patent addresses the same basic problem, but posed by a handgrip on a door, said handgrip, being generally designated 10 , and is attached by screws 12 adjacent a free edge 14 of a door 16 hinged, as at 18 , to partake of opening and closing movements about the axis of the hinges 18 , with the aid of the handgrip 10 being used by an individual (not shown) to urge the door 16 in the movements noted.
The grip 20 per se of the handgrip 10 is appropriately attached, by welding or otherwise, to be suspended between side brackets 22 and 24 , each of which brackets having flanges 26 and 28 used in the previously noted attachment to the door 16 implemented by the screws 12 . The grip 20 is cylindrical in shape presenting a 360-degree peripheral surface, as best noted in FIG. 3 at 30 , it being important to also note that widthwise of the grip 20 a nominal length portion 32 of the surface 30 is integral to an angularly oriented grip-blocking wall 34 extending to, and attached to the juncture of the side brackets 22 , 24 and flanges 26 , 28 , and consequently the grip 20 cannot be entirely gripped in a 360-degree encirclement relation by an individual. This partial grip is no impediment to urging the door 16 in opening and closing movements since the partial grip is achieved by a thumb placed under the grip 20 and at least one and a half digits of four fingers placed over the grip and the pressure applied therebetween has been found in practice to accomplish the gripping function intended. The placement of the wall 34 , as described which effectively prevents 360-degree encirclement of the grip 20 correspondingly effectively negates any suicidal attempt using a cord, rope or the like and the grip 20 , as a stationary elevated site of attachment.
Hypothesized in FIG. 4 is an individual 36 attempting a suicide using a belt 38 in a closed loop configuration in encirclement about the width expanse of the handgrip 10 which is thwarted, as noted by the arrow 40 , by slippage caused by an angularly oriented slope of the top edge surfaces 42 of the side brackets 22 and 24 , which in a preferred embodiment subtends an acute angle to the horizontal.
While the apparatus for practicing the within inventive method, as well as said method herein shown and disclosed in detail is fully capable of attaining the objects and providing the advantages hereinbefore stated, it is to be understood that it is merely illustrative of the presently preferred embodiment of the invention and that no limitations are intended to the detail of construction or design herein shown other than as defined in the appended claims.
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A handgrip that is restricted to only being partially gripped thereabout and by reason of sloped sides causing the slippage therefrom of a closed loop, and consequently is effective in negating its use in suicidal attempts.
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FIELD OF INVENTION
The present invention relates to a movable point crossing frog for a rail track, comprising:
a cradle assembly which comprises a movable point fitting component which has two projection elements which are mutually spaced-apart, a movable point which is mounted in the cradle assembly and fitted in the fitting component, spacer components which are interposed between the projection elements and the movable point, and means for removably fixing the movable point in the fitting component.
BACKGROUND
Generally, the design of known crossing frogs does not allow the movable point to be removed and replaced on the track (in situ) when it is worn or damaged.
For example, the crossing frogs described in patent FR 2 788 535 comprise spacers which are formed in one piece with the projection elements. Removing the movable point from the fish-plate chamber can thus be carried out, for crossing frogs of this type, only in the main direction of the track, that is to say, axially. This removal requires the fitting component to be removed beforehand, fixedly joined to the movable point, the removal of the movable point then being carried in the workshop and not in situ, which requires the worn or damaged frog to be removed and replaced with a replacement part of the same type.
A maintenance operation of this type not only involves very high cost, but also the track being closed for a very long period of time.
The object of the invention is to overcome this disadvantage and to make it possible to carry out a maintenance operation of this type in situ in order to very significantly reduce the duration and the cost of the maintenance operation.
SUMMARY OF INVENTION
To this end, the invention relates to a crossing frog of the above-mentioned type, in which the spacer components are fixed to the projection elements in a removable manner by the means for removable fixing, so that it is possible to vertically remove the point relative to the cradle assembly.
According to optional features of the invention:
the means for removable fixing comprise assembly elements which each have a threaded transverse shank which is fastened to the two projection elements and which, in cross-section, extends through the projection elements, the spacers and the movable point; the assembly elements each have a bush assembly in which the threaded shank is mounted, the bush assembly extending at least partially, in cross-section, through the projection elements, the spacers and the movable point; the crossing frog comprises, for each spacer component, at least one security shim which is fixed to a projection element in a removable manner, for example, by means of screwing, in abutment against an upper face of the spacer component so as to limit the vertical displacement of the point; the cradle assembly comprises a cradle at the side of the point end, the fitting component at the side of the projection end, and two intermediate elements which connect the cradle to the two projection elements, respectively, and the fitting component has a support plate which extends between the two projection elements and which supports the movable point.
According to a first embodiment of the invention:
the support plate is produced in one piece with the two projection elements; the fitting component is constituted by a unitary projection component, in particular cast from steel or special cast iron; and the projection component is assembled on the two intermediate elements by means of welding or by means of adhesively-bonded joints.
According to a second embodiment of the invention:
the support plate is a separate component from the two projection elements; and the two projection elements are produced by processing the two intermediate elements.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the invention will be described in greater detail below with reference to the appended drawings, in which:
FIG. 1 is a schematic plan view of a crossing frog according to the invention, positioned on a track;
FIG. 2 is a partial plan view of a crossing frog according to a first embodiment of the invention;
FIG. 3 is an enlarged section, taken in plane 3 - 3 , of the crossing frog of FIG. 2 ;
FIG. 4 is a view similar to FIG. 2 of a crossing frog according to a second embodiment of the invention; and
FIG. 5 is an enlarged section, taken in plane 5 - 5 , of the crossing frog of FIG. 4 .
FIG. 1 schematically illustrates a crossing frog 1 according to the invention, positioned on a track, in a state for use.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the remainder of the description below, the crossing frog will be assumed to be in its horizontal position for use and all the terms relating to directions and positions should be understood in accordance with this orientation.
In particular, the terms “horizontal” and “vertical”, which may qualify specific components of the crossing frog, should be understood in accordance with a horizontal position for use of the crossing frog.
Furthermore, the terms “axial” and “transverse” should be understood relative to the general direction of the track.
With reference to the schematic view of FIG. 1 , the crossing frog 1 substantially comprises a cradle assembly 3 which is fixed to the cross-pieces, and a movable point 5 which is mounted in the cradle assembly 3 .
The cradle assembly 3 is substantially constituted by a point cradle 11 , a fitting component 12 , and an intermediate component 13 which connects the fitting component 12 to the point cradle 11 .
At one point end, the cradle 11 has two regions 21 , 22 which are arranged symmetrically at one side and the other of the vertical axial plane.
These regions 21 , 22 have, in cross-section, respective forms which are symmetrical relative to the vertical axial plane of the cradle 11 and have a rail-like profile.
Two lengths 21 A, 22 A of rail are welded to the regions 21 , 22 of the point end of the cradle 11 , respectively, each of these lengths having a rail-like profile identical to that of the corresponding end region 21 , 22 .
In the same manner, the cradle 11 has, at the projection end thereof, two regions 23 , 24 which are arranged symmetrically at one side and the other of the vertical axial plane, these regions 23 , 24 having, in cross-section, respective forms which are symmetrical relative to this plane.
The intermediate portion 13 comprises two intermediate elements 33 , 34 which each have a rolled rail-like profile or cast elements whose ends are identical to those of the corresponding region 23 , 24 .
The fitting component 12 correspondingly comprises two projection elements 35 , 36 whose profile ends correspond to those of the intermediate elements 33 , 34 and extend the intermediate elements 33 , 34 , respectively.
The cradle assembly 3 further comprises, generally as a plurality of assembled components, a base wall which extends horizontally between the profiles defined by the end regions 21 , 22 , 23 , 24 , the intermediate elements 33 , 34 and the projection elements 35 , 36 . The movable point 5 rests on this base wall when it is mounted in the cradle assembly 3 .
The movable point 5 comprises a tapered free end region 41 (or point end) having a profile which is provided in order to ensure continuity of the guiding surface, selectively with one or other of the point regions 21 , 22 of the cradle 11 , in accordance with the position of the point end 41 .
As will also be seen more clearly with reference to FIGS. 3 and 5 , the movable point 5 comprises two rails 43 , 44 having a special profile having a thick web 46 which has a mushroom-like member 47 and a reinforced runner 48 . These rails 43 , 44 extend so as to converge towards the point end 41 , this being constituted at the end of one of the two rails.
The movable point 5 has a fitting section 49 which is fixed in the cradle assembly 3 by means which will be described below.
FIGS. 2 and 3 illustrate a first embodiment of the invention, in which the fitting component 12 is constituted by a unitary cradle. For example, this unitary cradle 12 is produced by means of casting from steel or special cast iron, and the projection elements 35 , 36 thereof are assembled with the respective intermediate elements 33 , 34 by means of welding or by means of adhesively-bonded joints.
As illustrated in FIG. 2 , the cradle assembly 3 is fixed to cross-pieces 50 by means of fixing devices which are all generally designated 51 but which may be of a different type for each of the elements of the cradle assembly 3 , that is to say the cradle 11 , the fitting component 12 , and the intermediate component 13 . The invention does not relate to these fixing devices and they are therefore not described in greater detail.
As can be seen in FIG. 3 , the unitary cradle 12 which forms a fitting component has a support plate 55 which forms a base wall, on which the runners 48 of the two rails 43 , 44 which form the movable point rest.
The support plate 55 which is formed in one piece with the projection elements 35 , 36 defines, with the projection elements 35 , 36 , a generally U-shaped cross-section of the cradle 12 . The support plate 55 is extended laterally, externally relative to the projection elements 35 , 36 , by means of outer rims 57 which allow it to be fixed to the cross-pieces 50 of the cradle 12 using the fixing devices 51 .
The two rails 43 , 44 are mutually secured by means of a spacer 60 which conforms to the inner profile portions thereof and is supported thereon.
In order to ensure the fixing and securing of the movable point 5 in the region of the section 49 thereof in the cradle 12 (or fitting component), the crossing frog 1 comprises removable fixing and securing means 61 .
These means 61 comprise spacer components 63 , of which there are four in the example illustrated in FIG. 2 and which are arranged in pairs facing each other each side of the movable point.
Each spacer component 63 has a generally parallelpipedal form which is axially elongate. The two spacer components 63 of the same pair are substantially symmetrical relative to the vertical axial plane and each secure one of the two rails 43 , 44 on the corresponding projection element 35 , 36 .
Each spacer component 63 is supported, by means of an outer lateral face, on an inner face of the corresponding projection element 35 , 36 and, by means of an inner lateral face, on an outer side of the web 46 of the corresponding rail 43 , 44 .
The spacers 63 have a shape which is suitable for co-operating, by means of complementary shape over the entire axial length of the spacer, with a portion of the outer profile of the respective rail 43 , 44 , this portion comprising the upper surface of the runner 48 , the outer surface of the web 46 , as far as the transition surface between the web 46 and the mushroom-like member 47 .
Transverse holes 69 , for example, four per spacer, extend coaxially through the projection elements 35 , 36 , the webs 46 of the rails 43 , 44 , the spacer 60 and the spacer components 63 . These holes 69 are offset axially relative to each other in the example illustrated; they are illustrated by means of dot-dash lines in FIG. 2 .
The fixing and securing means 61 comprise, for each hole 69 , a fastening bolt 70 .
The bolt 70 comprises a screw 71 whose head 72 is supported on an outer face of a projection element 36 , by means of washers 73 , and whose threaded shank 75 extends coaxially through the hole 69 . The bolt 70 further comprises a nut 77 which is fastened to the threaded end of the threaded shank 75 and which is supported on an outer face of the other projection element 35 by means of washers 79 . The fastening of the nut 77 on the screw 71 is secured by means of a brake nut 80 .
The fixing and securing means 61 further comprise a bush assembly which is arranged coaxially between the threaded shank 75 and the inner face of the hole 69 . This bush assembly comprises a central cylindrical sleeve 81 which is arranged in the hole of the spacer 60 , and two pins 83 (preferably of the Mecanindus® type). These pins 83 are each engaged in a section of the hole 69 formed in a projection element 35 , 36 , a spacer component 61 , and a rail web 46 , at one side and the other of the central sleeve 81 .
Each bolt 70 defines, with the bush assembly 81 , 83 , a removable assembly element which, when used, is fastened to the two projection elements 35 , 36 by securing, in a transverse manner with no possibility of significant transverse play, the movable point 5 between the projection elements 35 , 36 by means of the spacer components 63 .
The fixing and securing means 61 comprise, in the example illustrated, although this is optional, security shims 89 which are associated with each spacer component 63 . Each shim 89 is fixed in a removable manner, in this instance by means of screws 90 , to a respective projection element 35 , 36 , in an upper portion of the projection element. The shim 89 protrudes towards the inner side of the cradle 12 and is supported, by means of a lower face, on an upper face of the corresponding spacer component 63 .
The shims 89 are provided in order to limit the vertical displacement of the spacer components 63 during actual use of the crossing frog, so as to reduce the vertical movements of the point 5 if one or more bolts 70 become(s) loose.
It should be understood that the movable point 5 may be removed vertically (in direction Z indicated in FIG. 3 ) from the fitting position thereof, after removing the fixing and securing means 61 .
In order to remove the movable point 5 from the cradle assembly 3 , operators may proceed in situ in the following manner:
releasing the ends of the rails 43 , 44 by separating them from the conventional track; removing the shims 89 by removing the screws 90 ; removing the bolts 70 with their bush assembly 81 , 83 (using appropriate means, such as hydraulic jacks); vertically removing, in direction Z, the movable point 5 with the spacer components 63 .
After replacing the damaged movable point, the movable point is reassembled in reverse order which it is not necessary to set out in detail.
The second embodiment of the invention illustrated in FIGS. 4 and 5 differs from the first embodiment described above only in that the fitting component 12 is not defined by a unitary cradle.
In this embodiment, the support plate 155 is a separate component from the two projection elements 35 , 36 which are obtained by processing the respective intermediate elements 33 , 34 . The support plate 155 is preferably produced from a different material from that of the projection elements 35 , 36 and is fixed to the support independently thereof.
It should be noted in particular that the spacer components 63 and the means 61 for fixing and securing the movable point in the fitting component 12 are, in all respects, similar or identical to those described in the first embodiment. They will therefore not be described again.
It should be noted that the cradle 11 is preferably produced by means of casting techniques and cast from alloyed steel, in particular from cast manganese steel which is hyper-quenched and, optionally, pre-hardened. It is processed over all the rolling, contact, sliding or connection surfaces.
The two rail lengths 21 A, 22 A which form part of the crossing frog are rail profiles of rolled carbon steel or lightly alloyed steel and are connected to the cradle 11 by means of welding, optionally using inserts.
The intermediate elements 33 , 34 are preferably produced in the form of a rail or from cast carbon steel or lightly alloyed steel which has a mechanical strength similar to that of the rails, and which allows them to be welded to the cradle 11 , optionally using an insert.
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A crossing frog includes: a cradle assembly which includes a movable point fitting component which has two projection elements which are mutually spaced-apart, a movable point which is mounted in the cradle assembly and fitted in the fitting component, spacer components which are interposed between the projection elements and the movable point, and accommodation for removably fixing the movable point in the fitting component. The spacer components are fixed to the projection elements in a removable manner by the accommodation for removable fixing so that it is possible to remove the point in a vertical direction relative to the cradle assembly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Ser. No. 61/028,063 filed Feb. 12, 2008, which application is fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to thermoelectric cooling, and more particularly to a system and its methods of use for cooling an interior of a vehicle by using a thermoelectric cooling assembly powered a solar photo-voltaic panel.
2. Description of the Related Art
Interior compartments of stationary vehicles tend to get enormously hot particularly during sunny, daylight periods of the day. On a warm sunny day, for example, a vehicle's windows collect light, trapping heat inside the vehicle and pushing the temperature inside to dangerous levels (100-130° F.). Such temperature increases can occur in a car even if the windows are opened slightly. An extremely hot interior of a vehicle poses a danger to pets, electronics and heat-sensitive items, such as medications, left in the vehicle, such as a car. An extremely hot stationary vehicle interior increases the cooling load on the vehicle air-conditioning unit when the vehicle is operated.
An existing method in cars to passively prevent this heating problem involves aluminum-coated reflectors mounted on the windshields of the parked cars which reflect the sun's incoming radiation. This technique is not effective because these reflectors are not so efficient in preventing the sun's radiation from entering the car and eventually the temperature inside the car becomes undesirable.
A thermoelectric cooler (TEC), also known as a thermoelectric module or Peltier cooler, is a semiconductor-based electronic component that functions as a small heat pump. By applying a low voltage DC power source to a TEC, heat will be moved through the thermoelectric material from one side to the other. One cooler face, the cold side, therefore is cooled while the opposite face, the hot side, is simultaneously heated.
FIG. 1 is a diagram of a practical TEC 101 comprising two or more elements of p-type and n-type semiconductor material P and N that are connected electrically in series and thermally in parallel. The semiconductor material is generally bismuth telluride. The elements of semiconductor material P and N are biased by a low DC voltage provided by a DC power source 102 . These thermoelectric elements and their electrical interconnects typically are mounted between two ceramic substrates 103 and 104 . One ceramic substrate is the cold side 103 removing heat from an object being cooled 105 . The object being cooled 105 may, in turn, be used to remove heat from another object or air. A heat sink 106 must remove from the other ceramic substrate, the hot side 104 . In turn, heat must be removed from the heat sink 106 . The heat sink may have fins fabricated into to enhance the exchange of heat between it and air and/or water. Placing TEC's on top of one another in stages to form a multi-stage thermoelectric module increases cooling performance.
Like mechanical refrigerators, TEC's are governed by the same fundamental laws of thermodynamics. In a mechanical refrigeration unit, a compressor raises the pressure of a liquid and circulates the refrigerant through the system. In the evaporator or “freezer” area, the refrigerant boils and in the process of changing to a vapor, the refrigerant absorbs heat causing the freezer to become cold. The heat absorbed in the freezer area is moved to the condenser where it is transferred to the environment from the condensing refrigerant.
In a thermoelectric cooling system, a doped semiconductor material essentially takes the place of the liquid refrigerant, the condenser is replaced by a heat sink 106 , and the compressor is replaced by a DC power source 102 . The heat sink 106 may be fabricated with fins to exchange heat from the heat sink 106 with surrounding air. The application of DC voltage to the thermoelectric module causes electrons to move through the semiconductor material. At the cold side 103 , heat is absorbed by the electron movement, moved through the semiconductor material P and N, and expelled at the hot side 104 .
It should be noted that thermoelectric modules can only transfer heat from the cold side 103 to the hot side 104 , but cannot dissipate heat by themselves into the atmosphere. Hence, heat sinks must be in contact at the hot side 104 of the thermoelectric module to dissipate heat to the atmosphere through convection. Applications for thermoelectric modules cover a wide spectrum of product areas. These include equipment used by the military, medical, industrial, consumer, scientific and telecommunication organizations. Uses range from simple food and beverage coolers for an afternoon picnic to extremely sophisticated temperature control systems in missiles and space vehicles. Some of the more significant features of thermoelectric modules include: no moving parts, small size, ability to cool below ambient as well as heat above ambient, reliability and environmental friendliness.
FIG. 2 is a diagram of the top view of a small enclosure 200 air-conditioned by the thermoelectric effect. An air-to-air heat exchanger 201 is used for the cooling of air in an enclosure. The air-to-air heat exchanger 201 utilizes the thermoelectric effect whereby the heat is transferred via the flow of current through thermoelectric modules 202 . One part absorbs the heat and, as a consequence, reduces the temperature on the cold side 203 and the other part dissipates the heat to ambient on the hot side 204 .
Fans 205 and 206 are used to move air over heat sinks 207 and 208 on both the hot and cold sides of the thermoelectric modules. The cold side 203 of the modules 202 is connected to a heat sink 207 with a fan 205 (forced convection) that absorbs heat from within the enclosure 200 and circulates the cooled air. The hot side 204 of the thermoelectric modules 201 is connected to another forced convection heat sink 208 that dissipates the heat absorbed through the cold side 203 to the atmosphere. Forced convection improves the cooling performance. In FIG. 2 , the thermoelectric modules 201 form the active cooling element and the fans 205 and 206 in combination with the respective heat sinks 207 and 208 form the passive cooling elements.
U.S. Pat. No. 6,119,463 describes a thermoelectric cooling system that cools seats by thermoelectric cooling air supplied to passages inside the surface of a seat. The heat is removed from the hot side of the TECs by a heat exchanger cooled by air passing over it and into the interior compartment of the vehicle. Thus, this apparatus cools the seat surface but heats the air in the interior of the vehicle.
Solar photovoltaic panels have been permanently constructed into vehicles. In land vehicles, such as cars and trucks, these panels have been built in the sun roof to supplement electric power for various applications in the vehicle. Some of these applications can operate without use of electric power provided by the vehicle's engine.
Permanently installed, solar photovoltaic panel-powered thermoelectric cooling systems have been developed for cars. Thermoelectric car air-conditioning has been previously described. Japanese Patent Application Publication No. 08-011517 discloses a built-in thermoelectric air-conditioning apparatus for a car powered by the battery, in turn, powered by the engine or, alternatively, a solar panel installed on top of the roof. However, this apparatus must be factory-installed for new cars or retrofit, at significant expense, in existing cars. Because the apparatus sticks out of the floor of the car, it is intrusive to the driver and/or passenger.
Additionally, Japanese Patent Application Publication No. 11-342731 discloses solar photovoltaic panel-powered thermoelectric cooling system. However, this system must also be factory-installed for new cars or retrofitted, at significant expense, in existing cars. Additionally, in a parked state, the hot sides of the TEC's are inefficiently passively cooled by external air flowing in a narrow passage between roof of the car where the TEC's are installed and the bottom of the solar photovoltaic panel. The apparatus sticks out of the roof of the passenger automobile such that the aerodynamics, stability and structural integrity of the car are compromised.
Accordingly, there is a need for a need for a compact, removable apparatus to prevent the temperature inside a vehicle from becoming dangerously high during stationary periods in sunny conditions without requiring an expensive retrofitting of existing vehicles, compromising the structures of vehicles, or using the battery of the vehicle.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved system, and its methods of use, for cooling the interior of a vehicle.
Another object of the present invention is to provide a compact and removable apparatus for cooling the interior of a vehicle.
Yet another object of the present invention is to provide a system, and its methods of use, for cooling an interior of a vehicle using a thermoelectric cooling assembly powered by a solar photo-voltaic panel without retrofitting the vehicle.
A further object of the present invention is to provide a system, and its methods of use, for cooling an interior of a vehicle using a thermoelectric cooling assembly powered by a low DC voltage from the solar photo-voltaic panel.
Yet another object of the present invention is to provide a system, and its methods of use, for cooling an interior of a vehicle using a thermoelectric cooling assembly powered by a low DC voltage from the solar photo-voltaic panel, wherein a direction of heat flow is controlled by a direction of the DC voltage applied to the TEC inside the thermoelectric cooling assembly.
These and other objects of the present invention are achieved in an apparatus for cooling the interior of a vehicle. A solar photo-voltaic panel is removably mounted on an inside of a window or a windshield of the vehicle. The solar photo-voltaic panel is mounted to block at least a portion of sun rays from entering the vehicle and configured to convert energy from the sun's rays to generate a DC voltage. A thermoelectric cooling assembly is powered by the low DC voltage from the removably mounted solar photo-voltaic panel.
In another embodiment of the present invention, an apparatus for cooling the interior of a vehicle includes a solar photo-voltaic panel removably mounted on an inside of a window or a windshield of the vehicle. The solar photo-voltaic panel is mounted to block at least a portion of sun rays from entering the vehicle and configured to convert energy from the sun's rays to generate a DC voltage. A thermoelectric cooling assembly is powered by the low DC voltage from the removably mounted solar photo-voltaic panel. Heat is transferred from air in the interior of the vehicle to an exterior of the vehicle through the thermoelectric cooling assembly.
In another embodiment of the present invention, an apparatus is provided for cooling the interior of a vehicle. A solar photo-voltaic panel is mounted on an inside of a window or a windshield of the vehicle. The solar photo-voltaic panel is mounted to block at least a portion of sun rays from entering the vehicle and configured to convert energy from the sun's rays to generate a DC voltage. A thermoelectric cooling assembly is included that is powered by the low DC voltage from the solar photo-voltaic panel. Heat is transferred from air in the interior of the vehicle to the exterior of vehicle through the thermoelectric cooling assembly. The thermoelectric cooling assembly includes a TEC. A direction of heat flow is controlled by a direction of the DC voltage applied to the TEC inside the thermoelectric cooling assembly.
In another embodiment of the present invention, a method is provided for cooling an interior of a vehicle. A solar photo-voltaic panel is mounted on an inside of a window or a windshield of the vehicle. The solar photo-voltaic panel is coupled to a thermoelectric cooling assembly that includes a TEC. The solar photo-voltaic panel is used to block at least a portion of sun rays from entering the vehicle. Energy from the sun's rays is converted to generate a DC voltage. At least a portion of the thermoelectric cooling assembly is powered by the low DC voltage.
In another embodiment, a method is provided for cooling an interior of a vehicle. A solar photo-voltaic panel is mounted on an inside of a window or windshield of the vehicle. The interior of the vehicle is thermoelectrically cooled using a thermoelectric cooling assembly powered by a low DC voltage from the solar photo-voltaic panel. The thermoelectric cooling assembly includes, a TEC with a cold side and a hot side, an internal heat sink in thermal contact with the cold side and in thermal contact with air in the interior of the vehicle on another side of the internal heat sink and an external heat sink in thermal contact with the hot side and in thermal contact with air in the exterior of the vehicle on another side of the external heat sink. The cold side of the TEC is sued to remove heat. Heat is transferred to the hot side of the TEC. The external heat sink is used to remove heat from the hot side of the TEC to an exterior of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a practical TEC comprising two or more elements of p-type and n-type semiconductor material that are connected electrically in series and thermally in parallel.
FIG. 2 is a diagram of the top view of a small enclosure air-conditioned by the thermoelectric effect.
FIG. 3 is a diagram of a solar photo-voltaic panel manually and removably mounted on the front windshield of a vehicle by the vehicle's operator.
FIG. 4 is a diagram of a thermoelectric cooling assembly.
FIG. 5 is a diagram of a vehicle with its interior thermoelectrically cooled.
FIG. 6 is a diagram of a casing configured to transfer heat from the air interior to the vehicle to the air exterior to the vehicle.
FIG. 7 is a diagram of the interior of a vehicle cooled by the thermoelectric cooling assembly comprising a casing by transferring heat to the air external to the vehicle through a narrow opening of the casing extending through a window slightly ajar.
DETAILED DESCRIPTION
In one embodiment of the present invention, an apparatus and associated methods are provided for cooling an interior of a vehicle. Suitable vehicles include but are not limited to cars, trucks, trailers, planes, boats and the like. In one embodiment, the cooling apparatus is a thermoelectric cooling assembly powered by a low DC voltage from a removably mounted solar photo-voltaic panel, as more fully described herein. “Low” is of a sufficient amount to provide the necessary power. The amount of DC voltage is dependent on the internal temperature conditions found inside the vehicle.
In one embodiment, a solar photo-voltaic panel is removably mounted on the inside of a window or a windshield of the vehicle. The apparatus also includes a thermoelectric cooling assembly powered by a low DC voltage from the removably mounted solar photo-voltaic panel. The thermoelectric cooling assembly can be a TEC with a cold side from which heat is removed and a hot side where heat is transferred. The thermoelectric cooling assembly can include an internal heat sink in fixed, thermal contact with the cold side on one side of the internal heat sink and in thermal contact with air in the interior of the vehicle on another side of the internal heat sink.
In one embodiment, the thermoelectric cooling assembly includes an external heat sink in a fixed, thermal contact relationship with the hot side on one side of the external heat sink. In this embodiment, the external heat sink is in thermal contact with air or water exterior to the vehicle on another side of the external heat sink.
In another embodiment of the present invention, a method is provided for cooling the interior of a vehicle. A solar photo-voltaic panel is mounted on the inside of a window or windshield of the vehicle. A thermoelectric cooling assembly is used to cool the interior of the vehicle. The thermoelectric cooling assembly is powered by a low DC voltage from the removably mounted solar photo-voltaic panel. The thermoelectric cooling assembly can include a TEC with a cold side from which heat is removed, and a hot side to which heat is transferred. The thermoelectric cooling assembly can also include an internal heat sink in a fixed, thermal contact with the cold side on one side of the internal heat sink and in thermal contact with air in the interior of the vehicle on another side of the internal heat sink. The thermoelectric cooling assembly can include an external heat sink in a fixed, thermal contact with the hot side on one side of the external heat sink and in thermal contact with air in the exterior of the vehicle on another side of the external heat sink.
FIG. 3 is a diagram of one embodiment of a solar photo-voltaic panel 301 of the present invention that is manually and removably mounted on the front windshield 302 of a vehicle 303 , such as a parked automobile, by the vehicle's operator 304 . The solar photo-voltaic panel 301 not only blocks the sun's rays 305 from entering the vehicle 303 , but also converts the energy of the sun's rays 305 to generate a DC voltage that can be applied to a thermoelectric cooling assembly, as described below, which pumps heat out of the interior 306 of the vehicle 303 into the atmosphere 307 .
FIG. 4 is a diagram of a thermoelectric cooling assembly 401 . The thermoelectric cooling assembly 401 is powered by a low DC voltage from the removably mounted solar photo-voltaic panel 301 . The thermoelectric cooling assembly 401 can include a TEC) 402 with a cold side 403 from which heat is removed and a hot side 404 to which heat is transferred. The thermoelectric cooling assembly 401 can further include an internal heat sink 405 in fixed, thermal contact with the cold side 403 on one side of the internal heat sink 405 and in thermal contact with air 406 in the interior 306 of the vehicle 303 on another side of the internal heat sink fabricated with fins 407 . The thermoelectric cooling assembly 401 can include an external heat sink 408 in fixed, thermal contact with the hot side 404 on one side of the external heat sink 408 and in thermal contact with air 409 exterior to the vehicle on another side of the external heat sink fabricated with fins 410 .
Heat is transferred from the air 406 in the interior 406 of the vehicle 303 to the air 409 exterior to the vehicle 303 through the various components of the thermoelectric cooling assembly 401 . Heat is extracted from the air 406 in the interior 306 of the vehicle 303 by the fins 407 fabricated into the internal heat sink 405 . This heat extraction may be improved by placing a fan (not shown) to blow the air 406 in the interior 306 of the vehicle 303 into the fins 407 fabricated into the internal heat sink.
The heat is then transferred from the internal heat sink 405 to the cold side 403 of the TEC 402 . From the cold side 403 , the heat is pumped to the hot side 404 of the TEC 402 . Subsequently, the heat is removed from the hot side 404 by the external heat sink 408 and expelled to the air 409 exterior to the vehicle through the fins 410 fabricated on the external heat sink 408 . The transfer of heat from the fins 410 of the external heat sink 408 to the air 409 exterior to the vehicle 303 may be enhanced by a fan 411 connected to the fins 410 fabricated on the external heat sink 408 wherein the fan is configured to blow air on to the fins 410 .
The solar photo-voltaic panel-powered thermoelectric cooling assembly has no moving parts except for optional fans, are extremely reliable with an almost unlimited life span and require no maintenance, other than replacement of optional fans. “Static” construction makes thermoelectric cooling assemblies immune to vibration thus allowing them to be used in any orientation and makes them particularly suitable for application on moving systems including ships, aircraft and automobiles, including passenger cars. The thermoelectric cooling assembly does not contain any polluting substances such as chlorofluorocarbons (CFC) or other gases, has a more compact and simple structure than a compressor system, and can also be easily adapted and mounted.
In this embodiment of the thermoelectric cooling assembly 401 , the air 409 exterior to the vehicle is the atmosphere 307 . Alternatively, for vehicles floating, including docked or anchored, in water, the external heat sink 407 is in thermal contact with water exterior to the vehicle.
FIG. 5 is a diagram of a vehicle 501 , such as a parked automobile, with its interior 502 thermoelectrically cooled. The solar photo-voltaic panel 503 is removably mounted on the windshield 504 of the vehicle 501 . The thermoelectric cooling assembly 505 is removably and manually placed in thermal contact between air in the interior 502 of the vehicle and the air 506 external to the vehicle at another window 507 in the vehicle left slightly open. The direction of heat flow is controlled by the direction of the voltage applied to the TEC 508 inside the thermoelectric cooling assembly 505 . The solar photo-voltaic panel 503 can be folded and stored safely before operation of the vehicle 501 requiring viewing through the windshield 504 . The apparatus of the solar photo-voltaic panel 503 and thermoelectric cooling assembly 505 can be used by owners of existing vehicles without any retrofitting.
FIG. 6 is a diagram of a casing 601 configured to transfer heat from the air 602 interior to a vehicle 501 , such as a parked automobile, to the air exterior to the vehicle 501 . The casing 601 can be a TEC 603 inside the casing comprising a cold side 604 from which heat is removed and a hot side 605 to which heat is transferred. The cold side 604 of the TEC 603 is exposed to air 602 inside the vehicle 501 and the hot side 605 of the TEC 603 is exposed to air 606 exterior to the vehicle 501 .
An internal heat sink 607 is in fixed contact with an external surface of the wall of the casing 601 configured to be in thermal contact with the cold side 604 on one side of the internal heat sink 607 and air in the interior of the vehicle on another side of the internal heat sink 607 . The internal heat sink 607 may be fabricated with fins (not shown) on its other side to exchange heat from the air 602 interior to the vehicle with the internal heat sink 607 . The other side of the internal heat sink 607 may also be connected to a fan (not shown) to enhance heat removal from the air 602 interior to the vehicle.
An external heat sink 608 is in fixed, thermal contact with the hot side 605 on one side of the external heat sink and air outside the vehicle on another side of the external heat sink 608 . The other side of the external heat sink 608 may additionally be fabricated with fins (not shown) to exchange heat from the external heat sink 608 and the air surrounding the fins. Moreover, the other side of the external heat sink 608 may be connected to a fan 609 configured to blow air inside the casing on to the other sided of the external heat sink 608 and to facilitate the exchange of the air and heat inside the casing 601 with air 602 external to the vehicle 501 .
FIG. 7 is a diagram of the interior 701 of a vehicle 501 , such as parked automobile, cooled by the thermoelectric cooling assembly comprising a casing 702 transferring heat to air 703 external to the vehicle 501 through a narrow opening 704 of the casing 702 extending through a window 705 of the vehicle slightly ajar. The solar photo-voltaic panel 706 used to provide a low DC voltage to the thermoelectric cooling assembly is removably mounted on the windshield 707 of the vehicle 501 . Below the windshield 707 are shown various controls for the vehicle 501 . To prevent air leaking from the interior 701 of the car to the exterior of the car, a removable, sealing grommet 708 is placed in the area bounded by the top of the window 705 and the exposed frame 709 . The window 705 may be a window of a door of a parked automobile.
Additionally, the casing may be configured to have a fan 710 to facilitate cooling the interior 701 of the vehicle 501 with the thermoelectric cooling assembly comprising the casing 702 . The solar photo-voltaic panel 706 , the casing 702 and the removable, sealing grommet 708 can be manually installed by the vehicle operator without any retrofitting of the vehicle.
While the present invention has been described in connection with a number of embodiments and implementations, the present invention is not so limited but covers various obvious modifications and equivalent arrangements, which fall into the purview of the appended claims.
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An apparatus for providing air-conditioning to a vehicle is disclosed. The apparatus includes a solar photovoltaic panel positioned in a window or windshield to provide direct current to power a thermoelectric assembly to pump excess heat out of the interior of the car. The car is air-conditioned in a parked state and pre-air-conditioned before use.
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[0001] This application claims benefit of U.S. Provisional Patent Application No. 60/133,179 filed May 7, 1999, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to an drug-delivery tool and method of delivering selected therapeutic and/or diagnostic agents to target sites in selected body tissues. More particularly, the invention provides for the creation of temporary cavities in desired layers of a selected tissue, for example, myocardial tissue of the heart, and for the delivery of one or more selected agents therein.
BACKGROUND OF THE INVENTION
[0003] Intra-muscular needle injection of therapeutic compounds is well known in the medical arts, as is intra-coronary injection where pre-existing intra-coronary arteries provide perfusate conduits. In heart disease, the existing coronary artery in-flows to capillary beds is often compromised. Newly developed gene and protein therapeutic agents hold promise in their ability to act on the surviving smaller capillary beds to grow and expand them. As has been witnessed, the intra-myocardial cellular lattice limits angiogenic response to about 5-10 mm and similar limits occur with direct needle injections in stunned or ischemic heart tissue. The physician must work within an environment of compromised capillary bed vascularity. Physicians are further limited to some degree by drug viscosity—where the drug viscosity is too low, rapid wash-out can occur; and where too high, capillary occlusion can occur—as well as by high infusate pressure induced cellular damages. These problems are not typical of common healthy muscle tissue injections in the arm or leg. The prior art teaches the creation of permanent channels with the use of lasers, radio frequency heating and mechanical cutting means. Such channels often compromise the capillaries that are sought to be accessed with a drug, wash out readily, and resolve ultimately as fibrous connective scar tissue. Needle and membrane tools may improve access to capillaries but offer no stretching forces and don't offer unobstructed capillary access.
SUMMARY OF THE INVENTION
[0004] One embodiment of the invention provides a drug-delivery tool for delivering a drug to an internal member of a tissue, such as a heart-wall. The tool comprises an accessing device having distal and proximal ends, an inner lumen extending therebetween, a drug-delivery reservoir adapted to hold such drug, and a user-control structure at the accessing device's proximal end. The tool further includes a tissue-penetrating implement carried at the accessing device's distal end for axial movement into and out of the lumen. The implement has first and second expandable members which are disposed in a substantially co-extension condition, when the implement is disposed in a retracted condition within the lumen. Alternatively, the implement may assume an expanded, spaced-apart condition when the implement is advanced to an extended condition out of the lumen. At least one of the members has a tip for penetrating such tissue. A first operative connection exists between the control structure and the implement that is operable, upon user activation of the control structure, to advance the implement from its retracted to its extended condition. When the accessing device's distal end is placed against a surface region of the tissue, the implement is advanced into the tissue, causing the two expandable members to expand to form a cavity within the tissue. A second operative connection exists between the control structure and the reservoir that is operable, upon user activation of the control structure, to deliver drug from the reservoir into such cavity. Placement of the accessing device's distal end against a surface region of such tissue, and activation of the control structure results in the delivery of drug into a cavity within the tissue.
[0005] In another embodiment, the implement includes at least two expandable elements which move away from one another as the implement is being advanced, from its retracted to its extended condition, into such tissue, to form a cavity in the tissue.
[0006] In yet another embodiment, the second expandable member of the tissue-penetrating implement defines a lumen having a plurality of openings that permit direct communication of an drug passed into a cavity formed by the tool with at least about 90% of the surface area of the tissue directly bordering the drug receiving space.
[0007] In a particularly preferred embodiment, the accessing device is a flexible catheter accessing device; and further comprises a pull-wire assembly extending longitudinally through the catheter accessing device, the pull-wire assembly being operable to deflect the distal end of the accessing device substantially within a plane; and one or more force contact transducers mounted at the distal end of the accessing device within the deflection plane. This embodiment may further comprise one or more additional force contact transducers mounted at the distal end of the accessing device outside of the deflection plane.
[0008] In another embodiment, the first expandable member further comprises construction from a shape memory material capable of a first remembered curved shape, and a second, stress induced linear shape causing the first expandable member to cut in an arc shape as it is advanced through a tissue upon extension from the confines of the accessing device lumen.
[0009] In still another embodiment, the second expandable member comprises a ribbed balloon, wherein each rib defines a lumen in fluid communication with the drug-delivery reservoir, and each rib further defines a plurality of exit ports from the rib lumen that the drug may perfuse through into the formed cavity.
[0010] In another embodiment, the first expandable member is formed in a cork-screw shape tubular member defining a lumen within exiting at an end distal to the accessing device and in communication with the drug-delivery reservoir, the first expandable member is rotatable along its axis to permit it to screw into a tissue upon axial rotation, and upon stopping axial rotation, withdraw into the lumen of the accessing device thereby pulling the tissue up into the lumen of the accessing device until such tissue is sealably urged against the accessing implement's lumen edge causing a seal to form between the accessing implement's lumen edge and the tissue, and further causing a cavity to form between the distal region of the first expandable member and the tissue adjacent to that region.
[0011] In one embodiment, some of the expandable members of the tissue-penetrating implement define lumens with a plurality of openings in fluid communication with the drug-delivery reservoir such that a drug may be introduced into a formed cavity with at least about 90%, and preferably greater than about 95%, of the surface area of the tissue directly bordering the cavity.
[0012] The accessing device can be, for example, a flexible catheter accessing device or the accessing device of an endoscope-type tool. In an embodiment of the former (i.e., a catheter-type tool), the tool further includes (i) a pull-wire assembly extending longitudinally through the catheter accessing device, with the pull-wire assembly being operable to deflect a distal-end region of the accessing device substantially within a plane; and (ii) one or more (for example, two) ultrasound or force contact transducers mounted on opposing sides of the orifice at the distal end of the accessing device within the deflection plane. Optionally, one or more (for example, two) additional transducers can be mounted at the distal end of the accessing device outside of the deflection plane.
[0013] One aspect of the present invention provides an drug-delivery tool for delivering a selected diagnostic or therapeutic agent to a target site within a selected body tissue, such as myocardial tissue of the heart. Generally, the drug-delivery tool includes an accessing device having proximal and distal ends, with a lumen extending between such ends and terminating at an orifice at the distal end. A tissue-penetrating implement is movable between a retracted condition, within a distal region of the lumen, and an extended condition, extending out of the orifice. The tissue-penetrating implement includes a tip configured to penetrate a selected body tissue when (i) the distal end of the accessing device is placed thereagainst and (ii) the implement is advanced from its retracted condition to its extended condition. In addition, the tissue-penetrating implement includes a first expandable member, disposed proximal of the tip, for following the tip to a target site as the tip penetrates the selected tissue. A second expandable member, also proximal to the tip of the implement, is adapted to expand radially as the implement is advanced to its extended condition, with a force sufficient to form a cavity at the target site by pressing the tissue adjacent the penetration site away from the longitudinal axis of the implement. An agent-delivery passage or conduit extends longitudinally through at least a member of the accessing device, with a distal end of the passage defining an exit port facing the expandable member of the tissue-penetrating implement. By this construction, an agent, passed or drawn through the passage and out of the exit port, is directed into a central region of the expandable member, and any cavity formed thereby.
[0014] In one embodiment, the tissue-penetrating implement of the drug-delivery tool includes (i) a cutting or slicing tip at its distal-end region, and (ii) one or more resiliently flexible expandable members extending proximally therefrom, with the expandable members being adapted to expand radially outward in their normal state. The expandable members can be, for example, wires or filaments made of Nintinol, or the like. Movement of the tissue-penetrating implement can be effected using an actuation line attached at one end to a proximal end of the implement and attached at its other end to a manually operable deflection mechanism at a proximal end of the drug-delivery tool. By this construction, sliding movement of the line within the accessing device is transmitted to the implement—causing the implement to move.
[0015] The agent-delivery passage of the drug-delivery tool can be formed, for example, by an elongate conduit having an internal lumen that extends between the proximal end of the accessing device and a distal-end region of the accessing device. In one embodiment, such a conduit is adapted for sliding movement within the accessing device, coupled with movement of the tissue-penetrating implement.
[0016] One embodiment of the drug-delivery tool, particularly useful for delivering a selected agent having a net negative charge (for example, DNA), further comprises first and second electrodes adapted to be placed in electrical communication with a power supply. The first electrode, in this embodiment, is disposed at a distal region of the tissue-penetrating implement and the second electrode is disposed proximally of the implement. Generation of a positive charge at the first terminal is effective to draw at least a portion of the negatively charge species from a supply or holding reservoir, through the agent-delivery passage, and into the expandable member of the tissue-penetrating implement.
[0017] Another embodiment of the drug-delivery tool is particularly well suited for placing a solid or semi-solid agent in a cavity formed by the cavity forming implement and then permitting the agent to move outwardly as portions of it dissolve or otherwise slough off. In one particular construction, the expandable member of the tissue-penetrating implement includes a plurality of resiliently flexible expandable members (for example, wires or filaments of Nintinol, or the like) disposed at spaced positions about the longitudinal axis of the implement so as to define a cage or skeleton capable of holding the agent as it is placed in a cavity formed by the implement. The cage is provided with open regions between its expandable members sufficient to provide direct exposure of the agent to at least about 95% of the tissue bordering the cavity.
[0018] Another general embodiment of the drug-delivery tool of the invention includes (i) an accessing device having proximal and distal ends, with a lumen extending therebetween and terminating at an orifice at the distal end; (ii) a tissue-penetrating implement movable between a retracted condition, within a distal region of the lumen, and an extended condition, extending out of the orifice; with the implement including (a) a tip configured to penetrate a selected body tissue when the distal end of the accessing device is placed thereagainst and the implement is moved from its retracted condition to its extended condition, and (b) a cage member disposed proximal of the tip for following the tip to a target site within such tissue, and adapted to assist in the formation and maintenance of a cavity at the target site by pressing the tissue at the target site away from the longitudinal axis of the implement as it is inserted therein and having sufficient rigidity to resist inwardly directed forces of the tissue tending to collapse the cavity; and (iii) an agent-delivery passage extending longitudinally through at least a member of the accessing device, with a distal end of the passage defining an exit port facing the cage member for directing a selected agent, passed through the passage, into a central region of the cage member and any such cavity formed thereby.
[0019] The cage member can comprise, for example, a plurality of expandable elements disposed about the central, longitudinal axis of the implement, with open regions between adjacent expandable members. Preferably, at least about 95% of the cage member is open. The cage member can be expandable (tending to flex outwardly), or generally non-expandable.
[0020] In another of its aspects, the present invention provides a method for delivering a selected diagnostic or therapeutic agent to a target site within a selected body tissue.
[0021] According to one general embodiment, the method includes the steps of:
[0022] (i) forming a cut or slice extending from a wall of the selected tissue to the target site;
[0023] (ii) moving or pressing the tissue bordering the cut or slice radially outward, thereby forming a cavity within the tissue at the target site;
[0024] (iii) delivering a selected agent into the cavity, with the cavity being maintained; and
[0025] (iv) permitting the cavity to collapse once a selected amount of the agent has been delivered therein.
[0026] In one embodiment, at least about 90 % (and preferably greater than 95%) of the surface area of the tissue bordering the cavity is directly exposed to the cavity, so that the agent delivered into the cavity can pass directly into the exposed tissue.
[0027] Step (i) of the method (i.e., cutting/slicing) is preferably effected using a cutting or slicing implement, such as a blade edge or tip, that is configured to avoid the removal of tissue along the region of the cut or slice beyond the inherent cellular injury due to the cutting or slicing.
[0028] According to one embodiment, the cut or slice formed in step (i) is made along a substantially linear axis, with the axis being oriented generally normal to the wall of the selected tissue. Ultrasound can be used to achieve such orientation.
[0029] The agent can be delivered using, for example, an elongate agent-delivery conduit defining a passage or lumen terminating at a distal orifice through which the agent can exit. Preferably, during delivery of the agent using such a tool, the orifice does not make substantial contact with the selected tissue, thereby maximizing the tissue surface area available for contact with the agent.
[0030] In one embodiment, the selected tissue is heart tissue (for example, myocardial tissue), and the cut or slice is formed from an endocardial wall, a septal wall, or an epicardial wall.
[0031] In another embodiment, the selected tissue is stunned, ischemic and/or hibernating organ tissue that has at least partially lost its normal capillary ability at vasomotion. The greater surface area and capillary access provided by practicing the present invention permits the agent to be moved through micro-capillaries even where assistance by natural vasomotion is greatly diminished or unavailable.
[0032] A wide variety of agents can be delivered using the present invention. The selected agent can be, for example, an angiogenic agent (for example, a protein and/or nucleic acid). In one embodiment, the agent is a nucleic acid, for example, naked DNA, intended for delivery to heart tissue.
[0033] A further aspect of the present invention provides a method where the normal pressure drug tissue treatment area of 5-10 mm obtained with direct needle injection or TMR can be improved upon by creating a temporary cavity having significantly greater direct capillary access due to surface area, lack of non-perfusing delivery implement to cell contact patches and implement stretching force.
[0034] These and other features and advantages of the present invention will become clear from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The structure and manner of operation of the invention, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in which:
[0036] [0036]FIG. 1 is an elevational view of a steerable catheter assembly, with its distal end region enlarged and in section showing a tissue-penetrating implement therein, as taught by an embodiment of the present invention;
[0037] [0037]FIG. 2 is a side sectional view showing two angle-mounted ultrasound transducers on the distal end of a steerable catheter accessing device, in accordance with an embodiment of the present invention;
[0038] [0038]FIG. 3 is a cross sectional view of the catheter assembly shown in FIG. 1, taken laterally across a mid-member of the catheter accessing device;
[0039] [0039]FIG. 4 is a side sectional view of the catheter-assembly distal-end region of FIG. 1, taken longitudinally therealong, with the tissue-penetrating implement inserted into a selected tissue to form a cavity therein for receiving a selected agent;
[0040] [0040]FIG. 5A illustrates a section of normal myocardial tissue;
[0041] [0041]FIG. 5B illustrates a section of myocardial tissue with a temporary cavity formed therein;
[0042] [0042]FIG. 6 is a side elevational view, with members shown in cross section, of an endoscope-type agent delivery tool having a tissue-penetrating implement like that of the catheter assembly of FIG. 1;
[0043] FIGS. 7 (A)- 7 (C) illustrate an accessing device, shown in section, with a movable implement for forming a cavity in a selected tissue and delivering a selected agent therein, in accordance with the teachings of one embodiment of the present invention; and,
[0044] FIGS. 8 (A)- 8 (C) illustrate an accessing device, shown in section, with a movable implement for forming a cavity in a selected tissue and placing a selected agent therein, in accordance with an embodiment of the present invention.
[0045] FIGS. 9 ( a - d ) depict an embodiment having a force contact transducer.
[0046] FIGS. 10 ( a - b ) depict a corkscrew shaped expandable member embodiment.
[0047] FIGS. 11 ( a - c ) depict a balloon expandable member embodiment.
[0048] FIGS. 12 ( a - c ) depict an arc cutting embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0049] The following discussion of the preferred embodiments of the present invention is merely exemplary in nature. Accordingly, this discussion is in no way intended to limit the scope of the invention.
[0050] An exemplary drug-delivery tool which embodies various features of the invention is shown in FIGS. 1 through 4. As will become apparent, the illustrated drug-delivery tool is particularly well suited for percutaneous introduction into a subject for intravascular delivery of a selected agent into temporary cavities formed in a desired layer of a selected tissue. With initial reference to FIG. 1, a catheter assembly (which may be disposable, in whole or in part), indicated generally by the reference numeral 12 , includes a control structure (hand unit) 14 attached to a steerable catheter accessing device 16 having a controllably deflectable distal-end member. Steering of the catheter assembly can be accomplished in a variety of ways. For example, the catheter assembly can include steering components like those disclosed in U.S. Pat. No. 5,876,373, entitled “Steerable Catheter,” to Giba et al.; and/or in co-pending U.S. Provisional patent application Ser. No. 09/080,175 filed May 16, 1998, entitled, “Drug Delivery Module,” to Glines et al.; and/or in published European Patent Application No. EP 0 908 194 A2, each of which is expressly incorporated herein by reference. Briefly, in the illustrated embodiment, a pull wire 18 , having an enlarged head member 18 a at its distal end, extends from the tip of catheter accessing device 16 , through a wire-guide channel 19 extending through catheter accessing device 16 , to control structure (hand unit) 14 , whereat the wire's proximal end is coupled to a deflection or steering actuator assembly. Rotation of a deflection knob 20 , which is threadedly mounted along a forward end of the hand unit, causes the pull wire to be pulled backward, or the catheter accessing device to be pushed forward, relative to one another, thereby inducing deflection of the distal end of the steerable catheter accessing device. Rather than running the pull wire through a channel extending through the catheter accessing device, another embodiment provides the pull wire extending longitudinally along the interior wall of the catheter accessing device (FIG. 3). Other steering mechanisms and arrangements, suitable for use herein, will be apparent to those skilled in the art. In yet another preferred embodiment, the catheter is further guided by a coaxial second catheter as described in co-pending application U.S. Ser. No. 09/052,971 and PCT publication WO 9949773A2 titled “Delivery catheter system for heart chamber” by Payne, filed Mar. 31, 1998, both herein incorporated in their entireties by reference.
[0051] Catheter accessing device 16 is dimensioned to be placed in the vasculature of a subject and steered therethrough until the tip is disposed adjacent a selected region of tissue, for example, a surface or wall within a heart chamber (such as against the endocardial wall within the heart's left ventricle).
[0052] Visualization enhancement aids, including but not limited to radiopaque markers, tantalum and/or platinum bands, foils, and/or strips can be placed on the various components of drug-delivery tool-catheter assembly 12 , including on the deflectable end member of catheter accessing device 16 . In one embodiment, for example, a radio-opaque marker (not shown) made of platinum or other suitable radio-opaque material is disposed adjacent the tip for visualization via fluoroscopy or other methods. In addition, or as an alternative, one or more ultra-sonic transducers can be mounted on the catheter accessing device at or near its tip to assist in determining its location and/or placement (for example, degree of perpendicularity) with respect to a selected tissue in a subject, as well as to sense wall contact with, and/or wall thickness of, the tissue. Ultra-sonic transducer assemblies, and methods of using the same, are disclosed, for example, in published Canadian Patent Application No. 2,236,958, entitled, “Ultrasound Tool for Axial Ranging,” to Zanelli et al., and in co-pending U.S. patent application Ser. No. 08/852,977, filed May 7, 1997, entitled, “Ultrasound Tool for Axial Ranging,” to Zanelli et al., each of which is expressly incorporated herein by reference. In one embodiment of the present invention, depicted in FIG. 2, two transducers, denoted as 26 and 28 , are angle mounted at the tip of catheter accessing device 16 in the axis of pull-wire deflection. This construction permits an operator to determine, by comparing signal strength, whether the catheter tip region is perpendicular to a selected tissue surface or wall. Additionally, this two-transducer arrangement provides an operator with information useful for determining an appropriate adjustment direction for improving perpendicularity, as compared to single-transducer arrangements that, while capable of indicating perpendicularity by signal strength amplitude, are generally incapable of indicating a suitable direction in which to move the tip to improve perpendicularity. In a related embodiment, third and fourth transducers (not shown) are added, off of the deflection axis, to aid an operator with rotational movement and rotational perpendicularity in the non-deflecting plane of the subject tissue surface. Each of the above ultrasound transducers may preferably be substituted with force contact transducers described in co-pending U.S. patent application Ser. No. 60/191,610 by C. Tom titled “Apparatus and method for affecting a body tissue at its surface”, filed Mar. 23, 2000, [Attorney docket 5756-0011] herein incorporated by reference. An additional benefit of using a force contact transducer is that the contact force and incident angle are know to the user enabling the user to achieve a seal between the distal end of the accessing device and a tissue such that a seal is formed between the two preventing administered drug from seeping out of a formed cavity.
[0053] In some preferred embodiments, one or more elongate lumens may extend between the proximal and distal ends of the catheter accessing device, with (i) at least one lumen being dimensioned to accommodate a cavity forming implement for axial movement along a region of the assembly's distal end, and (ii) at least one lumen being configured to permit passage of one or more selected therapeutic and/or diagnostic agents from an agent-supply region (for example, a reservoir in the hand unit) to, and out of, a terminal orifice at the assembly's distal end. The just-described items (i) and (ii) can be achieved using a single lumen, or multiple lumens. In one embodiment, for example, catheter accessing device 16 , as depicted in FIG. 1, is preferably formed with an outer diameter of between about 2.25 to 2.75 mm (preferably 7 French), and an inner diameter, defining a primary lumen 22 , of about 1 mm. At its distal end, lumen 22 terminates at an orifice 24 . A tissue-penetrating implement 48 (described below) is adapted for movement within a distal-end region of lumen 22 . A selected agent can be passed through the main lumen directly, i.e., in contact with the main lumen's interior walls, and/or indirectly, for example, using one or more additional lumens (for example, sub-lumens) extending coextensively and/or coaxially with the main lumen. An embodiment of the latter construction is also illustrated, in part, in FIGS. 3 and 4. For example, FIGS. 1, 3, and 4 each depict different aspects of an elongate, flexible agent-delivery conduit 30 is disposed substantially coaxially within catheter accessing device 16 , extending from control structure (hand unit) 14 to a distal region of lumen 22 . Conduit 30 can be formed, for example, of a substantially inert polymeric material that resists collapse during bending or twisting, such as braided polyimide, braided PEBAX, or the like. Conduit 30 defines a hollow, axial lumen or passage 32 , having a diameter within a range of from about 0.25 mm to about 1 mm (for example, about 0.5 mm), or from about 0.010″ to about 0.040″ (for example, about 0.020″), that communicates at its proximal end with an agent-supply reservoir disposed in control structure (hand unit) 14 , and terminates at its distal end at an exit or infusion port 34 , through which a selected therapeutic and/or diagnostic agent can pass. As described below, conduit 30 is adapted for reciprocal sliding movement within catheter accessing device 16 and, thus, is provided with an outer diameter less than the inner diameter of catheter accessing device 16 , for example, about 1 mm or less in certain constructions.
[0054] At this point, certain details of the hand unit relating to agent storage and dispensing will be described, bearing in mind that additional details are set forth in co-pending U.S. Provisional Patent Application Ser. No. 09/080,175 filed May 16, 1998, entitled, “Drug Delivery Module,” to Glines et al., incorporated herein by reference. In one preferred embodiment depicted in FIG. 1, control structure (hand unit) 14 is provided with a fixed drug-delivery reservoir for holding a supply of a selected agent to be dispensed. In this embodiment, a supply vessel, such as syringe 36 , can communicate with the drug-delivery reservoir via a connector provided in the unit's outer housing 38 . The connector is preferably a substantially sterile connector, such as a standard Luer-type fitting or other known standard or proprietary connector. In another embodiment, the supply reservoir comprises a syringe, pre-loaded with a selected agent, that can be removably fit into a holding area inside the housing. In both such embodiments, a dosage volume adjustment thumbscrew 40 can be mounted in the housing 38 so as to be externally accessible for accurate, local and rapid dosage volume adjustment. Also, a dosage volume scale or indicator, as at 42 , can be provided in the housing 38 . Upon depressing a trigger mechanism 44 along one side of control structure (hand unit) 14 , manually or otherwise, the agent stored in the drug-delivery reservoir moves into conduit 30 . It should also be noted that trigger mechanism 44 is coupled to the proximal end of conduit 30 such that, upon being depressed, the conduit is pushed forward (advanced) within catheter accessing device 16 from a normal, retracted condition, depicted in FIG. 1, to a dispensing condition, shown in FIG. 4, whereat conduit orifice 34 can be positioned closely adjacent a selected tissue, such as 46 , against which catheter-accessing device orifice 24 has been placed. Upon releasing the trigger mechanism, conduit 30 shifts back to its normal condition. The distance traversed by conduit 30 , in each direction, is from about 2 to about 10 mm, and preferably about 5 mm.
[0055] A tissue-penetrating implement, indicated generally as 48 , is also longitudinally movable within catheter accessing device 16 , between a retracted condition, within a distal region of lumen 22 (FIG. 1), and an extended (advanced) condition, passed through and extending out of orifice 24 (FIG. 4), over a stroke of about 4-6 mm, and preferably about 5 mm. Movement of implement 48 is effected by way of an elongate actuation line 50 , depicted in cross-section in FIG. 3, operatively coupled at one end to trigger mechanism 44 (FIG. 1) and extending axially through conduit 30 from control structure (hand unit) 14 to a proximal end of implement 48 . Preferred materials for forming the actuation line are laterally flexible, permitting movement through tortuous pathways, and sufficiently incompressible along the longitudinal direction to provide for the efficient transmission of motion from the proximal end to the distal end. Suitable materials include, for example, stainless steel or a braided composite. In operation, upon the depressing trigger mechanism, implement 48 is shifted from its normal, retracted condition to its extended condition, and upon release of the trigger mechanism, implement 48 returns to its retracted condition.
[0056] For reasons that will become apparent below, it should be noted that the above-described advancement of both conduit 30 and cutting implement 48 takes place substantially simultaneously (i.e., these motions are coupled) with a single depression of trigger mechanism 44 . In addition, optionally, with the same trigger depression, an agent held in a reservoir in the hand unit is dispensed from conduit 30 . Preferably, such dispensing is effected immediately after (not before) the conduit and cutting implement have reached their respective extended conditions. For example, the initial depression can actuate axial movement of the conduit and cutting implement, and the latter member of the depression can effect dispensing. Similarly, both conduit 30 and cutting implement 48 are retracted together with release of the trigger mechanism, and the dispensing of the selected agent is stopped.
[0057] With further regard to the tissue-penetrating implement 48 , its distal end includes a cutting or slicing tip, denoted as 52 . In the illustrated arrangement, tip 52 takes the form of a narrow, three-sided pyramid-like structure that tapers to a sharp point. Alternatively, tip 52 could taper to a two-sided knife edge or blade, or any other suitable cutting or slicing structure. Preferred cutting or slicing structures are configured to substantially avoid the removal of tissue beyond the cellular injury inherent in cutting.
[0058] Implement 48 further includes an expandable member, proximal of tip 52 , comprised of one or more resiliently flexible expandable elements or expandable members, three of which are visible (out of a total of four) at 54 in the embodiment of FIGS. 1 and 4. The expandable members are arranged at spaced positions about the implement's longitudinal axis, and configured to flex outwardly, away from such axis, to collectively form a three dimensional support skeleton or cage. The expandable members can be, for example, narrow, elongate wires, filaments or ribbons, formed of a substantially inert, resiliently flexible material, such as a metal or metal alloy (for example, stainless steel, nickel-titanium, or similar material) or from an injection molded plastic. The distal end of each expander is turned inward and attached to the proximal side of tip 52 . When the expandable member is disposed at its retracted condition (FIG. 1), the expandable members are compressed toward the implement's longitudinal axis; and when advanced to its extended condition (FIG. 4), the expandable members are allowed to flex outward, so that, overall, the expandable member achieves a maximum diameter of about 1-3 mm, and preferably from about 1.75 mm to about 2 mm.
[0059] According to one preferred construction of the expandable member, between about 3-10 nickel-titanium (for example, as available commercially under the name “Nintinol”) filaments, each between about 4-5 mm in length and from about 0.003″ to about 0.005″ in diameter are employed as expandable members. The particular number, dimensions, and material composition of the expandable members are not critical, provided only that the expandable members are capable of forming a cavity when inserted into a selected tissue (i.e., they have sufficient strength and spring capabilities), and, when in the expanded condition, a drug or other agent delivered into the region within the expandable members can move outwardly into the tissue about the cavity, with very little interference presented by the expandable members themselves, as shown in FIG. 4 with agent 58 in cavity 60 . Regarding the latter, the expandable members preferably occupy no more than about 10%, and more preferably less than about 3%, of the region defining the boundary between the cavity and the target tissue thereabout. In this way, the vast majority of the tissue boarding a cavity can be directly exposed to an agent delivered into the cavity.
[0060] An exemplary method of using the above catheter assembly will now be described, wherein the catheter assembly is used for intra-myocardial delivery of a selected therapeutic and/or diagnostic agent. Initially, catheter accessing device 16 is percutaneously introduced via femoral or radial artery access. This can be accomplished, for example, by way of the Seldinger technique ( Acta Radiologica, 38, [1953], 368-376; incorporated herein by reference), a variation thereof, or other conventional technique. Optionally, a conventional guiding or shielding catheter (not shown) can be employed to assist in tracking the catheter tool through the patient's vasculature and into targeted regions of the heart. Once arterial access is established, the catheter accessing device 16 is slid across the aortic valve and into the left ventricle chamber. The distal end of the catheter accessing device 16 is maneuvered so as to be substantially perpendicular to the endocardial wall 46 (FIG. 4), using fluoroscopic visualization and/or ultrasound guidance, and pressed thereagainst. Trigger mechanism 44 is next depressed, causing cutting tip 52 to advance into the myocardial tissue, in the direction of arrow 64 , to a pre-set or adjustable depth. Expandable members 54 follow cutting tip 52 into the myocardium and expand radially (for example, in the direction of arrows 66 ), creating a cavity about the axis of penetration (i.e., the axis of cutting or slicing). Once the cavity has been created, the expandable members serve to maintain the cavity by resisting heart contractile forces. The same trigger depression serves to deliver a selected agent through conduit 30 into the cavity 60 . After allowing the agent to enter into the surrounding tissue for appropriate period of time, for example, typically less than about 2 minutes, the tissue-penetrating implement is withdrawn, at which point the cavity can close.
[0061] Healthy myocardial tissue is illustrated in FIG. 5A. As shown, healthy tissue contains capillaries 70 , interstitial tissue 72 , and heart muscle cells 74 (See, for example, “Gray's Anatomy” (1959) at page 597). FIG. 5B shows how a temporary cavity 60 can be created to directly access, for example, along the direction of arrows 68 , more capillaries 70 , more heart muscle cells 74 , and tissue surface area 76 . It should be appreciated that the creation of temporary cavities, as taught therein, provides direct access to a greater number of capillaries than has been possible by the prior techniques. As a result, the performance of the infusate tool is greatly enhanced.
[0062] It is believed that abrasion to the wall of the cavities may aid in absorption of the agent. Accordingly, it may be desirable to configure the cutting tip and/or cavity expandable members of the invention so as to allow selective abrasion. This can also be accomplished, for example, by RF, thermal, acidic and/or ultrasonic means acting on the cutting tip and/or cavity expandable members.
[0063] It is noted that the above-described method is exemplary in nature. Those skilled in the art will appreciate that the present invention provides for the delivery of selected agents to a wide variety of body organs and regions.
[0064] Another embodiment of the drug-delivery tool of the present invention is shown in FIG. 6, wherein the tool is embodied in an endoscope-type tool, shown generally at 80 . As described next, the drug-delivery tool of this embodiment is configured for intraoperative use, to be introduced thoracoscopically or through a thoracotomy, to form temporary cavities in a selected tissue. The tool includes a proximal handpiece 82 (similar to the previously-described control structure (hand unit) 14 ) adapted to accommodate an drug-delivery reservoir syringe 84 , and a depressible trigger mechanism 86 . This particular surgical tool incorporates a reusable 5 mm thoracoscopic camera 88 axially mounted to provide an operator with a field of view 90 through lens 92 . This allows the operator to work through a common Trocar access port 94 placed, for example, through a patient's chest wall 96 . In an exemplary use, upon traversing the epicardial surface 98 of the heart, a tissue-penetrating implement 48 , substantially as described above, can create a temporary cavity for receiving a selected agent. As with the catheter assembly, the tool is adapted to permit a user to both extend the tissue-penetrating implement and dispense a drug or other agent, with a single depression of the trigger mechanism 86 . Additional details of the handpiece are presented in co-pending U.S. Provisional Patent Application Ser. No. 09/080,175 filed May 16, 1998, entitled, “Drug Delivery Module,” to Glines et al., incorporated herein by reference. One skilled in the art would recognize that the above mentioned endoscopic embodiment may further be adapted for use without an endoscopic port, for example, such as in open surgery. Such an embodiment may be guided with or without visualization aids such as an optical endoscope or other optical enhancement device.
[0065] It should be noted that, especially when used in open surgery, the tissue-penetrating implement need not retract. Thus, movement of the implement between its retracted and advanced conditions, in such cases, need only involve movement of the implement move from its retracted to its advanced condition.
[0066] In another embodiment of the present invention, a selected therapeutic and/or diagnostic agent comprising a charged species (for example, DNA) is held within the distal-end region of an accessing device and delivered into a cavity formed by in a selected tissue via an electrical field. An exemplary cavity-forming and delivery implement, which can be incorporated in a catheter-type tool or an endoscope-type, such as previously described, is shown in FIGS. 7 A- 7 C. Here, the implement includes drug-delivery reservoir or storage vessel 114 which opens into the region between a plurality of expandable members 116 via short passage 118 through a neck member 120 . First and second lead wires, denoted as 122 and 124 respectively, extend through a flexible actuation accessing device 126 and terminate at respective terminals, or electrodes, fixed in the implement. The first terminal, indicated as 123 , being placed at a rearward (proximal) region of the vessel 114 , and the second terminal, denoted as 125 , being placed at a forward (distal) region of the implement's cutting/slicing tip 128 . In an exemplary operation, whereby DNA, indicated as 130 , is delivered into myocardial tissue 132 of a subject, the catheter accessing device 134 is introduced into a subject body and placed against an endocardial or epicardial wall 136 of the heart's left ventricle (FIG. 7A). During such introduction and placement, the vessel terminal 123 is made positive (+) and the tip terminal 125 is made negative (−), thereby establishing an electrical field that maintains the negatively charged DNA in the vessel 114 . It should be noted that the lead wires 122 , 124 and regions about the terminals 123 , 125 are shielded, using conventional materials, to limit the field's reach into the surrounding heart tissue. Such shielding about the forward (distal) region of the implement is indicated by back-hatching in the drawings. After placement of the catheter, actuation accessing device 126 is advanced, via a remote shifting mechanism (such as previously described), to push the slicing tip 128 through the wall 136 and into a region of myocardium 132 , with the expandable members 116 following the tip therein. Once a cavity has been formed in the myocardium, the polarity is reversed, so that the tip terminal 128 is positive (+) and the vessel terminal 123 is negative (−) (FIG. 7B), thereby establishing an electrical field effective to draw the negatively charged DNA 130 toward the tip 128 . After a short time, with at least a substantial member of the DNA drawn out of the vessel 114 , the electrical field is discontinued (FIG. 7C), so that the DNA can move outwardly into the surrounding tissue and capillaries of the myocardium.
[0067] In another embodiment, a selected therapeutic and/or diagnostic agent is held within the distal-end region of an accessing device and placed in a cavity formed in a selected tissue. An exemplary cavity-forming and placement implement, which can be incorporated in a catheter-type tool or an endoscope-type, such as previously described, is shown in FIGS. 8 A- 8 C. Here, the implement includes a plurality of expandable members 142 attached at their rearward (proximal) ends to a flexible actuation accessing device 144 , and at their forward (distal) ends to a cutting/slicing tip 146 . The expandable members 142 are arranged to serve as a cage or skeleton for containing a selected agent 148 , in solid or semi-solid form, as the catheter accessing device 150 is placed against a selected organ wall, as at 152 (FIG. 8A). Actuation accessing device 144 is then advanced, via a remote shifting mechanism, to push the slicing tip 146 of the implement through the wall 152 and into a selected layer of tissue 154 , with the expandable members 142 following the tip 146 therein (FIG. 8B). Once a cavity has been formed in this manner, the agent 148 is allowed to move outward into the surrounding tissue and capillaries (FIGS. 8 B- 8 C). The agent can be configured to for controlled release after placement, for example, via swelling and sloughing over a period of several minutes. In one embodiment, wherein the agent is DNA, controlled-release preparations are formulated through the use of polymers to complex or absorb the selected gene sequence (with or without an associated carrier, for example, liposomes, etc.). The agents can be formulated according to known methods to prepare pharmaceutically useful compositions, whereby these materials, or their functional derivatives, are combined in admixture with a pharmaceutically acceptable carrier vehicle. Suitable vehicles and their formulation, are described, for example, in Nicolau, C. et al. ( Crit. Rev. Ther. Drug Carrier Syst 6:239-271 (1989)), which is incorporated herein by reference. In order to form a pharmaceutically acceptable composition suitable for effective administration, such compositions will contain an effective amount of the desired gene sequence together with a suitable amount of carrier vehicle.
[0068] [0068]FIG. 9 a depicts a preferred embodiment of the invention where accessing device 900 further comprises force contact transducer 902 mounted on distal end 904 of accessing device 900 . As accessing device 900 is urged toward tissue 906 , as shown in FIG. 9 b, force contact transducer 902 contacts tissue 906 causing detectable contact pressure to develop between force contact transducer 902 and tissue 906 . Such detectable pressure, detected by force contact transducer 902 is communicated back to the end user who then can further manipulate accessing device 900 to achieve perpendicularity between the thrust axis of accessing device 900 and tissue 906 . Upon achieving perpendicularity and contact force, tissue-penetrating implement 908 , with cutting tip 908 a, may be advanced to an extended condition, from a retracted position, thus causing the formation of cavity 910 in tissue 906 . Because accessing device 900 is urged against tissue 906 in a perpendicular manner, distal end 904 of accessing device 900 develops a seal for sealing in later delivered drug into cavity 910 . FIG. 9 c depicts accessing device 900 without force contact transducer 902 . FIG. 9 c suggests how a non-perpendicular orientation of accessing device 900 with respect to tissue 906 could result in seepage of delivered drug 912 from cavity 910 . FIG. 9 d further depicts accessing device 900 without force contact transducer 902 urged against tissue 900 . Tissue 900 is further depicted in two states, diastolic state tissue 906 a and systolic state tissue 906 b correlating to the movement of myocardial tissue in a beating heart. As shown in FIG. 9 d, diastolic position tissue 906 a provides a seal between tissue 906 and accessing device 900 . However, upon systolic movement, tissue 906 moves away from accessing device 900 unless sufficient contact force exists between accessing device 900 and tissue 906 . Force contact transducer 902 provides information to the user to enable the user to apply sufficient and perpendicular force to the accessing device to create a seal between accessing device 900 and tissue 906 during the movements of beating heart between tissue 900 a and 900 b states. Moreover, FIG. 9 d depicts how delivered drug 912 may be further ejected or pumped out of cavity 910 by the contractile actions between heart tissue 900 a and 900 b states.
[0069] [0069]FIG. 10 depicts another embodiment of the invention utilizing corkscrew shaped tissue-penetrating implement 1000 . Accessing device 1002 houses tissue-penetrating implement 1000 that may be rotated within accessing device in either a retracted condition or an extended condition. FIG. 10 a depicts tissue-penetrating implement 1000 secured into tissue 1004 by screwing. As tissue-penetrating implement 1000 is withdrawn back towards a retracted condition, tissue 1004 is likewise pulled into lumen 1006 of accessing device 1002 thus creating seal 1006 between accessing device 1002 and tissue 1004 . Such pulling further creates cavity 1008 at distal end 1010 of tissue-penetrating implement 1000 . Cavity 1008 may then be filled with delivered-drug, not shown, delivered through lumen orifice 1012 to treat the walls of cavity 1008 with such drug.
[0070] [0070]FIG. 11 depicts another embodiment of the invention where the expandable members comprise a balloon structure with drug-delivery lumen orifices distributed along the surface of the expandable members. FIGS. 11 a and 11 b depicts a tissue-penetrating implement 1101 comprising four radially distributed expandable members 1100 defining lumens 1102 with exit ports 1104 outwardly situated on balloon 1106 . Penetrating tip 1108 is situated on the end of the balloon distal from accessing device 1110 , not shown. As balloon 1106 is inflated, expandable members 1100 are urged outward against the tissue of a cavity, not shown. FIG. 11 c further shows yet another embodiment using a balloon as an expandable member and drug-delivery channel. Accessing tool 1110 is urged against tissue 1112 , whereby tissue-penetrating implement 1101 comprises a balloon expandable member 1106 with distally situated exit ports 1104 and penetrating or cutting tip 1108 .
[0071] [0071]FIG. 12 depicts a preferred embodiment of the invention where tissue penetrating implement 1200 comprises at least one first expandable member 1202 made from a shape memory material composition having a first remembered arc shape and a second, stress induced, straight shape. First expandable member 1202 assumes a stress induced straight shape when housed within lumen 1204 of accessing tool 1206 , but returns to its remembered shape upon extension beyond lumen 1204 . As first expandable member 1202 extends from lumen 1202 , it cuts an arc shaped path through tissue 1210 as first expandable member 1202 regains its remembered shape. Tissue-penetrating implement 1200 has cutting tip 1208 situated distal to accessing tool 1206 for cutting tissue 1210 as tissue-penetrating implement 1200 is advanced into tissue 1210 when advanced from a retracted condition to an extended condition out of lumen 1204 . Second expandable member 1211 extends from lumen 1204 coaxial to first expandable member 1202 . Adjacent tissue-penetration implement's distal end, first and second expandable members are positioned together either fixedly or slidably. When fixedly positioned, both expandable members 1202 and 1211 extend together, but expand longitudinally from one another to form cavity 1212 . When first and second expandable members 1202 and 1211 are slidably positioned, the user may either extend one expandable member, preferably the first expandable member 1202 having cutting tip 1208 , and then extend second expandable member 1211 to follow along cut path 1216 created by previously extended first expandable member 1202 , expanding longitudinally away from first expandable member 1202 to create cavity 1212 where a drug may be infused from a drug-delivery reservoir, not shown, in fluid communication through a conduit with the distal region of accessing device 1222 . FIG. 12 b depicts a variation where second expandable member further comprises construction from shape memory tube 1218 , such as nitinol or NiTi tubing, defining a longitudinal lumen in fluid communication with a drug-delivery reservoir, not shown, and terminating with exit ports 1220 adjacent to the distal end of second expandable member. During or after the formation of cavity 1212 , drug may be delivered from the drug-delivery reservoir, not shown, to the cavity 1212 through the lumen and exit ports 1220 of second expandable member 1211 . FIG. 12 c depicts a variation where first and second expandable members 1202 and 1211 are spaced-apart from one another by, for example, having two lumens, not shown, defined within accessing device 1222 . Force contact transducer 1224 is located on the distal end of accessing device 1222 to assist a user in achieving the sufficient and perpendicular contact force with respect to tissue 1210 to create a seal between tissue 1210 and the distal end of accessing device 1222 . One skilled in the art would readily recognize the benefits of the above mentioned embodiment. In particular, the presence of second expandable member 1211 made from a shape memory material that assumes a stress induced straight shape when housed within lumen 1204 of accessing tool 1206 , but returns to its remembered shape upon extension beyond lumen 1204 , when configured as shown in FIG. 12, provides the ability to shepherd first expandable member 1202 further in its arc shape cutting path by applying lateral force to cutting tip 1208 as it cuts through tissue 1210 . This further prevents cutting tip from accidentally cutting too deep through a wall like tissue and thus perforating the wall and turning a cavity into a passage.
[0072] Additional pharmaceutical methods may be employed to control the duration of action. Controlled delivery may be exercised by selecting appropriate macromolecules (for example polyesters, polyamino acids, polyvinyl, pyrrolidone, ethylenevinylacetate, methylcellulose, carboxymethylcellulose, or protamine, sulfate) and the concentration of macromolecules as well as the methods of incorporation in order to control release. Another method to control the duration of action by controlled release preparations is to incorporate the agent into particles of a polymeric material such as polyesters, polyamino acids, hydrogels, poly(lactic acid) or ethylene vinyl acetate copolymers. Alternatively, instead of incorporating these agents into polymeric particles, it is possible to entrap these materials in microcapsules prepared, for example, by coacervation techniques or by interfacial polymerization, for example, hydroxymethylcellulose or gelatin microcapsules and poly(methylmethacylate) microcapsules, respectively, or in colloidal drug delivery systems, for example, liposomes, albumin microspheres, microemulsions, nanoparticles, and nanocapsules or in macroemulsions.
[0073] The drug-delivery tool and method of the present invention may employ a wide variety of agents, for example, ranging from active compounds to markers to gene therapy compounds. Exemplary agents, contemplated for use herein, are set forth in U.S. Pat. Nos. 5,840,059; 5,861,397; 5,846,946; 5,703,055; 5,693,622; 5,589,466; and 5,580,859, each expressly incorporated herein by reference. In one embodiment, for example, the invention is employed to deliver one or more genes (for example, as so-called “naked DNA”) into cavities formed in the myocardium of a subject.
[0074] In appropriate situations, the agent can be delivered in a form that keeps the agent associated with the target tissue for a useful period of time, such as with a viscosity-enhancer to produce a thixotropic gel. In certain embodiments, the therapeutic or diagnostic agent is mixed with a viscous biocompatible polyol to maintain prolonged, high concentration of the agent in the channels and affect the kinetics of the agent-target region interaction.
[0075] Alternatively, a catheter could be employed to deliver an agent incorporated in a biocompatible polymer matrix. Suitable polymeric materials are known in the art, for example, as set forth in U.S. Pat. No. 5,840,059, incorporated herein by reference. For example, non-biodegradable polymers can be employed as hollow reservoirs or other structures. Additionally, conventional pharmacologically inert fillers may be employed to tailor the time release characteristics of the agent. Certain embodiments contemplate the use of biodegradable polymers, such as collagen, polylactic-polyglycolic acid, and polyanhydride. For example, the agent can be dispersed in a polymer which is configured to degrade over a useful period of time, releasing the agent. In one embodiment, the agent is released by swelling and sloughing of the biodegradable polymer. Various means for employing polymer compounds to secure a therapeutic agent are disclosed, for example, in Levy et al., WO 94/21237 and in U.S. application Ser. No. 08/033,307, filed Mar. 15, 1993, which is hereby incorporated by reference. In still other embodiments, a biocompatible material is delivered to seal and retain the agent within the cavity. For example, a delivery lumen could be employed to deliver a sealing agent after delivery of the agent.
[0076] Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular embodiments and examples thereof, the true scope of the invention should not be so limited. Various changes and modification may be made without departing from the scope of the invention, as defined by the appended claims. For example, the expandable members of the tissue-penetrating implement can be configured not to expand, but rather to maintain a substantially constant configuration as it is moved between its retracted and advanced conditions. By this construction, the cage or skeleton structure defined by the expandable members can serve, when inserted into a tissue, to help form a temporary cavity, and maintain the cavity as one or more selected agents are delivered and/or drawn therein. Thus, while an expandable member (as described above) is advantageous for many purposes, a non-expandable cage or skeleton in place of the previously described expandable member can provide useful advantages, as well.
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The present invention provides an drug-delivery tool and method for delivering a selected diagnostic or therapeutic agent to a target site within a selected body tissue, such as the myocardium of the heart. In one embodiment, the drug-delivery tool is configured to be introduced percutaneously for intravascular delivery into temporary cavities formed in the myocardium from the epicardial surface. In another embodiment, the drug-delivery tool is configured for intraoperative use, to be introduced thoracoscopically or through a thoracotomy, to form temporary cavities in the myocardium from the epicardial surface. The drug-delivery tool generally comprises an accessing device having a tissue-penetrating implement in its distal-end region, and means for delivering a selected agent in a cavity formed by the implement. In an exemplary use, wherein a patient's heart is treated with an agent for transferring genetic information to the heart tissue, the distal end of the accessing device is conditioned adjacent a selected region of the heart wall, and the tissue-penetrating implement is advanced to form a temporary channel in the myocardium. The gene-therapy agent is introduced into the cavity by the delivery means and retained therein by means overcoming the intra-myocardial pressures. In one embodiment, the treated tissue is stunned, ischemic or hibernating organ tissue that has at least partially lost its normal capillary ability at natural vasomotion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an enclosure, such as a habitat for use in earth orbit, for example, as well as for use in terrestrial environments, on land or underwater. The present invention also relates to the method of constructing the enclosure.
2. Description of Background and Other Information
In the art of building structures, economy and efficiency are usually sought in the selection of the materials used and the methods employed in construction. For example, in both residential and commercial construction, it is known to utilize prefabricated components, factory-assembled, e.g., which are then transported to the construction site and appropriately arranged in a predetermined manner to complete the building structure. The structure is thereby produced in the minimal amount of time, but at a predetermined level of quality, usually mandated by regulation or code.
When building structures are designed for use in space, efficiency and economy are likewise sought and are even more critical. Indeed, due to the cost of transporting building materials and components to a space location, it is important that the method of construction be as efficient as possible. Ease of deployment and assembly, not material and strength factors, are most important. On the one hand, the cost and practicality of transporting relatively large preassembled components to a space location, which can be assembled in a relatively minimal amount of time, has to be balanced with the cost and practicality of merely transporting the necessary building materials to such a space location, which would then be used in construction of the structure in a relatively greater amount of time.
In either case, a primary constraint is the limitation in the size and weight of the payload, comprised of the necessary materials and/or components that can be transported to the space location, and the cost of transporting the payload. For example, the cargo capacity of the transport vehicle used would constrain the size of any given component. Necessarily, therefore, it is an objective to produce a relatively compact and light-weight payload during transportation, yet one which is comprised of the necessary materials and/or components for efficiently completing the enclosure, whether a habitat for human occupation or other enclosure for storage, support or other function.
In the United States, a presently planned space station design, which itself is already at least a second generation design, is planned to be constructed in eighteen components assembled on earth and transported to earth orbit, at an altitude of about 250 to 300 miles (403 to 483 kilometers), and assembled together during 28 space shuttle missions. The design includes, as the constituent foundation, two major structural beams, each about 360 feet (110 meters) in length and parallel to one another, which are crossed at an intermediate point, by another beam, about 400 feet (122 meters) in length. The two parallel beams are closed at their ends by smaller length beams to form two large box-like areas. Various modules for docking, habitation, experimentation, etc. are to be affixed to the structural framework. Construction of the structure is expected to begin in March, 1995 and is expected to be completed in four and one-half years.
At a currently projected cost of $37 billion, the U.S. structure is under critical Congressional review and critics contend that it is overweight, underpowered, and may require more frequent space shuttle flights than projected to complete the assembly. These critics cite the complexity of the present design as a significant problem. For example, thousands of different pieces are necessary to be assembled, which have been compared to pieces of a giant jig-saw puzzle, which are difficult to fit together properly.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to enable the construction of an enclosure, which is assembled from a relatively compact assembly of materials for transportation, but which enables a relatively simple and efficient construction at a building site.
To this end, the apparatus of the present invention includes a quantity of material movable between a coiled transport position to an uncoiled assembling position, wherein the quantity of material is adapted to form a coil. The quantity of material includes a first end portion which, in the coiled transport position, is located within an interior of the coil of material, a second end portion which, in the coiled transport position, is located on an exterior of the coil, and a pair of edge portions longitudinally extending between the first end portion and the second end portion. The material has a shape and a flexibility such that, as the quantity of material moves from the coiled transport position to the uncoiled assembling position, the material becomes transversely curved and longitudinally curved.
Preferably, the material is elastic, whereby, as the quantity of material moves from the coiled transport position to the uncoiled assembling position, the material becomes transversely curved due to elastic recovery of the material.
In a particular embodiment of the invention, each of the edge portions includes a series of cut-outs in the coiled transport position of the quantity of material, forming a series of spaced apart ribs
In this embodiment, the apparatus further includes means for moving the series of spaced apart ribs together on each respective edge portion in the uncoiled assembling position of the quantity of material. Further, the material includes a generally centrally positioned longitudinally extending spine, the ribs extending in a transverse direction from the spine.
Further according to this embodiment, the means for moving the series of spaced apart ribs together includes at least one cable uniting the series of ribs on each respective side of the material.
Further according to the invention, the transversely and longitudinally curved material is adapted to generate a toroid by the edge portions being connected together, thereby forming the enclosure.
In a variation of a particular embodiment of the invention, the transversely and longitudinally curved material is adapted to generate a semi-toroid, whereby a plurality of the coils of material are adapted to form a toroid by respective ones of the edge portions of respective ones of the coils being connected together, thereby forming the enclosure.
According to a particular aspect of the invention, the edge portions are adapted to be overlapped, the apparatus further including means for facilitating connection of the edge portions.
More specifically according to this feature of the invention, the means for facilitating connection of the edge portions includes a plurality of grip hook members extending from one of the pair of edge portions and a complementary plurality of grip slots located in the other of the pair of edge portions for receiving respective ones of the grip hook members.
Still further, the means for facilitating connection of the edge portions further includes providing the pair of edge portions with complementary corrugations in transverse cross section. In addition, a contact adhesive is adapted to be placed between the overlapped edge portions.
Still further, each of the pair of edge portions has a respective terminal edge, and the plurality of grip hook members extend in a transverse direction away from the terminal edge of the one edge portion to thereby increase a holding force of the plurality of grip hook members within the grip slots in response to a force tending to move the overlapped edge portions apart.
According to a particular feature of a particular embodiment of the present invention, in the coiled transport position, the coil of the material generally forms a cylinder having a cross-sectional dimension which increases in a direction from either of two ends of the cylinder toward a central portion of the cylinder.
The material from which the toroidal tubular enclosure of the present invention is made can be a metal, such as aluminum or an aluminum alloy, spring steel, cold rolled steel, or a plastic.
The present invention further includes a floor and a rigidifying structure for the floor, including a plurality of elements adapted to be assembled within the enclosure. If desired, a second floor or additional floors, generally parallel to the floor, can also be added.
Further according to the invention, the enclosure includes an interior surface having opposite side walls, wherein the floor includes at least one flat member extending from one of the opposite side walls to another of the opposite side walls, and wherein the rigidifying structure for the floor includes a plurality of joists adapted to be positioned to rigidify the floor.
Still further according to the invention, the rigidifying structure for the floor includes a plurality of floor joists adapted to be affixed to the floor and a plurality of end joists adapted to be affixed to the interior surface of the enclosure and adapted to be affixed to the floor joists.
According to a particular feature of the present invention, the generally flat member and the plurality of joists are adapted to be positioned within the coil to longitudinally curve and to transversely flatten from the generally corrugated cross-sectional shape. Further, each of the plurality of joists can have a predetermined length and a generally corrugated cross-sectional shape.
In a particular preferred embodiment, the plurality of joists includes a longitudinally extending quantity of a unitary material formed with weakened areas for defining the joists, whereby the joists are adapted to be separated from the unitary material at the weakened areas.
In a particular use of the enclosure of the invention, the enclosure is capable of being used as a satellite and the coil of material has a length less than or equal to 18.3 meters and a maximum diameter of less than or equal to 4.6 meters.
In a specific embodiment of the invention, the coil of material is adapted to be uncoiled for use in constructing an enclosure, the material being prestressed to become transversely curved and longitudinally curved in the uncoiled assembling position. Specifically, the material is prestressed to generally form a toroidal shape in the uncoiled assembling position.
It is a further object of the present invention to provide an assembly of parts capable of being assembled in constructing an enclosure, the assembly including:
a coil of material adapted to be uncoiled to an assembling position, the coil having a predetermined length and a predetermined diameter along the length, the material being prestressed to become transversely curved in the uncoiled assembling position; and
a plurality of elements positioned within the coil, the plurality of elements having a size and shape enabling the elements to be adapted to be affixed to respective parts of the assembly within the enclosure in respective positions along the length of the material in the uncoiled assembling position of the material to constitute an internal structure for the enclosure, whereby the plurality of elements are coiled with the coil of material for permitting access to the elements for assembly of the elements to the respective parts as the material is uncoiled to the assembling position.
It is a further object of the present invention to provide a method of assembling an enclosure with the use of at least one coil of material, the material having a pair of longitudinally extending edge portions extending between opposite end portions, the material being prestressed to curve transversely and longitudinally in an uncoiled assembling position, the method including:
(a) uncoiling the material to form a transversely and longitudinally curved shape; and
(b) connecting edge portions of at least the one coil to form a toroidal shape.
More specifically, the step of connecting the edge portions of the at least one coil includes positioning the grip hook members within the grip slots.
Still further according to the method of the present invention, the step of connecting the edge portions includes applying an adhesive to respective surfaces of the edge portions.
In another aspect of the method of the invention, air is transmitted to within the toroidal shape. By adding air to the enclosure, the force retaining the grip hook members within the grip slots is increased.
In an additional aspect of the method of the present invention, a floor and a rigidifying structure for the floor are assembled within the toroidal shape.
In particular, the step of assembling a floor and the rigidifying structure includes the step of uncoiling the material for gaining access to the floor and the rigidifying structure, which had been located within the coil.
In a preferred embodiment, the rigidifying structure includes a plurality of joists which includes a longitudinally extending quantity of a unitary material formed with weakened areas for defining the joists, wherein the step of assembling a floor and a rigidifying structure includes separating the joists from the unitary material at the weakened areas.
In an additional embodiment of the invention in which a plurality of tubular toroidal enclosures are utilized for forming a composite toroidal enclosure, the method further includes forming a plurality of toroidal shapes by performing the initial two steps mentioned above repeatedly with a respective plurality of coils of material, and the method further including affixing the plurality of toroidal shapes together.
In a still further embodiment of the invention, a toroidal enclosure is comprised of a plurality of telescopic sections which can be moved from a collapsed, telescoped assembly of tubular sections, for transportation, to an extended deployed assembly of sections which, when extended form the toroidal enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and additional objects, characteristics, and advantages of the present invention will become apparent in the following detailed description of preferred embodiments, with reference to the accompanying drawings which are presented as non-limiting examples, in which:
FIG. 1 is a schematic cross-sectional elevation view of the toroidal enclosure of the present invention;
FIG. 2 is a schematic plan view of the enclosure shown in FIG. 1;
FIG. 3a is a perspective view of a coil of material, partially uncoiled, and which is utilized in a first embodiment of the invention, illustrating the manner in which the enclosure is created;
FIG. 3b is a view, in transverse cross-sectional taken across the tubular toroid, of a variation of the embodiment of the invention shown in FIG. 3a, spaced from the toroidal axis;
FIG. 3c is a perspective view of a coil of material from which the variation shown in FIG. 3b is made;
FIG. 3d is a view, in transverse cross-sectional taken across the tubular toroid, of a further variation of the embodiment of the invention, made from a pair of semi-toroids;
FIG. 3e is a perspective view of the coils of material from which the variation shown in FIG. 3d is made;
FIG. 3f is a view, in transverse cross-sectional taken across the tubular toroid, of a still further variation of the embodiment of the invention;
FIG. 3g is a perspective view of the coils of material from which the variation shown in FIG. 3f is made;
FIG. 4 is partial view of the tubular enclosure, illustrating a particular connection of the edge portions of the uncoiled material forming the enclosure;
FIG. 5 is a partial view of the connection of FIG. 4, showing the edge portions slightly separated from each other;
FIG. 6a is a partial view of a variation of the connection shown in FIGS. 4 and 5;
FIG. 6b is a partial view of a variation of the grip hook members of the connection;
FIG. 6c is a partial view of another variation of the grip hook members of the connection;
FIG. 7a is a partial schematic cross-sectional perspective view of the enclosure of the invention, illustrating a floor and a rigidifying structure for the enclosure;
FIG. 7b is a variation of the structure of FIG. 7a;
FIG. 7c is a transverse cross-sectional view, taken along lines 7c--7c of FIG. 7b;
FIG. 7d illustrates a preassembled portion of the structure of the variation of FIG. 7b;
FIG. 7e illustrates a variation of the preassembled portion shown in FIG. 7d;
FIG. 8 is a partial cross-sectional view in elevation of the floor and rigidifying joists for the floor within the enclosure;
FIG. 9 is a perspective view of a joist for rigidifying the interior structure of the enclosure;
FIG. 10 is a perspective view of the joist of FIG. 9, illustrating the manner in which the joist curves longitudinally curves and at least partially flattens for being coiled with the material coil which forms the toroid;
FIG. 11a is a schematic view illustrating the manner in which the floor and joists are positioned with respect to the material forming the toroid and which is coiled with the material coil;
FIG. 11b illustrates a longitudinally extending member having weakened areas at which the joists are separated from one another;
FIG. 11c illustrates an alternate manner by which the floor is supported;
FIG. 12 is a partial plan view of an alternative embodiment for forming the toroidal enclosure;
FIG. 13 is an end elevation view of the material utilized in the alternative embodiment of FIG. 12;
FIG. 14 is a perspective view of the coil of material used in the embodiment of FIG. 12;
FIG. 15 is a partial perspective view of the uncoiled material of the embodiment of FIG. 12;
FIG. 16 is a partial plan view of the toroid of the embodiment of FIG. 12;
FIG. 17 is a partial exploded perspective view of a further embodiment of the invention, illustrating a layered toroidal enclosure;
FIG. 18 illustrates a transverse cross-sectional view through the completed multi-layered enclosure of FIG. 17;
FIG. 19a illustrates, in a transverse cross-sectional view taken along lines 19a--19a of FIG. 17, an optional constructional detail of the invention usable in the embodiment of FIGS. 17, 18;
FIG. 19b illustrates the optional constructional detail of FIG. 19a, in which plural layers are spaced from each other;
FIG. 20 is a schematic cross-sectional view of a further alternative embodiment in which a toroidal enclosure is formed by use of a plurality of smaller cross-sectional toroids connected together;
FIG. 21 illustrates, in transverse cross-section, a further alternative embodiment of the invention, in which a plurality of tubular members are telescoped for transportation;
FIG. 22 illustrates, in transverse cross-section, the embodiment of FIG. 21 in an extended, deployed position;
FIG. 23 illustrates, in perspective, one of the tubular members of the FIG. 21 embodiment; and
FIG. 24 illustrates, in plan view, the formation of the toroidal enclosure by means of the deployed position of tubular members in the FIG. 21 embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is directed to an enclosure which is contemplated to be used in space, within a body of water, or on land, and can be constructed in a number of alternative manners, as further described below.
In FIG. 1, a schematic cross-sectional view of the enclosure 1 of the invention is illustrated. As shown, the enclosure is generally toroidal in shape, having a central axis C and a toroidal plane P, perpendicular thereto. In a specific example, utilized presently, the diameter D o is approximately one (1) kilometer. In this example, the interior cross-sectional diameter D 3 of the tube is approximately ten (10) meters.
In view of the aforementioned objective of compactness for transportation described above, the constituent material from which the toroidal enclosure is constructed is coiled into a generally cylindrical configuration 3, as illustrated in FIG. 3a. In the example under discussion, the length H of the coil is approximately 31.4 meters. The material has a thickness of approximately five (5) millimeters, the average coil diameter is approximately 3.5 meters, and the material is coiled to form approximately 285.7 layers. On the other hand, it is contemplated that the enclosure of the present invention could be made of any desired size, including significantly smaller than that mentioned, to accommodate any desired application.
The material from which the toroidal enclosure is made can be either metal or plastic. As an example, aluminum or an aluminum alloy can be used, although spring steel or cold rolled steel could also be used.
In FIG. 3a, which shows the material partially uncoiled, the layers of the coil are located between outer diameter D 2 and inner diameter D 1 . For the example under discussion, D 1 is approximately 2.79 meters and D 2 is approximately 4.20 meters, the material coil thereby having a thickness of approximately 1.41 meters.
In the embodiment of the invention illustrated in FIG. 3a, the material forming the coil is prestressed both transversely and longitudinally. That is, as the material is uncoiled, as shown in FIG. 3a, the inherent biasing, i.e., prestressing, of the material, by which the material elastically recovers, causes the material to curve transversely about tubular axis O, as indicated by the double headed arrow 4. In addition, as also shown in FIG. 3a, as the material is uncoiled, it is biased to curve longitudinally about central axis C, as indicated by the double headed arrow 5.
In the FIG. 3a embodiment of the invention, because the material is prestressed to curve longitudinally when the material is uncoiled a slight bulge exists when the material is coiled, as shown by dimension e. As shown, the outer diameter of the coil changes along the length of the coil 3 from an end, at diameter D 2 , to a maximum diameter at a central portion of the coil, D 2 +2e, to an opposite end, also at diameter D 2 . The value of dimension e can be calculated by the following equation: e=(D 3 ·D 2 )/(D o -1/2D 3 ).
In the embodiment shown in FIG. 3a, to complete the tubular enclosure, a seam 6 is formed longitudinally around the toroidal enclosure 1 along the inner side of the toroid. The construction of the seam is discussed further below.
When used in an outer space environment, hundreds of miles (or kilometers) above the earth's surface, for example, the various steps in the assembly of the enclosure, described in further detail below, can be performed by outstretched robot arms and astronauts in self-propelled maneuvering units. The uncoiling of the material itself would occur automatically due to the internal stress, or prestress, in the material, once it is placed in position after being removed from containment in the transportation vehicle, by elastic recovery from the coiled position to the uncoiled position. The present invention is intended to provide a completed enclosure with a minimal number of operations, considering the environments in which the enclosure is contemplated to be assembled, viz., outer space or underwater.
As an alternative embodiment to that of FIG. 3a, the toroid can be formed to have the seam 6' located on the outer side of the toroid, as shown in FIG. 3b. In FIG. 3b only one transverse cross-section of the tubular enclosure 1' is shown, for simplicity, spaced from axis C.
In this embodiment, the material is prestressed to form a coil in the shape shown in FIG. 3c, i.e., a concave coil, rather than a convex coil, shown in FIG. 3a. An advantage of the embodiment of FIGS. 3b, 3c is that the seam can be sealed with a much greater force than in the embodiment of FIG. 3a, since the edges at seam 6' would not tend to move outwardly, away from each other, since such movement would be counter to the tension that would exist at the edges tending to retain the edges in a sealed position.
Further, at the inner side of the toroid of any of the embodiments disclosed herein, where the seam 6 is formed in the embodiment of FIG. 3a, the material might have a tendency to buckle, although this could be minimized or eliminated by appropriately controlling the magnitude of the prestress and the consequential toroid diameter. On the other hand, if buckling occurs at the inner side of the toroid upon completion of the assembly, the consequences are less significant in the embodiment of FIG. 3b, where there is no seam at the inner side.
FIG. 3d illustrates a modified form of the invention which can retain the aforementioned dimensions of the completed toroid, but which is designed for compatibility with the present configuration of the U.S. space shuttle. Specifically, the cargo bay of the shuttle is 60 feet (18.3 meters) in length and 15 feet (4.6 meters) in diameter. Therefore, the foregoing example of the present invention can be modified to be transported to earth orbit by the shuttle by forming the toroid from at least two coils 7', 8', each of which has a size such that the coils can be carried within the shuttle bay. Specifically, each coil can have a length of 1/2H, i.e., about 15.7 meters. In this example, therefore, instead of the material being prestressed to the extent that the opposite edge portions are brought together to form a seam, each of the two coils 7', 8' forms a semi-toroid 7, 8, which are joined together at seams 9, 10 by means of any of the methods to be discussed below.
Further, the respective coiled configurations of the material from which the semi-toroids 7 and 8 are shown in FIG. 3e. As can be seen, each semi-toroid forms a coil having the shape identified by 7' and 8', which are identical, coil 8' merely being inverted to illustrate how two such coils would be utilized to form a single toroid. Upon the uncoiling of coils 7' and 8', a complete toroid is produced, having seams 9 and 10, formed along a diametrical plane of the toroid.
An alternative to the FIGS. 3d, 3e construction is shown in FIGS. 3f, 3g, which also contemplates the use of two coils. Unlike the FIGS. 3d embodiment, however, in FIG. 3f the seams 9' and 10' are formed, in transverse cross-section, along a line perpendicular to the toroidal plane P, by means of a pair of semi-toroids 7a and 8a. As shown in FIG. 3g, semi-toroid 7a is formed from a concave coil 7a' and semi-toroid 8a is formed from a convex coil 8a'. Since the coils 7a', 8a' form semi-toroids, rather than complete toroids, the magnitude of their respective convexity and concavity is not required to be as great as with the coils of FIGS. 3a and 3c.
The seams 6, 6', 9, 9', 10 and 10' between edge portions 11 and 12 of the uncoiled material shown in FIG. 3a, for example, can be effected by means of the grip hook members 13 and grip slots 14. As shown in FIGS. 4 and 5, grip hook members 13 extend inwardly of the enclosure and away from edge 15 of edge portion 11, transversely across the edge portion 11. Also, grip slots 14 are positioned transversely across the edge portion 12. As the toroidal enclosure is assembled together, i.e., as the coil 3 of material is uncoiled, the grip hook members 13 are inserted in respective ones of grip slots 14.
After the coil 3 is completely uncoiled, the toroidal enclosure 1, as shown in FIG. 2, is completed by placing end 20 of the material within end 21 to create a predetermined amount of overlap between ends 20 and 21. For this purpose, the interior of the tube, within end 21, can be slightly enlarged along the tube through a distance at least equal to the amount of overlap of the ends, as shown in FIG. 2, to accommodate the introduction of end 20 within end 21. In addition, a grip hook member/grip slot connection, as disclosed for the longitudinal seams, can be employed to effect a secure connection. FIG. 2 also illustrates that the coil of material 3 transversely and longitudinally curves in a generally continuous manner from one end 20 to the other end 21 to form a completely closed enclosure.
In the embodiment shown in FIGS. 4, 5, 6a, 6b, and 6c, the edge portions 11 and 12 are overlapped by an amount depicted by the double headed arrow 17 in FIG. 4. To further enhance the connection, the edge portions 11 and 12 are corrugated, as shown in FIGS. 4 and 5. Specifically, as shown in FIG. 5, in which the edge portions 11 and 12 are separated for clarity, a transversely extending corrugation 18 is formed in edge portion for registration within transverse corrugation 19, which is formed in edge portion 12.
Still further, and particularly for making the seam airtight for use in high altitudes or underwater, a contact adhesive tape 22 can be applied to one of the edge surface portions. As shown in FIG. 5, the adhesive tape 22 is applied to edge portion 12, the tape having a release surface 23. The tape at least completely covers the grip slots 14 to ensure that the seam is airtight.
After completion of the seams necessary to form the toroidal enclosure 1, the interior of the enclosure can be appropriately pressurized, by means of an appropriate air pressure source 24, as schematically depicted in FIG. 2, particularly if the enclosure is utilized in a space or underwater environment. In pressurizing the interior of the enclosure, the seams are secured and the rigidity of the enclosure is increased by creating a tension force T-T, schematically shown in FIG. 4, tending to pull the overlapped edge portions 11, 12 apart. However, due to the direction in which the grip hook members 13 extend, they are more greatly forced within the grip slots 14. Further, due to the particular placement of the adhesive on the corrugation of edge portion 12 and the mating of the adhesive with the particular surface of the corrugation 18 of edge portion 11, the force T-T also forces the adhesive surfaces together.
If desired, as also mentioned below, the tubular enclosure can be compartmentalized by further internal construction, each compartment being individually pressurized, with airlocks separating the compartments, for example.
FIG. 6a illustrates, in cross section, an alternate embodiment of the grip hook members and grip hook slots. Therein, grip hook member 13' is shown on an edge portion of the material and a grip slot 14' is shown on a mating edge portion. The respective adhesive surfaces of the edge portions are indicated at 25. In this embodiment, which may or may not incorporate corrugations, a sealing membrane 26 is applied over the connection, after introduction of the grip hook members 13' within the respective grip slots 14' to ensure an airtight seal.
FIG. 6b illustrates another embodiment of grip hook member, identified as 13", and FIG. 6c illustrates a further embodiment of grip hook member, identified as 13"'. In the embodiments of FIGS. 5, 6a, and 6c, the grip hook members are punched out of the material from which the enclosure is made. The holes resulting from the punching-out of the hook members can be covered with an airtight membrane to facilitate sealing. In FIG. 6b, the grip hook members 13" are affixed to the surface of the edge portion.
After completion of the toroidal enclosure, spokes 27 can be affixed to the interior of the toroid, radiating from axis C, as shown in FIG. 2. Spokes 27, exemplarily shown as three in number, can be made from any suitable construction, subject to the above-mentioned constraints of size and weight for transportation, e.g., when used in a non-terrestrial environment. As an example, coils of material, only transversely prestressed, could be utilized, to be uncoiled to form generally straight tubular beams.
In the interior 28 of the toroidal enclosure, a floor and a rigidifying structure for the floor can be constructed. In FIG. 7a, the floor 29 is shown to extend from one surface 32 of the enclosure interior 28 to the opposite interior surface (not shown in FIG. 7a). On one side of the floor 29, floor joists 30 are positioned, which also can extend from one interior surface 32 to the opposite interior surface and are preferably laid parallel to each other, as shown in FIG. 8, which is a schematic cross-sectional view of the floor 29 and floor joists 30.
As also shown in FIG. 7a, end joists 31 are attached to interior surface 32 and on an edge surface of which the floor joists 30 are affixed. The means of attachment can take the form of rivets or other well-known fastening means. A sealant can be used, if desired, at the attachment points to ensure airtightness. The cross-sectional shape of the floor joists 30 and end joists 31 are preferably corrugated, or sinusoidal, as depicted in FIGS. 7a-7e, 8, and 9.
FIG. 7b illustrates a variation on the construction of FIG. 7a. Therein, a wall reinforcement element 40 is situated between the end joist 31 and the interior wall surface 32. The end joist 31 is affixed to the reinforcement element 40 by means of rivets 51a and 51b, shown in the upper and lower portions, respectively, of FIG. 7b. Although the floor joists 30 can be situated upon the upper edge of the end joist 31, as shown in FIG. 7a, the end of the floor joist can be complementarily formed, as shown in FIG. 7b, to accommodate the corrugated shape of the end joist. Appropriate fastening means, including adhesives, can be applied between the end joist and the floor joists, if necessary, to ensure the integrity of the connection.
FIG. 7c, which is a cross-sectional view of FIG. 7b, shows that the floor 29 can be attached to the floor joists 30 by means of rivets 52, or other convenient attachment means.
FIG. 7d illustrates a preassembled arrangement of the FIG. 7b variation, which is preassembled to the interior surface 32 before the coiling of the material prior to transportation to the assembly site. As can be seen in FIG. 7d, only the upper series of rivets 51a secure the end joist 31 to the reinforcement element 40, the lower rivets 51b are not affixed at this time, to permit the lower edge of the end joist to slide relative to the reinforcement element 40, due to the flattening of the end joist, described below in connection with FIG. 10, as the joist is coiled. After uncoiling of the material to form the toroid, the lower rivets 51b would be affixed, after the end joist assumes the unflattened shape shown in FIG. 7d.
Also as shown in FIG. 7d, the end joist 31 can be attached by means of upper rivets 51a both to the reinforcement element 40 and to the interior surface 32. Alternatively, the end joist 31 can be attached merely to the reinforcement element 40. In that event, the end joist 31 would be firmly affixed to the interior wall of the enclosure during assembling of the toroid with upper as well as lower rivets.
FIG. 7e shows a variation of the preassembled arrangement of FIG. 7d. In FIG. 7e, one edge of end joist 31, instead of being firmly affixed by rivets 51a, is positioned within guides 51c, which are preferably a series of longitudinally spaced elements, to locate the end joist 31 appropriately with respect to the interior surface, or reinforcement element, but which, compared to the FIG. 7d arrangement, permits an even greater freedom of movement during coiling of the material
FIG. 9 illustrates, in perspective, a joist 30 (or 31), in a non-stressed condition. In FIG. 10, the joist is illustrated in a curved condition, as it would assume when coiled within coil 3, as is explained further below, with regard to FIG. 11a. In the curved condition of FIG. 10, the joist generally flattens from its sinusoidal, or corrugated, form shown in FIG. 9, due to the inherent flexibility of the material from which the joist is made. Preferably, the joists, as well as the floor, can be made from a flexible metal or plastic Aluminum or an aluminum alloy, spring steel, or a cold rolled steel can be used, for example.
FIG. 11a illustrates a cross-sectional view of the toroidal enclosure 1 having a first floor 29' and a second floor 29" affixed to the interior of the enclosure and rigidified by floor joists 30' and 30", respectively. The axis C about which the toroid is generated is shown to the right in FIG. 11a. Respective end joists are to be affixed to the interior surface 32 of the enclosure I, as previously described. To the left in FIG. 11, one layer of the coil 3 is shown, in which the two floors 29' and 29" and the various floor joists 30' and 30" longitudinally extend with the material from which the enclosure 1 is made. In addition, the appropriate end joists extend coextensively with the floors and the floor joists. Since the end joists are to be affixed to the interior surface 32 in the completed enclosure, they can be preassembled before coiling within the coil 3, if desired, as described above.
As shown in FIG. 1a, floor 29" has a greater width than floor 29', since floor 29" extends across a greater cross-sectional dimension of the tube of the enclosure. In the formation of the coil 3, as shown in the leftmost portion of FIG. 11a, the first floor 29', which can extend the full length of the toroid, is first laid against surface 32, upon which floor joists 30' are laid. Next, the second floor 29", which can also extend the full toroidal length of the enclosure, is laid upon the joists 30'. Finally, the floor joists 30" are placed upon the second floor 29". By such a placement, the respective floors and joists are presented for assembly in a convenient manner as the coil 3 is unwound at the assembly location.
In FIG. 11b, a plurality of joists are shown as they would preferably be positioned prior to being coiled in the coil 3, in the layer as shown in the leftmost portion of FIG. 11a. Specifically, for convenience of manufacture and formation of coil 3, the various joists necessary for assembly of the completed enclosure can be made from a continuous longitudinally extending beam 34, with weakened areas 33, i.e., areas of lesser cross-sectional thickness or areas of perforation, defining the individual joists 30. Upon the unwinding of the coil 3, as schematically illustrated in FIG. 3a, the joists 30 are separated by breaking the beam 34 at weakened areas 33, as needed for assembly.
After completion of the toroidal enclosure, the enclosure can be appropriately caused to rotate about axis C to generate artificial gravity, if desired. The floors 30' and 30" are shown in FIG. 11a to appropriately orient the personnel and various accoutrements within the enclosure during such rotation.
FIG. 11c illustrates a further embodiment of the invention in which the floor 29"' is supported upon toroidal tubular elements 45a, 45b, and 45c, which have respective diameters, to support the floor at a desired level. The number of supporting toroidal elements 45a-45c is determined as needed. The interior of the elements 45a-45c can be utilized for necessary services, such as electricity, water, sewage, and/or other desired services.
Since the present invention is primarily directed to the superstructure of the enclosure, details of the interior for accommodation of various laboratories, habitation quarters, docking facilities, for example, are not shown. It is noted, however, that the interior of the toroidal enclosure can be appropriately segmented and separated by air locks, for example. Further, doors and windows can also be provided, as needed.
FIGS. 12-16 illustrate a second embodiment by which a toroidal enclosure can be constructed In this embodiment, the material which is to be coiled and transported to the assembly location is comprised of a plurality of ribs 35 extending transversely from opposite transverse sides of a longitudinally extending spine 36 at regular intervals, separated by respective cut-outs The spine 36 has a thickness greater than that of the ribs for appropriate reinforcement and riqidity.
For transportation to the assembly location, the material is wound into a coil 3', as schematically shown in FIG. 14. As shown therein, the coil 3' does not have an enlarged diameter near the center, such as that of coil 3, shown in FIG. 3a by dimension e, due to the use of the ribs 35, which can spread apart in the coiled configuration.
In the perspective view of FIG. 15, the enclosure of the second embodiment is partially shown, after uncoiling of the coil 3', but before the free ends of the various ribs are brought together. By bringing together the free ends of the various ribs, the toroidal shape of the enclosure is effected, around center C', as schematically illustrated in partial plan view in FIG. 16. As shown in FIG. 16, the spine 36 forms the outermost rim of the toroidal enclosure 1'. Therefore, a transverse toroidal segment is comprised by a pair of oppositely extending ribs 35. As shown in FIG. 16, any given segment is preferably defined by a width L 2 at the spine which tapers to a minimal width L 1 at the inner portion of the toroid.
It is contemplated that the material from which the ribs 35 and spine 36 is made is not prestressed either transversely or longitudinally. It is contemplated, however, that the free ends of longitudinally adjacent ones of the respective ribs 35 can be connected by an elastic element or cable 37 which, when the coil 3' is unwound, forces the ribs together, generally into the toroidal configuration of FIG. 16, by means of elastic return forces T'--T'.
Alternatively, prestressing could, if desired, be used in this embodiment. Prestressing would ensure the final assembly being accomplished automatically, as described above. In such an event, the aforementioned cable would complete the final locking of the assembly in place.
In the embodiment of FIGS. 12-16, although each of the adjacent ribs 35 can be seamed together with an adhesive, for example, it is contemplated that the toroidal enclosure 1' can be completed without providing airtight seams, particularly due to the relatively great number of seams that would be required to be made. If so, each compartment within the enclosure can be separately sealed and pressurized and the toroidal enclosure 1' would serve primarily as merely the superstructure for the enclosure.
It is contemplated that a multi-layered toroidal structure can be assembled by utilizing the structures described above to provide a predetermined wall thickness to secure the enclosure, particularly for use in a space environment, against collisions with high-speed particles which might tend to penetrate the wall of the enclosure. In such an embodiment, an example of which is illustrated in perspective in FIG. 17, the ribbed embodiment of the enclosure of FIGS. 12-16 can be alternately layered with the solid embodiment a sufficient number of times until the desired wall thickness is achieved.
FIG. 18 shows a cross-section of a three layered assembly comprised of, e.g., an inner solid toroid 60, an intermediate ribbed toroid 70, and an outer solid toroid 80. Although the seams for each of the three toroids 60, 70, 80 are shown to be in the same relative position such the seams overlie each other, alternatively, the toroids can be chosen appropriately so that the locations of the respective longitudinally extending seams are varied, i.e., by using various ones of the embodiments of FIGS. 3a-3g, e.g., with regard to the solid toroids.
FIGS. 19a and 19b, both of which are partial cross-sectional views of a three layered toroidal enclosure, in which a ribbed toroid is positioned between a pair of solid toroids 60, 80, show a means for spacing the outer solid toroid 80 further from the inner solid toroid 60, for insulation purposes, for example.
In FIG. 19a, in which a rib 70' of the intermediate ribbed toroid is shown in cross-section through a rib, a highly flexible bladder 71, made of rubber or nylon, e.g., is attached to the rib and extends along the rib, as well as along a transverse adjacent rib, on the opposite side of the spine of the ribbed toroid, to generally extend around the periphery of the tube. Similar bladders are to be provided on other ribs or on alternate or fewer ribs, as necessary, to provide reasonable structural integrity.
Subsequently, upon inflation of the bladders, the outer toroid 80 is spaced apart from inner toroid 60 to create a space therebetween, for insulation purposes, for example.
FIG. 20 illustrates a third embodiment of the toroidal enclosure of the present invention which is comprised of a plurality of tubular toroidal enclosures 38, which are of substantially the same configuration as that of tubular toroidal enclosure 1 of the first embodiment, but of much smaller internal diameter D 3 '. As shown in FIG. 20, the tubular toroidal enclosure 1" is centered around axis C", preferably having the same diameter D o as the aforementioned embodiments.
In the embodiment of FIG. 20, a plurality of tubular toroids 38 are uncoiled and joined together with adhesive, such as a double-sided aircraft tape, and/or with pop rivets, to form a composition structure, until the structure is completed and then sealed.
Each toroid 38 is filled with air after it is completed and sealed by adhesive and/or other means, as mentioned above. Thereafter, the entire composite enclosure 1" is sealed and also filled with air.
As also shown in FIG. 20, a floor or a number of floors 39 are positioned, as well as openings for doors and windows, as desired. Further certain of the tubes 38 can be dedicated for housing the necessary utilities, such as electrical wiring, effluent, and water storage, etc.
FIGS. 21-24 illustrate a further embodiment of the invention, which differs from the preceding embodiments in that the tubular sections 82, 92, 102, 112, etc., from which the toroidal enclosure 1"' is composed, are not prestressed in the sense of that of the coils in the embodiments described above.
Specifically, FIG. 21 illustrates tubular sections 82, 92, 102, 112, in transverse cross-section, in a collapsed telescoped configuration. Although only four sections are shown, this number is intended merely for the purposes of simplicity and convenience of this description and many more such sections are contemplated to comprise the completed enclosure, as will be described below.
Each tubular section is contemplated to have a geometrically identical shape, in a relaxed condition, as illustrated in perspective in FIG. 23. For the purpose of illustration, the tubular section 92 is referred to in FIG. 23. Along the length of section 92 is a slit 95 which permits the section to be compressed and overlapped to the extent necessary, to collapse it within a plurality of similar sections, as shown in FIG. 21. For example, since section 92 is collapsed within section 82, the edges of slit 95 would be compressed together somewhat, and perhaps overlapped, while telescopically collapsed therein. Likewise, the edges of the slit (not illustrated) in tubular section 102 would be compressed and overlapped together somewhat more than those of section 92, since section 102 is to be collapsed within section 95. However, upon extension of the tubular sections, as shown in FIG. 22, each section is free to resume its identical shape. That is, as section 92, e.g., is extended from within section 82, the compression of the edges of slit 95 is relieved and section 92 can assume the shape shown in FIG. 23.
As each section extends, cooperating internal lips on the sections restrain the respective sections from extending beyond the end of adjacent sections, as illustrated in FIG. 22. Specifically, as shown in FIGS. 21 and 22, section 82 has an external peripheral lip 83 at its left end and an internal peripheral lip 84 at its right end. As section 92 extends rightwardly in FIG. 22, external lip 93 of section 92 engages with internal lip 84 of section 82. Likewise, external lip 103 of section 102 engages with internal lip 94 of section 92, external lip 113 of section 112 engages with internal lip 104 of section 102, etc.
To permit the extension of the sections to form a toroidal enclosure, the transverse plane defined by the end of each section can be made to be slightly less than 90° to the longitudinal axis of the section. For example, if 360 sections were to be used in forming the completed enclosure in this embodiment, as shown in FIG. 24, angle α, between the end plane and the longitudinal axis of the tubular section (see FIG. 21) would be 89°, thereby permitting each adjacent section to form a 1° angle with respect to the other. Thereby, the toroid would be completed upon the right internal peripheral lip of the 360th section being engaged with external peripheral lip 83 of first section 82. An internal longitudinal guide, or reference mark, not shown in the drawings, could be utilized with each section to prevent any relative movement of adjacent sections as they are telescoped and/or to permit the assembler(s) of the toroid to ensure accuracy and alignment in the formation of the toroid.
It is contemplated that instead of all sections being telescoped into a single telescopically collapsed assembly, a plurality of collapsed assemblies, like that of FIG. 21 could be used to complete the toroidal enclosure of FIG. 24. In this case, the peripheral lips of the respective end sections of adjacent assemblies would be engaged to connect the plurality of assemblies after extension.
Further, to effect the extension of the assemblies, e.g., to effect the extension from the collapsed configuration shown in FIG. 21 to the extended configuration shown in FIG. 23, air pressure could be introduced within the collapsed assembly, after temporarily sealing the ends of the assembly with appropriate end seals 150, 151, against which the air pressure within the assembly would effect the extension of the assembly as shown schematically by the oppositely directed arrows in FIG. 21. Upon extension, the seals would be removed to permit the connection of adjacent assemblies.
After completion of the toroidal enclosure of the embodiment of FIGS. 21-24, the interior of the enclosure could be completed using various ones of the techniques described above. The seams at the slits of each section could be made and sealed as described above as well.
Whether the completed enclosure is formed from one or multiple sections, or coils, in accordance with any of the embodiments described above, it is contemplated that the completed toroid curves both transversely and longitudinally in a generally continuous manner along the entire circumference of the toroid, as schematically shown in FIGS. 2 and 24, for example.
Finally, although the invention has been described with reference of particular means, materials and embodiments, it is to be understood that the invention is not limited to the particulars disclosed and extends to all equivalents within the scope of the claims.
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A method and apparatus for assembling an enclosure, in which the assembly includes a coil of material adapted to be uncoiled to an assembling position. The material can be prestressed to become at least transversely curved in the uncoiled assembling position. In a particular embodiment, the material is also prestressed to curve longitudinally, as the coil is unwound to form a toroidal shape. Further, the assembly can include a plurality of elements positioned within the coil, the elements having a size and shape enabling them to be adapted to be affixed to respective parts of the assembly within the enclosure in respective positions along the length of the material in the uncoiled assembling position to constitute an internal structure for the enclosure. The plurality of elements are coiled with the coil of material for permitting access to the elements for assembling them after the material is uncoiled. The enclosure is adapted to be used in space or terrestrially, on land or underwater, and can be appropriately sealed and pressurized.
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This invention relates to a woven fabric filter medium and more particularly to a method of forming the medium and to the materials woven to make the fabric filter medium.
BACKGROUND OF THE INVENTION
Filter apparatus using filter mediums are shown in my issued patents U.S. Pat. No. 5,059,318 issued Oct. 22, 1991 for Fluid Seal For A Travelling Sheet Filter Press and U.S. Pat. No. 5,292,434 issued Mar. 8, 1994 for Filter Apparatus And Method Using Belt Filter Medium. In such filters separable plate members are [Dressed together to form a filter chamber. The plates have mating surfaces and hollow interior portions that create a filter chamber. A filter medium is placed between the mating surfaces before the plates are closed. In the usual operation, a slurry of liquid and solids is introduced into the formed chamber above the filter medium and, in a series of operations that may include forcing wash fluids, liquids or gasses through the slurry within the chamber, fluids are forced out of the slurry and through the filter medium to produce a dry filter cake of solids on the filter medium within the chamber. The plates may then be separated leaving the filter cake on the filter medium and the filter medium may be advanced out of the filter chamber to be replaced by a clean filter medium for a repeat operation of the filter mechanism. The filter medium may be advanced to a dump position for the filter cake and then cleaned and reused or may be discarded.
Because slurries are of varied formation and characteristics the filter medium used in the filter apparatus shown in my issued patents and in functionally similar filter apparatus frequently are specifically designed for the slurry being encountered. Some slurries include coarse solids and some include almost colloidal suspensions of fine solids. Filter media for filter apparatus operating with these variations in particle size need to be designed to provide the desired permeability for the media while providing a media with openings that will capture the smallest particles that are desired to be retained. The filter media must also be capable of performing the desired filter operation without becoming clogged by retained solids.
In designing a filter media that is intended for repeated uses, it is desirable to produce a filter media that will release the produced filter cake and may be easily cleaned for reuse in the filter chamber.
Slurries are also of varying chemical characteristics; some being toxic, some caustic, some acidic, some hot, some cold. Filter media designed for these different chemical characteristics may be woven with fibers that can withstand the conditions to be encountered within the filter chamber.
FIELD OF THE INVENTION
Filter media of the type used in pressure filters described above are usually woven of selected yarns. The yarns may be monofilaments or multifilaments or spun of man-made or natural origin. The yarns are woven in suitable weaving looms that are operated under controllable conditions to produce the desired weave of yarns. Woven fabrics are described by their warp yarn and their weft yarn, the fibers used in each of those yarns, the number of warp yarns per inch, the number of weft yarns per inch, the weight per square yard for the woven fabric, and the treatments during or after weaving for the woven fabric.
In a weaving loom there are provisions for a plurality of warp yarns across the loom. Each warp yarn is withdrawn from its own yarn spool or may be positioned on a supply beam and strung through a harness that moves the individual warp yarns up or down while a rapier or shuttle quill runs weft yarns through the wedge created by the specific warp yarns. The warp yarns extend in the direction of the loom; that direction being referred to as "machine" direction. Each warp yarn is separated from its adjacent yarn and the loom is equipped with means for moving the warp yarns with respect to each other and the loom to provide for different weave patterns. The warp yarns usually are tensioned by applying a force against the yarn as it is drawn from a spool or supply beam within the loom. The number of warp yarns in a fabric is referred to as "ends per inch" or the number of warp yarns in a linear inch in the cross machine direction of the fabric.
The weaving loom has provisions for passing weft yarns across the loom and between warp yarns. The weft yarns extend across the loom; that direction being referred to as "cross machine" direction. Each weft yarn is passed across the loom and may be a continuous yarn that returns through the loom after each cross machine path or is cut at the end of each pass. Each path across the loom may be with a different positioning of the warp yarns so as to produce the desired weave. Weft yarns are pressed against the previous adjacent weft yarn with a comb-like bar for packing each weft yarn. The woven fabric may pass over rollers, through an oven for heat treatment and over a load sensing beam to a take-up roll all under controllable tensions. The speed of take up or accumulation of the woven fabric on a spool or roll or the like may be used to determine the proximity of adjacent of weft yarns or packing of the yarns in a weave. The number of weft yarns per inch in a woven fabric is referred to as "picks per inch" or the number of weft yarns in a linear inch in the machine direction of the fabric. A "pick" is a single weft or fill yarn along the fabric; those weft yarns may be a multifilament, a monofilament or a spun yarn.
Yarns include single monofilament fibers, multifilament fibers, spun yarns and twisted combinations of either or both of such fibers. Multifilament fibers may be twisted or untwisted and may be wrapped with fibers of the same or different fibers. Yarns may be described in terms of denier which is the weight in grams of 9,000 meters of yarn before heat shrinking. Spun yarns are measured in "cotton count" which is the number of 840 yard hanks of yarn per pound. The higher the cotton count number, the smaller the yarn. Spun yarns are identified by two numbers, for example 4.00/2. The first number is the cotton count of 840 hanks per pound and the second number is the number of plies twisted together to form the yarn. Each ply of a multi-ply yarn can be twisted and when two or more twisted yarns are used, those twisted yarns can be twisted with each other to form a single yarn. Twist in a yarn is measured in "twists per inch". When twisted yarns are used in a fabric, the yarns with less twists per inch can produce a weave with less permeability and can prevent penetration of particles in the filtration process.
Monofilament yarns can be used in the cross machine direction yarns and can be sized for more "packing" or picks per inch. Smaller monofilament yarns in a weave can create a less permeable, more stable fabric with higher particle capture, with other variable being the same. Larger monofilaments result in fewer picks per inch, less dimensional stability and higher permeability, with all other variables being the same.
In weaving fabrics the tension and heat applied to the individual yarns may be used to produce "crimp" in the yarns. Crimp is defined as a percent and is the amount of loss in length of a specific length of yarn.
Weaving patterns produced by variations in the movement of adjacent warp yarns are known. One such pattern is referred to as a "twill" weave. In a twill weave, the pattern of movement of adjacent ward yarns is controlled in a repeating manner such that groups of warp yarns are moved for each passage of a weft yarn across the loom. Twill weaves can be uniform, that is repeating with the same changes of warp yarn movement on each pass of a weft yarn or may be a "broken" twill where the movement of adjacent warp yarns may be in groups and the groups may be in a controlled pattern that is not uniform for each weft passage but is repeating in some pattern order. Weaving looms may be controlled to produce almost any desired pattern of weaves.
SUMMARY OF THE INVENTION
Woven fabrics are known for use as filter media but no known woven fabrics have been specifically designed for the applications in pressure filters for slurry separations. Pressure filters require the filter media to be capable of operation in the pressure and environment of the slurry being treated in the filter. Fabrics for filter media in such operations may need to be specifically designed for the slurry being filtered. Further, the fabrics must be dimensionally stable and capable of being transported through the filter apparatus and sealed between the plates that form the filtration chamber. The woven filter media described herein is capable of being woven in a manner and of materials that will perform the desired functions.
In accord with the present invention, a woven fabric filter medium is produced that will meet a set of criteria for the filtration process that is to be performed. By establishing the size of the warp and weft yarns in the weaving of the fabric it is possible to produce a fabric that will have the desired permeability and particle capture characteristic that is needed. By selecting the proper yarn materials the woven medium can be designed to meet the physical and chemical conditions that will occur in the filtering process.
The fabric that is produced in accord with the method and materials herein disclosed is capable of being woven in a pattern that will produce the desired permeability and capture for the media. By selecting the appropriate warp yarns and the spacing of the warp yarns in the loom it is possible to use smaller yarns to establish more picks per inch in the cross machine direction and to create a less permeable, more dimensionally stable fabric with higher particle capture; or with the use of a larger monofilament warp yarn and fewer picks per inch to create a more permeable, less stable medium that will capture larger slurry solids.
Fabrics woven as described herein and heat treated under tensioned conditions applied to the warp yarns can produce desired crimp in the weft yarns and can produce more dimensionally stable fabrics. With the desired amount of crimp in the yarns, the woven fabric can be stable in the machine direction, cross machine direction and in diagonal directions thus creating a uniformly stable fabric.
The use of spun yarns in the weft yarns can be used to improve the capture characteristic of the woven fabric. Multifilament yarns passing across the weave can also create improved capture characteristics. The selection of different yarns can improve the wear characteristic of the resultant yarn. In accord with the present invention, multifilament yarns are produced by twisting filaments to produce a first twisted yarn and then that twisted yarn is twisted with another twisted multifilament yarn to produce one warp or weft yarn. The yarns twisted to produce the twisted weft yarn can be selected to produce a desired yarn weight that may be crimped to the desired percent crimp.
Preshrunk, high modulus yarns may be used to achieve a desired chemical, heat or abrasion resistance. Polyester, polyproplyene, nylon or other synthetic fibers as well as glass fibers can be used to accomplish a desired resultant yarn. Combinations of synthetic, natural and manmade fibers can be used.
It is therefore an object of the present invention to produce an improved woven fabric filter medium that will be dimensionally stable, of designable permeability and capture, easily movable within a filter mechanism, and easily cleanable for reuse.
Another object in accord with the preceding object is a method for producing an improved woven fabric filter medium.
Further objects and features of the present invention will be readily apparent to those skilled in the art from the appended drawings and specification illustrating preferred embodiments wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view a filter apparatus adapted for use of the woven fabric filter medium of the present invention.
FIG. 2 is a schematic representation of a weaving loom for performing the method and producing the fabrics of the present invention.
FIG. 3 is an enlarged representation of a woven fabric of the present invention.
FIG. 4 is an enlarged representation of a woven twill fabric of the present invention.
FIG. 5 is an enlarged representation of a broken twill fabric as contemplated in the present invention.
FIG. 6 is a representation of twisted warp yarns as used in the present invention.
FIG. 7 is a representation of twisted weft yarns as used in the present invention.
FIG. 8 is a cross-section view of a pair of wrapped yarns.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in the assembly drawing of FIG. 1, the filter apparatus 10 that would use a filter medium produced in accord with the present invention comprises a pair of plate members, an upper plate member 12 and a lower plate member 14, supported on and relatively movable within a support frame assembly comprising a pair of base beams 16, a pair of lower strongback members 18, a pair of spaced tension columns 20, and an upper strongback member 22. The support frame assembly is an assembly of the lower strongback members 18 on the base beams 16 with the spaced tension columns 20 mounted on the lower strongback member 18 and the upper strongback member 22 mounted on the tension columns. The frame assembly has an open interior portion for the support of the lower plate member 14 on the lower strongback 18, with suitable spacing and bracing. The upper plate member 12 is suspended from the upper strongback 22. A hydraulic jack mechanism 24 is provided between the upper plate member 12 and the upper strongback 22. As shown in FIG. 1 for a continuous belt operation, at each side of the assembly and mounted on the base beams 16, a pair of filter belt drive, treatment and washing assemblies 26 including rollers 27 are mounted for movement and treatment of a filter belt 28; the feed or drive function and the treatment and washing function can be performed at either side of the assembly. It should also be understood that in the alternative form of the apparatus using a disposable medium, there will be a different feed apparatus; however, the medium will be placed in the same location within the chamber and advanced with each operation of the apparatus.
The assembled filter apparatus of the present invention is adapted to open and close the plate members placing the upper plate member 12 in contact with lower plate member 14. When the plate members are closed, the filter medium 28 is between the upper plate 12 and the lower plate 14. The hydraulic jack mechanism 24 has been operated to force the plates together at a force at least exceeding the force created by the pressurized fluid with the filter medium in between the plates to seal the filter chamber that is created between the closed plates.
As described in my issued U.S. Pat. No. 5,292,434, the filter apparatus may be operated to perform a series of operational steps for the treatment of a slurry within the closed chamber so as to produce the desired filter cake or desired filtrate. Such steps can include preliminary slurry washes, pressure fluid washes or gas blowdown through the chamber, as well as treatment of the filter cake after fluids have been removed all for the purpose of separating solids from liquids and retaining the solids within the chamber on the filter medium. Those particular treatment steps do not form a part of this application except to the extent that the steps cause the movement of solid particles within the slurry and the capture of those particles on the filter medium. Each slurry or each process that produces a slurry may differ because of the size of particles within the slurry or because of the chemical make-up of either the liquid or the solid portions of the slurry. The filter medium of the present invention is designed to perform its function based on the characteristics of the slurry that is to be separated.
In pressure filtration of slurry, woven filter media is commonly used to separate liquid from solids. The weaving of such woven filter media involves the placement of warp and weft yarns in a prescribed pattern to produce a desired weave. Weaving is performed with a loom that has a machine direction representing the linear dimension of a fabric woven in the loom and a cross machine direction representing the dimension across the woven fabric. Machine direction yarns are referred to as warp yarns; cross machine directions are referred to as weft yarns. Warp yarns are usually uniformly spaced across the loom in parallel paths with the individual yarns drawn from separate spools or a beam and across a bar through separate harness eyes and controllers that permit each warp yarn to be moved with respect to the axis of the loom. Cross machine direction yarns, the weft yarns, are passed across the loom between the warp yarns. The weft yarns are separately placed and can be a single pass yarn or a continuous yarn from a spool, returning through the loom to produce the desired finished edge on the resultant woven fabric. The weft yarns can be pressed into the warp yarns to produce the desired density of a woven fabric.
The resultant woven fabric is usually accumulated on some from of accumulator, such as a spool. The rate of accumulation of the woven fabric and the rate of passage of the weft yarns across the loom can determine the density or tightness of the woven fabric. Tension of the warp yarns can also determine the tightness of the weave and the bending or crimp of weft yarns as the woven fabric is further treated. The present invention is directed to the selection and control of the warp and weft yarns, the control of the loom, the treatment of the woven fabric during and after the weaving to accomplish the formation of a preferred woven fabric filter medium for use with a pressure filter apparatus.
Characteristics of the slurry to be filtered are a major factor in determining a suitable woven material to effectively separate liquid from solids. It is known that woven media with smaller openings than the particle size of the solids in the slurry may retain the slurry solids while allowing the liquid to pass. It is also known that though an opening in the woven material may be larger than the particle size, a tortuous path through the woven media may prevent the particle from passing through the media.
The use of monofilament, multifilament and spun yarns of several weights, materials and weaves is also known as well as limits of materials used. The material limits include:
1. exceeding certain temperatures where properties of the fabric may break down,
2. chemical or pH limits of the material used, or
3. any of several factors, such as durability, swell, stretching, etc.
Use of woven filter media that also serves as a belt to transport filtered solids is known. Thus filter belts must be suitable for both filtering slurries and also serve as a belt to move retained solids from the filter area to a disposal or processing site. The belt characteristic of such filter fabric may include:
1. dimensional stability of fabric with resistance to stretching and shrinking under varying conditions including heat, moisture, chemical attack, high load tension,
2. durability with resistance to wear,
3. strength to pull solids retained on the belt and strength to overcome inertia when the loaded portion of the filter belt is first moved from the filter area.
Some of the problems associated with tracking and filtering characteristics of filter media within the filter apparatus include:
1. weave opening or stretching in areas of the belt fabric when tension is applied to the belt causing the belt to become misaligned and to track to one side of the chamber,
2. bowing of the fabric,
3. shrinking of the weft (width) of the belt,
4. loss of belt tension from stretching of the fabric resulting in belt drive means being not effective in pulling retained solids and the belt from the filter chamber,
5. changing filtration characteristics from non-uniform fabric,
6. shrinking of the fabric from exposure to heat or drying out of the material,
7. overtightening of the fabric with tearing or pulling of seams in the belt,
8. swelling of yarns with accompanying changes in filtration characteristics such as blinding.
Several techniques may be used to prevent these problems. The following techniques are applied to provide fabrics with a combination of superior filtration characteristics and superior belting characteristics.
1. Dimensional stability of fabric to facilitate tracking;
This can be accomplished by:
a) heat setting-pulling fabric through an oven,
b) heat setting under certain speed, with a certain load on the woven fabric takeup roll,
c) heat setting using a "tenter frame" where weft is stretched across the frame while heat is applied,
d) resin treating of fabric and heat-activating the resin,
e) using resin treated yarns,
f) using preshrunk yarns,
g) using heat activated adhesive yarns,
h) pulling and monitoring each yarn with load sensors during the weaving process,
i) stretching woven fabric under certain loads,
j) using yarn (or multiple yarn to replace large single yarn) that will crimp during the weaving or finishing,
k) calendaring the fabric usually between two rollers under pressure. Rollers can be heated to a certain temperature. The speed of the fabric going through the rollers is controlled and the pressure of the rollers on the fabric is controlled.
2. Permeability of the fabric; permeability is controlled by:
a) yarn type-monofilament, multifilament, or spun,
b) yarn size as measured in micrometers or denier (weight per unit) in case of monofilament, denier in case of multifilament, and cotton count is case of spun,
c) yarn material: polyester, polyproplyene, nylon, kedlar, saran, glass, cotton, etc.-some fibers swell under certain conditions, some fibers are hydrophyllic, some are hydrophobic, some facilitate weaving and fitting "picks" or yarns per inch, some are difficult to weave and only a limited amount of picks per inch can be used,some materials are heat and chemical resistant, etc.,
d) picks per inch, monofilament, multifilament or spun, multiple yarns spun together, heaviness of spun yarn inclusion,
e) heat applied during weaving,
f) amount of stretch or pull load on the fabric,
g) resin impregnation of yarn used on fabric.
I have found that certain problems in the filter medium can be avoided by the proper selection of yarns for the warp and weft in the weaving process, for example:
1. If the fabric tracks to one side in part due to warp yarns moving along "rigid" 20 mil weft yarns. A solution is to use smaller diameter weft monofilament yarns and increase the number of weft yarns per inch. Bending of the smaller weft yarns keeps the warp yarns in place and stabilizes the fabric dimensionally.
2. If the belt shrinks both in warp (length) and weft (width) from exposure to heat and shrinking of open weave; the weft shrinks and does not cover filter area well; the warp shrinks and does not track well; the belt life is reduced also from blinding from shrinking pores. A solution is to use high modulus heat set yarns and more yarns per inch. Use heat set yarns in both the warp and the weft. Pull (stretch) the fabric and heat set. Heat set of weft yarns with a tenter frame. Use of heat set yarn also helps reduce blinding.
3. If the belt slips on drive rollers because the fabric stretches (opens) on one side and does not wrap around the drive roller uniformily. The solution suggested above in 2 and further balance the load across the full width of the fabric when stretching and heat setting.
EXAMPLES
The following fabrics have been woven in the manner just identified.
______________________________________Fabric No. 1Warp: 70 EPI 2/1000 denier or one 2000 denier.Weft: 20-32 PPI 2×(9 to 13 mil monofilament with 4.00/1, 6.00/1 or 8.00/2 spun yarns) twisted together.Fabric No. 2Warp: 70 EPI 2/1000 denier or one 2000 denier.Weft: 21-37 PPI Fiberglass filament core with spun wrap (dref yarn)Fabric No.3Warp: 70 EPI 2/1000 denier or one 2000 denier.Weft: 21-38 PPI 2/1000 denier or one 2000 denier.Fabric No. 4Warp: 70 EPI 2/1000 denier or one 2000 denire.Weft: 21-32 PPI 3.50/1 or (2.5-4.0)/1 or (6.00-8.00)/2 spun yarns.Fabric No. 5Warp: 70 EPI 2/1000 denier or one 2000 denier.Weft: 20-40 PPI one 9-18 mil monofilament or two to four 4-9 mil monofilament.Fabric No. 6Warp: 120-140 EPI Two 1500 denier yarns pulled through the same harness eye and pulled without twisting. 60-70 × 2 EPI Two distinct yarns multifilament.Weft: 22-28 PPI one 15 mil +/- .002 mono- filament.Fabric No. 7Warp: 120-140 EPI Two 1500 denier yarns pulled as in Fabric No. 6 through the same harness eye.Weft: 19.5-24 PPI 19-20.5 mil monofilament.______________________________________
All of the above fabrics can be made with polyester, polyproplyene or nylon yarns of pre-shrunk multifilament or monofilament yarns. These yarns are chemical, heat and abrasion resistant yarns. All of the fabrics utilize 200 pound to 5000 pound pull in the warp direction equally distributed across the fabric. All of the fabrics are heat set at about 200° F. to 400° F. depending on the yarn polymer used and weaving speed or travel of woven fabric in the machine direction. These fabrics may also be heat set after weaving as a separate treatment step.
FIG. 2 is a schematic representation of a weaving loom as could be used to weave the fabrics of the present invention. As illustrated, the loom 30 includes a source of warp yarns 32 from a beam or individual spools 34 with the warp yarns passing through harness eyes 36 to be in parallel alignment along the machine direction of the loom. The yarns 32 are uniformly and equally pulled to be in identical tension as sensed by a suitable sensing device. The loom includes means 38 for individually moving each warp yarn into or out of the loom and perpendicular or vertical to the machine direction of the loom. A shuttle or rapier 40, depending upon the type of loom, carries weft yarn 42 across the loom and between separated warp yarns 32. The warp yarns are then moved to a different order of alignments and the next weft yarn is passed across the loom. The weft yarns may be pressed against the warp yarns by a reed or comb like means 43 in a machine direction to compact the weave and the woven fabric may be advanced onto a take-up roll or accumulator 44 at a controlled speed to produce the desired woven fabric density.
The loom shown in FIG. 2 includes a heat treating means 45 that may include an internal idler roll 46 and tension monitor 47 for transporting the woven fabric through the heat treating means. The fabric is maintained under a desired tension within the heat treating means as controlling the tension at the idler roll 46 and the take-up rate at the roller 44 where the woven fabric is accumulated. The temperature within the heat treating means and the tension on the fabric is used to control both the heat setting of the woven fabric and the crimp of yarns within the fabric. Different temperatures, for example within the range of 200° F. to 400° F. and different tensions within the range of 200 to 5000 pounds uniformily applied across the warp yarns are effective to create the desired heat setting and/or crimping of the fabrics. Temperature and tension force are also selected based on the yarns used in the warp and weft of the fabric.
It should be understood that the heat setting and/or crimp may be performed after the fabric has been woven and in a suitable separate apparatus where temperature and tension may be monitored and controlled. Heat setting and crimping may also be performed with the fabric stretched on a tenting frame that applies the desired forces on the woven yarns of the fabric.
The pattern of movement of the warp yarns determines the weave that will be produced in the loom. A simple over-under movement of adjacent warp yarns produces a simple weave as illustrated in FIG. 3 where warp yarn A passes over then under adjacent weft yarns a, b, c, d, etc. FIG. 4 illustrates a twill weave where adjacent warp yarns A, B and C are moved to produce a warp yarn pattern of adjacent warp yarns, for example A, passes over a first of three adjacent weft yarns a, b, and c, and then under three adjacent weft yarns d, e and f; then adjacent warp yarns, for example B, passes over a first of three weft yarns, c, d, and e, two weft yarn along the plurality of weft yarns in the direction of the warp yarns. The repeat of the over-under pattern places adjacent weft yarns under or over adjacent warp yarns in a uniformly repeating pattern across and along the woven fabric.
FIG. 5 illustrates a weave pattern known as a broken twill. Fabrics No. 6 and 7, previously identified, are woven in the broken twill pattern and have a pair of warp yarns drawn through each harness eye in the loom. In the case of fabrics 6 and 7 and as shown in FIG. 5, the broken twill has the following pattern:
a) two approximately 1500 denier multifilament yarns as a single untwisted warp yarn (A,B) pass together under three adjacent monofilament weft yarns (a,b,c) in the machine direction then over one adjacent weft yarn (d) in the machine direction in a repeating pattern;
b) the next adjacent two approximately 1500 denier multifilament yarns (C,D) pass together over three adjacent monofilament weft yarns (b,c,d) in the machine direction then under one adjacent weft yarn (e) in the machine direction in a repeating pattern;
c) the next adjacent two multifilament warp yarns (E,F) to "over three under one" multifilament warp yarns (C,D) in b) above going over three (d,e,f) then under one (g) weft yarn in a repeating pattern in the machine direction;
d) the next adjacent two multifilament warp yarns (G,H) to warp yarns (E,F) described in c) going under three weft yarns (c,d,e) then over the second weft yarn (f) in a repeating pattern in the machine direction;
e) the next adjacent two multifilament warp yarns (I,J) to the "under three and over one" warp yarns (G,H) in d) above, woven over three weft yarns (e,f,g) and under one weft yarn (h) in a repeating pattern in the machine direction;
f) the next adjacent two multifilament warp yarns (K,L) to warp yarns in e) above woven under three weft yarns (d,e,f) and over one weft yarn (g) in a repeating pattern in the machine direction;
g) the next adjacent tow multifilament warp yarns (M,N) to warp yarns in f) above woven under three weft yarns (b,c,d) and over one weft yarn (e) in a repeating pattern in the machine direction;
h) the next adjacent two multifilament warp yarns (O,P) to warp yarns in (g) above woven over three weft yarns (c,d,e) and under one weft yarn (f) in a repeating pattern in the machine direction;
i) the broken twill fabric is woven so that no more than two adjacent sets of two multifilament yarns described in b),c),e) and h) above occur;
j) the broken twill fabric is woven so that no more than two adjacent sets of two multifilament yarns described in a),d),f) and g) occur;
k) the broken twill fabric is woven repeating the steps a),b),c),d),e),f),g)and h) above.
When woven in this broken twill pattern, Fabric No. 6 described with weft yarns being a 15 mil monofilament ±.003 and weft yarns with crimp is more stable than Fabric No. 7 with 19-20.5 mil monofilament weft yarns with little or no crimp.
FIG. 6 is a schematic representation of twisted pairs of yarns. As here illustrated two yarns 50 and 51 are twisted together to produce a single warp yarn 52. It should be understood that each of the yarns 50 and 51 may also be a multifilament yarn of twisted or untwisted filaments. In the case of warp yarns as used in the fabrics of the present invention, the yarns are twisted at two twists per inch to produce a first twisted yarn such as 50 or 51 and those two twisted yarns are then twisted together at two twists per inch to produce a single warp yarn 52.
FIG. 7 is a schematic representation of twisted pairs of yarns for weft yarns. As here illustrated two yarns 53 and 54 are twisted together to produce a single weft yarn 55. In the case of the weft yarns as used in the fabrics of the present invention, the yarns are twisted at three twists per inch to produce a first twisted yarn 53 or 54 and those two twisted yarns are then twisted together at three twists per inch to produce a single weft yarn 55.
In the case of Fabric No. 1, the weft yarn of that fabric is made of two yarns twisted together each of those yarns is a 9-13 mil monofilament twisted with a 4.00/1 or 6.00/1 or 8.00/2 spun yarn at three twists per inch, then those two yarns are twisted together at three twists per inch to form the weft yarn.
FIG. 8 is a cross-sectional view of a wrapped core yarn 56 for example the yarn used in Fabric No. 2 where a fiberglass filament core 57 is wrapped with spun yarn 58. The core yarn 57 may be a multifilament polymer yarn and the spun yarn is wrapped around the core 57 to produce the yarn shown in FIG. 8. Wrapping the fiberglass core 57 in this manner retains the strength of the multifilament core while giving the yarn exterior a spun texture.
The fabrics herein described and the method of their formation produces a woven fabric filter medium that has a plurality of warp yarns of about 2000 denier, a plurality of weft yarns or several different formations including twisted and untwisted I monofilaments, multifilaments, spun and wrapped dref yarns that are woven across a machine loom to produce a fabric with warp yarns at about 69 to 71 ends per inch and with weft yarns at about 20 to 40 picks per inch, the fabric is woven in a weave pattern including conventional weaves, twill weaves and broken twill weaves, to produce a fabric that weighs about 20 to 40 ounces per square yard, and the fabric can be heat treated while the warp yarns are under tension to produce a desired amount of crimp in the yarns to thus dimensionally stabilize the fabric.
While certain preferred embodiments of the present invention have been specifically disclosed, it should be understood that the invention is not limited thereto as many variations will be readily apparent to those skilled in the art and the invention is to be given the broadest possible interpertation within the terms of the following claims.
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A woven fabric filter medium having particular use in a pressure filter apparatus. The fabric is useful in separating liquids from solids in a slurry fed into the pressure filter apparatus. The fabric is woven in a pattern and of materials that provide desired permeability while being capable of capture of the solids in the slurry and permitting the fluids to flow through. The materials used in the fabric are selected for their ability to resist deterioration from the chemical, heat or abrasive characteristics of the slurry while being capable of being cleaned for reuse in a filter apparatus.
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TECHNICAL FIELD
The present invention relates to a device for heating a fluent material (e.g., gaseous or liquid media, such as air or water) by means of one or more electrical induction coils which heat the fluent material through the intermediary of metallic heating elements which form one or more electrically-closed circuits that become heated when the induction coils are supplied with current and then transfer heat to the fluent material made to flow past the elements.
It is notoriously well known to heat a metallic material by means of an induction coil and the inductive field of force such a coil produces. It is desired to extend this principle to the heating of fluent material, for example, for preheating air used in heating metallic scrap. One problem in this connection is in obtaining good heat transmission to the fluent material that is to be heated, and another problem is obtaining a heater which is simple to use and easy to manufacture. Among other things, it is desirable to be able to heat the fluent material at a relatively large volumetric flow and preferably also at a low pressure.
One object of the present invention is to provide a solution to the above-mentioned problems and other problems associated therewith.
BRIEF STATEMENT OF INVENTION
According to the invention there is provided a device for heating a fluent material comprising; an induction coil means, an inlet duct for conveying fluent material to be heated to the device, an outer material flow passage disposed within the coil means and having an inlet communicating with the inlet duct and an outlet, an inner material flow passage disposed within the outer passage having an inlet connected to the outlet of the outer passage and an outlet through which heated fluent material can leave the inner passage, and at least one annular metallic heating element disposed in at least one of the passages, each heating element being adapted to be inductively heated when the coil means in energized and to transfer heat to the fluent material flowing through the associated passage.
By means of the invention, a simple and efficient heater is obtained which is not particularly space-demanding and which can be expected to find a number of atrractive fields of application. An inductive heating device according to the invention is specially suitable for heating air or other fluids of relatively low pressure and large volumetric flows, and can also be used with other gases, such as water vapor, CO or N 2 .
Where a metallic cylinder is used to separate the inner and outer passages, this cylinder can be employed to contribute to the transmission of thermal energy to the fluent material by electrical currents being induced in the cylinder (relatively high current, low voltage drops).
When the induction coils are energized, electrical currents are induced in the annular heating elements, which currents generate heat in the electrical circuits formed by the heating elements and possibly also in the passage-separating metallic cylinders, and in this way the passing fluent material, for example, air, becomes efficiently heated. The inner and outer passages are suitably mutual concentric passages. Means can be provided to induce turbulence in the flowing fluent material and/or to extend the surface area of the heating element(s) to enhance thermal transfer to the flowing medium.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be exemplified in greater detail with reference to the accompanying drawing, in which:
FIG. 1 shows, purely schematically, a fluent material heating device according to the invention,
FIG. 2 shows a fluent material heating device according to the scheme of FIG. 1 as seen from above,
FIG. 3 shows the fluent material heating device of FIG. 2 in side sectional elevation,
FIG. 4 shows a cross section through one type of heating element disposed in one of the two passages in the fluent material heating device of FIG. 3,
FIGS. 5 and 6 schematically depict two alternative types and placements of heating elements which can be used within one of the two passages in the fluent material heating device of FIG. 3, and
FIG. 7 shows comparative cross sections through two types of heating elements which can be currently disposed within one of the two passages in the fluent materal heating device of FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
The fluent material to be heated (for example, air at low temperature) enters a supply conduit 1 and is passed into a gas-tight outer casing 16 (see FIG. 1) which is located within a treatment space S within one or more induction coils 2, the induction coils being supplied with alternating current at mains frequency (or at some other suitable frequency). The casing 16 is shown as defining a labyrinth passage with two or more mutually concentrically-arranged passages 3, 4 for the fluent material. The fluent material passes from the supply duct 1 into the inlet end 3a of passage 3, along the passage 3, out the outlet end 3b of the passage 3, into the inlet end 4a of passage 4, along the passage 4, and out the outlet end 4b of passage 4 into the discharge channel 5. During this journey the fluent material is heated to a high temperature. Such a labyrinth passage is desirable, but not essential, the preferred passage shape being chosen with regard to the expected volumetric flow and pressure of the fluent material which, instead of air, could be, for example, water vapor, CO or N 2 . As shown, the passages 3, 4 and discharge channel 5 are separated by metallic cylinders 6 (e.g., of sheet metal), which are suitably gas-tight. Metallic rings 7 or helices form heating elements and are arranged axially one after the other in the passages 3, 4. In the case illustrated, the heating elements 7 are concentric rings arranged axially one after the other, which rings are also arranged in a plurality of concentric layers, with at least one layer arranged in each passage 3, 4. FIG. 3 illustrates the disposition of the heating elements more clearly. The metallic cylinders 6 can be provided with flanges or other surface-enlarging means, which is also true of the heating elements 7.
Each individual ring 7 may define a separate heating element, or several rings together may define a heating element, by arranging it or them as an electrically-closed circuit, possibly by means of a shot-circuiting device (not shown). The heating elements 7 may also be arranged as one or more helix (helices), or spiral(s), also with short-curcuiting means (not shown). The heating elements 7 may be arranged concentrically around each other and/or axially one after another. The coil/coils 2 may be one or more in number. In the case of one coil, normally a single-phase electrical power supply is used, and this can also be the case when several coils are used. In the case of a plurality of coils, these can be supplied with multi-phase current--e.g., with one phase per coil--and the coils can be arranged axially after each other around the medium passageway or at the side of each other, for example, in the case of several heating devices where one single-phase coil is used for each phase of the supply.
When the induction coil or coils 2 is/are supplied with current, currents are induced in each heating element 7 which defines an electrically-closed circuit. Heat is generated in the elements 7 by the induced currents and the heat output is controlled by the selection of the electrical resistance of each element 7. The use of short-circuit elements may be necessary in order to ensure each element 7 is an electrically-closed circuit. The metallic cylinders 6 are also inductively heated and thus also contribute to the generated heating power. During this heating it is a question of low voltage drops and relatively high currents in heating elements 7 and cylinders 6.
The outer wall of the casing 16 is suitably made of a non-electrically conducting material, such as a ceramic material, a plastic material or glass, which is suitably gas-tight. Austenitic sheet metal can be used for fabricating the casing 16 and/or the cylinders 6. Each cylinder 6 may either be short-circuited or not, for example, by making the cylinder with a combination of a sheet metal and a ceramic material.
During the heating operation, the fluent material will contact the heating elements 7, which may be made from tubes, rods, or sheet metal bands, and which can be welded together into rings, helices or spirals. The material in the casing 16 and in the cylinders 6 should be suitably temperature-resistant and may possibly be non-ferromagnetic. By varying the amount of material in the heating elements 7, the inductive power may be varied from element to element. In this way an optimum heat transmission can be obtained having regard to the limitations of the material(s) used for the elements 7. The heating elements 7 may possibly be provided with turbulence-promoting members (which will be described in more detail with reference to FIG. 3) which will enhance the heat transfer to the fluent material.
One suitable field of application for the embodiment of the invention shown in FIG. 1 may be as an air preheater in a scrap heating plant and/or for recovering useful energy when undertaking power factor corrections.
FIGS. 2 and 3 show a practical realization of the heater schematically shown in FIG. 1. Sheet metal cylinders 12, 13, as well as the outer casing 16, are arranged so as to form a labyrinth passage according to FIG. 1. The heating elements 7 are in the form of rings or spirals and are heated inductively by the coils 2 and thus heat up the passing air, which flows according to the arrows 11. Also the outer casing 16, which may be provided with flanges or other surface-enlarging elements (not shown), is suitably made of ceramic material.
The heat transmission to air from a heated body is dependent on the product of the heat transmission number α, the heat-transmitting surface area A of the body and the temperature difference Δt between the body and the air. The heat transmission is thus proportional to A·α·Δt.
With a heater as described, a high α is obtained even at relatively moderate pressure drops. α can be further increased by increasing the turbulence in the air, for example, by varying the dimensions of some of the rings 7 relative to others so that the rings present an enhanced area A to the air current (see FIG. 3). In addition, it is a relatively simple matter to increase the area A by providing the heating elements with flanges (such as those shown dotted at 15' on the tube 15 in FIG. 4). Another great advantage is that Δt, which is limited by the maximum permissible temperature of the heating elements and the air temperature which increases through the heater, can be influenced individually for each heating element. As already mentioned, this can be done, for example, by varying the amount of metal in each heating element 7, which means that the induction power absorbed by each respective heating element can be varied. Therefore a maximum value of Δt and thus maximum heat transmission can be obtained from each at each stage of the heating. FIG. 3 shows in more detail the passage of the air (represented by the arrows 11) and the arrangement of flow-separating sheet metal cylinders 12, 13, which are also heated inductively together with the heating elements 7. By different locations of the heating elements (see, e.g., elements 8 and 14 in FIGS. 5 and 6), the heat transmission can be improved; as mentioned, this can also be done by varying the amounts (thicknesses) of materials used to form the heating elements (see the thin-walled tube 17 and the thick-walled tube 17a FIG. 7 which represent the tubes found at points 18 and 19 in FIG. 3). The turbulence can also be increased by displacing certain elements, for example every tenth ring, in addition to or as a substitute for other turbulence-increasing measures.
The passages through which the fluent material flows back and forth within the induction coils 2 need not pass exactly through the center of these coils; a certain lateral displacement can occur to make possible a suitable location of the heating elements.
Turbulence means can also be arranged individually, separate from the heating elements and the positional change of the different heating elements may also be arranged to take place along the entire length of the heater, or just at certain parts thereof.
In one practical case, an air preheater according to FIGS. 2 and 3 had a length (shown as X in FIG. 3) of 3600 mm.
The invention can be varied in many ways within the scope of the following claims.
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A device for heating a fluent material (e.g., gaseous or liquid media, such as air, water, etc.) comprises one or more electrical induction coils arranged around one or more central conduits for the medium to be heated, inside which coils there are arranged rings or spirals of metals which form one or more electrically-closed circuits, possibly after addition of short-circuit parts, which circuits, and possible metallic partition walls at these, are arranged to be inductively heated when the induction coils are electrically energized, heat generated in the heating elements passing to the fluent material flowing through the passageways.
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[0001] The present invention is directed to controlled-release (CR) oral pharmaceutical dosage forms of 5,8,14-triazatetracyclo[10.3.1.0 2,11 .0 4.9 ]-hexadeca-2(11),3,5,7,9-pentaene, 1, and related compounds, and methods of using them to reduce nicotine addiction or aiding in the cessation or lessening of tobacco use while reducing nausea as an adverse effect. The present invention also relates to an immediate-release (IR) low dosage composition having a stable formulation with uniform drug distribution and potency.
BACKGROUND OF THE INVENTION
[0002] Compound 1, also known as 7,8,9,10-tetrahydro-6,10-methano-6H-pyrazino[2,3-h][3]-benzazepine, binds to neuronal nicotinic acetylcholine specific receptor sites and are useful in modulating cholinergic function. Accordingly, this compound is useful in the treatment of inflammatory bowel disease (including but not limited to ulcerative colitis, pyoderma gangrenosum and Crohn's disease), irritable bowel syndrome, spastic dystonia, chronic pain, acute pain, celiac sprue, pouchitis, vasoconstriction, anxiety, panic disorder, depression, bipolar disorder, autism, sleep disorders, jet lag, amyotrophic lateral sclerosis (ALS), cognitive dysfunction, hypertension, bulimia, anorexia, obesity, cardiac arrhythmias, gastric acid hypersecretion, ulcers, pheochromocytoma, progressive supranuclear palsy, chemical dependencies and addictions (e.g., dependencies on, or addictions to nicotine (and/or tobacco products), alcohol, benzodiazepines, barbiturates, opioids or cocaine), headache, migraine, stroke, traumatic brain injury (TBI), obsessive-compulsive disorder (OCD), psychosis, Huntington's chorea, tardive dyskinesia, hyperkinesia, dyslexia, schizophrenia, multi-infarct dementia, age-related cognitive decline, epilepsy, including petit mal absence epilepsy, senile dementia of the Alzheimer's type (AD), Parkinson's disease (PD), attention deficit hyperactivity disorder (ADHD) and Tourette's Syndrome.
[0003] Compound 1 and pharmaceutically acceptable acid addition salts thereof are referred to in International Patent Publication WO 99/35131, published Jul. 15, 1999, which is incorporated herein by reference in its entirety.
[0004] Whereas immediate release (IR) dosage forms of the aforementioned compound, that is, dosage forms designed to provide the drug in a dissolved form upon swallowing in less than about 30 minutes, provide therapeutically useful levels of drug in the blood and brain, it has been observed that there is a significant level of nausea in patients, especially at doses sufficiently high to be therapeutically useful for some patients. Since nausea can lead to poor patient compliance with a dosing regimen, there is a need to provide 1 in a form that reduces the incidence of nausea.
[0005] Accordingly, the present invention provides CR dosage forms of 1 that reduce or eliminate nausea while maintaining a therapeutic level of the drug in the blood and central nervous system (CNS). While examples exist in the art suggesting that CR dosage forms may in some cases provide for a reduction in such side effects as nausea (e.g., oxycodone (J. R. Caldwell, et al., J. of Rheumatology 1999, 26, 862-869), venlafaxine (R. Entsuah and R. Chitra, Psychopharmacology Bulletin, 1997, 33, 671-676) and paroxetine (R. N. Golden, et al., J. Clin. Psychiatry, 2002, 63, 577-584), counter examples also exist which indicate that CR dosage forms are sometimes no better than immediate release dosage forms for the reduction of nausea, and therefore teach away from the utility of the CR form as a means of reducing side effects. Examples of this teaching away include morphine sulfate (T. D. Walsh, et al., J. Clin. Oncology, 1992, 15, 268-272), hydromorphone (H. Hays, et al., Cancer, 1994, 74, 1808-1816), dihydrocodeine tartrate (G. Xu, et al., Zhongguo Yaowu Yilaixing Zazhi, 1999, 8, 52-57) and carbidopa/levodopa (G. Block, et al., European Neurology, 1997, 37, 23-27). In addition, in many cases, CR dosage forms result in reduction in bioavailability compared to the IR dosage form, necessitating an increase in dose or even making the use of a CR dosage form infeasible. It therefore remains impossible to predict a priori which drugs showing nausea will actually benefit from CR dosage forms. Moreover, the rate at which the drug is made available, that is, its dissolution rate, can range considerably from slightly slower than the IR dosage form to deliver over an extended period (up to about 24 hours). The inventors have discovered that for 1, CR dosage forms with a certain range of delivery rates will provide therapeutic blood and CNS drug levels while reducing the incidence of nausea when compared to the IR dosage form. The inventors have also discovered specific preferred ways of formulating 1 to achieve the desired drug administration rates. The inventors have also discovered preferred dosing regimens that provide therapeutic drug levels while maintaining low levels of nausea.
[0006] The high potency of compound 1 as a nicotinic receptor ligand allows the use of low dosage strengths for administration. For ease of handling, manufacturing and patient convenience, low dosage strength drugs are often formulated at high dilution with excipients. In the preparation and storage of such dilute formulations, however, unique challenges are introduced. First, the high dilution can enable excipients or even excipient impurities to cause significant drug degradation during storage. Examples of excipient properties that may impact drug degradation include moisture content and mobility of moisture (see J. T. Carstensen, Drug Stability: Principles and Practices, 2 nd Ed, Marcel Dekker, NY, 1995, 449-452)., and excipient acidity affecting local pH microenvironments (see K. Waterman et al., Pharm Dev. Tech., 2002, 7(2), 113-146). Examples of excipient impurities that affect drug degradation include trace metals, peroxides, and formic acid (see K. Waterman, et al., Pharm. Dev. Tech., 2002, 7(1), 1-32). Although consideration of the chemical structure and identification of reactive moieties therein can be used to theorize potential degradation pathways, it remains impossible to predict a priori whether a particular excipient will form an acceptably stable formulation with a given drug. Moreover, 1 has been observed to react with many common excipients and excipient impurities. It therefore remains a need to provide excipient and excipient combinations which can provide acceptable formulations (for such properties as tableting) while providing suitable stability for 1. The inventors have discovered specific preferred ways of formulating 1 to achieve the desired stability. More specifically for a film coated tablet, the inventors have discovered specific formulations and processes to achieve the desired stability.
[0007] A second issue sometimes seen with potent drugs prepared at high dilution is variability in potency due to segregation and adhesion to equipment during manufacturing. This issue has been found to be a problem with formulations of 1. One method recently reported for achieving a uniform drug distribution in a blend of a low dose drug makes use of a carrier excipient, lactose, to form an ordered mixture with a micronized drug (L. Wu, et al., AAPS PharmSciTech, 2000, 1(3), article 26). Although one can effectively implement a manual brushing step to recover active ingredient segregated by fluidization or adhered to the metal surfaces in small scale equipment, a manual brushing step is neither efficient not desirable in a production scale environment. Liquid processes can minimize the drug loss issues during drug product manufacturing; however, compounds that undergo form changes (e.g. polymorph, hydrate, or solvate changes) make liquid processes very difficult to perform while maintaining drug ingredient stability (physical and chemical). Although many techniques have been used to solve these general problems, it remains impossible to predict which particular techniques will be effective for a given set of drugs and excipients. Therefore, because of the high dilution necessary with 1, there is a need for a process suitable for commercialization of 1 whereby adequate potency uniformity from dosage form (e.g., tablet) to dosage form and lot to lot can be maintained. The inventors have also discovered preferred ways of processing formulations of 1 to achieve the desired uniform drug potency and uniform drug distribution.
SUMMARY OF THE INVENTION
[0008] The present invention relates to certain controlled-release (CR) pharmaceutical dosage forms of 1 or pharmaceutically acceptable salts thereof, to a subject in need thereof, said CR dosage form comprising the compound, or pharmaceutically acceptable salt thereof, and a means for delivering the compound, or pharmaceutically acceptable salt thereof, to said subject at a rate of less than about 6 mgA/hour (where mgA refers to milligrams of active drug in equivalence to the free base), whereby at least about 0.1 mgA of the compound, or pharmaceutically acceptable salt thereof, is administered over a 24 hour period. In certain subjects, it may be advantageous, after administration of the CR dosage form in a series of doses, to administer an immediate release (IR) dosage form comprising the compound, or pharmaceutically acceptable salt thereof, as described herein.
[0009] In particular, the present invention relates to methods of treatment using CR pharmaceutical dosage forms of 1 that result in a reduction in nausea as an adverse effect. Such CR dosage forms are characterized by providing drug in the gastrointestinal (GI) tract in a dissolved form at a rate ranging from about 0.03 mgA/hr to about 6 mgA/hr; more preferably from about 0.06 mgA/hr to about 3 mgA/hr; and most preferably from about 0.10 mgA/hr to about 1 mgA/hr. The present invention also provides for CR dosage forms which achieve a reduction in the average maximum blood concentration of the drug (C max ) upon the first administration of the dosage to a subject by between 10 and 80% of the average C max for an immediate release bolus initial administration; more preferably, between 30 and 70%. The present invention also provides for dosage forms which increase the time it takes to achieve this maximum blood level concentration, T max . In particular, it has been found that an increase of the average T max by 50% compared to the average found for an immediate release bolus results in a reduction in nausea. The present invention also provides for a dosage form whereby the release rate of 1 as determined by a USP type II dissolution method results in a release rate of less than 6 mgA/hr and such that the time for dissolution of 50% w:w of said drug is between 1 and 15 hours; more preferably between 2 and 10 hours.
[0010] The present invention also provides for pharmaceutical compositions to achieve these delivery rates. In particular, the present invention relates to dosage forms of 1 which comprise such means of delivery as hydrophilic matrixes, hydrophobic matrixes, coated CR tablets and multiparticulates, buccal systems, transdermal systems, suppositories and depot systems. Among the coated tablets, a particularly preferred dosage form is an asymmetric membrane technology system (as described in U.S. Pat. Nos. 5,612,059 and 5,698,220, the contents of which are hereby incorporated herein by reference).
[0011] The present invention further provides such a controlled release dosage form which is a combination delayed plus sustained release form exhibiting a delay period of up to eight hours prior to the onset of sustained release, wherein the pentaene is released at a rate of not more than about 0.1 mgA/hr during the delay period and wherein the delay period is controlled temporally or spatially by position in the gastrointestinal tract.
[0012] It is also the purpose of the present invention to provide for the reduction in nausea when compound 1 is dosed to patients by beginning a course of treatment with the CR dosage form, followed by a course of treatment with an IR dosage form.
[0013] As used herein, the term “controlled-release” (CR) refers to dosage forms which slowly release or deliver the drug to the patient at a rate such that at least some of the drug is unavailable in the first hour. A CR system can provide the drug at a constant rate (zero order), at a steadily decreasing rate (first order) or an uneven or pulsatile rate. The drug delivery can also involve a lag time in initial drug release. This lag can be temporal or be related to the position of the drug in the body. For example, a CR dosage form may be prepared by exploiting an enteric coating where drug is released upon reaching the pH of the intestine after oral administration.
[0014] In the present invention, a suitable CR dosage form of 1 can be identified by one or both of two methods:
[0015] (1) The first method involves measuring the behavior of the drug in the dosage form by sampling and analyzing blood after initial administration of the drug to a subject (generating a pharmacokinetic profile). Initial administration refers to drug administered to a subject either for the first time, or with at least four days since a previous dosing of any form of 1. It has been found that of particular importance in reducing nausea with 1 are the maximum blood level of 1 reached after initial administration of the drug (C max ) and the time it takes to reach that maximum (T max ). In measuring both C max and T max , it will be recognized by those skilled in the art that there is significant variability between dosings and between subjects. To achieve an adequate comparison in C max and T max and thereby to determine if a given dosage form will achieve the desired reduction in nausea, it is necessary to measure these parameters for at least 10 subjects in a cross-over experiment (i.e., each subject receives both dosage forms, IR and CR) with at least 7 days between experimental legs. In particular, it has been found that an average initial C max reduction to achieve a value of 10 to 80% of that achieved with an average initial IR bolus administration is needed for nausea reduction; more preferred is between 30 and 70%. For T max , an increase in the average initial T max for a CR dosage form compared to an IR bolus should be at least 50% (i.e., 1.5 times the number of hours for the average CR dosage vs. the average IR bolus dosage).
[0016] (2) The second method of analyzing the CR dosage form to determine if it will reduce nausea involves an in vitro test. The inventors have found that generating a plot of percent of 1 dissolved vs. time is best used to determine the time required for 50% of the drug to be dissolved. The data needed for generation of this plot is obtained using a standard USP (United States Pharmacopoeia) Type II dissolution apparatus (50 rpm; 500 mL of 0.01 N hydrochloric acid; 37° C.) such as a Hanson model SR8. Analysis of samples is accomplished using reverse phase HPLC. It has been found that nausea is reduced when the dosage form shows 50% w/w of the total dose is dissolved between about 1 and 15 hours; more preferably between 2 and 10 hours.
[0017] Accordingly, the present invention further relates to immediate-release dosage forms suitable for administration to a subject that result in stable dosage forms with uniform drug distribution and potency, comprising a core containing a compound of the formula 1, or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable substantially reducing carbohydrate—free diluent. The invention specifically provides such an immediate-release dosage form, wherein the IR dosage form comprises either the L-tartrate or citrate salt of 5,8,14-triazatetra-cyclo[10.3.1.0 2,11 .0 4,9 ]-hexadeca-2(11),3,5,7,9-pentaene.
[0018] As used herein, “substantially reducing carbohydrate-free” means less than approximately 20 w/w % of a reducing carbohydrate (including, but not limited to, lactose). Preferably, dosage forms prepared in accordance with the present invention will contain less than 10 w/w % of a reducing carbohydrate, and more preferably, less than 5 w/w %.
[0019] The immediate release dosage form of the invention may further comprise a glidant, disintegrant and/or a lubricant. The present invention also relates to processes for the production of these immediate release dosage forms.
[0020] The immediate release dosage form of the invention may further comprise a film coating. The present invention also relates to processes for production of these film coated immediate release dosage forms.
[0021] The present invention also provides a formulation suitable for film coating of immediate release dosage forms of 1 wherein the polymeric binder for such coatings comprises substantially a cellulosic polymer. A particularly preferred cellulosic polymer is hydroxypropyl methylcellulose (HPMC). This coating further comprises an opacifier (particularly titanium dioxide), plasticizer and/or glidant, all of which contain less than about 20% w:w reducing carbohydrates. Particularly preferred coating formulations comprise HPMC, titanium dioxide, and triacetin or PEG.
[0022] The present invention also provides for methods that produce good potency and content uniformity in blends as described herein. These methods include the process of geometric dilution of drug with excipients prior to tableting. These methods also include the use of moderate shear blending. The preferred blending process uses a “bin blender”; however, other blenders which produce similar shears are also usable.
[0023] The disclosed methods of treatment using CR pharmaceutical dosage forms of 1 that result in a reduction in nausea as an adverse effect are characterized by providing drug in the gastrointestinal (GI) tract in a dissolved form at a rate ranging from about 0.03 mgA/hr to about 8 mgA/hr; more preferably from about 0.06 mgA/hr to about 3 mgA/hr; and most preferably from about 0.10 mgA/hr to about 1 mgA/hr.
[0024] In particular, the present invention provides a method for reducing nicotine addiction or aiding in the cessation or lessening of tobacco use in a subject, comprising administering to said subject an amount of either the controlled release dosage form or the immediate-release dosage form of 1 that is effective in reducing nicotine addiction or aiding in the cessation or lessening of tobacco use. The invention specifically provides such a method, wherein the CR or IR dosage form comprises either the L-tartrate or citrate salt of 5,8,14-triazatetra-cyclo[10.3.1.0 2,11 .0 4,9 ]-hexadeca-2(11),3,5,7,9-pentaene.
[0025] The present invention further provides a method for treating a disorder or condition selected from inflammatory bowel disease, ulcerative colitis, pyoderma gangrenosum, Crohn's disease, irritable bowel syndrome, spastic dystonia, chronic pain, acute pain, celiac sprue, pouchitis, vasoconstriction, anxiety, panic disorder, depression, bipolar disorder, autism, sleep disorders, jet lag, amyotrophic lateral sclerosis (ALS), cognitive dysfunction, hypertension, bulimia, anorexia, obesity, cardiac arrythmias, gastric acid hypersecretion, ulcers, pheochromocytoma, progressive supranuclear palsy, chemical dependencies and addictions; dependencies on, or addictions to, nicotine, tobacco products, alcohol, benzodiazepines, barbiturates, opioids or cocaine; headache, stroke, traumatic brain injury (TBI), obsessive-compulsive disorder (OCD), psychosis, Huntington's Chorea, tardive dyskinesia, hyperkinesia, dyslexia, schizophrenia, multi-infarct dementia, age related cognitive decline, epilepsy, petit mal absence epilepsy, senile dementia of the Alzheimer's type (AD), Parkinson's disease (PD), attention deficit hyperactivity disorder (ADHD) and Tourette's Syndrome in a subject in need of such treatment, comprising administering to the subject an amount of either the controlled release dosage form or the immediate-release dosage form of 1 that is effective in treating such disorder or condition. The invention specifically provides such a method, wherein the CR or IR dosage form comprises either the L-tartrate or citrate salt of 5,8,14-triazatetra-cyclo[10.3.1.0 2,11 .0 4,9 ]-hexadeca-2(11),3,5,7,9-pentaene.
[0026] The present invention also provides for pharmaceutical compositions to achieve these administration rates. In particular, the present invention relates to dosage forms of 1 which comprise such means of administration as hydrophilic matrixes, hydrophobic matrixes, osmotic systems, multiparticulates, permeable-coating controlled dosage forms, suppositories, buccal systems, transdermal systems and implantable systems. Among the osmotic systems, a particularly preferred dosage form is an asymmetric membrane technology system (as described in U.S. Pat. Nos. 5,612,059 and 5,698,220, the contents of which are incorporated herein by reference).
[0027] The present invention also provides for methods of administration which result in the reduction in nausea as an adverse effect when compound 1 is dosed to patients by beginning a course of treatment with the CR dosage form, followed by a course of treatment with an IR dosage form.
[0028] As used herein, an “immediate-release” (IR) dosage form refers to a dosage form which when taken orally substantially provides the drug in a form available to be absorbed within about one hour.
[0029] A “matrix” system refers to a particular CR dosage form where the drug is admixed with excipients, often in compressed or extruded form, such that the release of the drug from the dosage form is controlled by a combination of erosion and diffusion. Erosional control of drug delivery involves the slow removal of the matrix material by the GI fluids to gradually expose and release the drug from the matrix. Diffusional control of drug delivery involves diffusion of soluble drug through the network of matrix excipients in a controlled fashion. In practice, many matrix dosage forms involve some degree of combination of the two mechanisms.
[0030] A “hydrophilic matrix” is a matrix CR dosage form where water-soluble or water-swellable polymers form a network containing the drug. The rate that drug diffuses to the surface of the dosage form and the rate that the matrix falls apart control the rate that drug is made available to the GI system.
[0031] A “hydrophobic matrix” is a matrix CR dosage form where water-insoluble or only partially water-soluble materials slow the rate that a drug is exposed to the fluid environment of the GI system, thereby controlling the rate drug is available for absorption.
[0032] A “permeable coating” CR system refers to various coatings on tablets or particulates that act as barriers to drug leaving a tablet or to water reaching the drug. These coatings include enteric coatings which become permeable as the pH increases when a dosage form exits the stomach. Examples of such coatings include Eudragits™ sold by Rohm GmbH Pharma Polymers (Darmstadt, Germany) and cellulose acetate hydrogen phthalate (CAP) sold by Eastman Chemical (Kingsport, Tenn.). One group of such coated CR systems includes osmotic systems. Such CR dosage forms involve a semi-permeable membrane surrounding a drug core containing sufficient osmotic pressure to drive water across the membrane in the GI system. The osmotic pressure can then force drug out of the core through preformed or in situ produced holes or pores in the coating. Such systems often involve the addition of agents (osmagents) designed to increase the osmotic pressure in the core. A review describing such systems is found in G. Santus and R. W. Baker, J. Control. Rel., 1995, 35, 1-21.
[0033] “Asymmetric membrane technology,” AMT, describes a particular osmotic CR system where the coating is made porous by a phase separation process during the coating operation as described in U.S. Pat. Nos. 5,612,059 and 5,698,220, the contents of which are hereby incorporated herein by reference.
[0034] “Transdermal delivery systems” are drug delivery devices designed to provide systemic drug to a patient through the skin. Such systems commonly involve a layer of material containing drug on a backing with an adhesive to attach the material to the subject's skin.
[0035] “Buccal delivery systems” are dosage forms which provide a method for drug absorption through the buccal (inner cheek) tissue.
[0036] A “depot” is a controlled-release drug dosage form where a drug and appropriate excipients are injected either sub-cutaneously or intramuscularly and form a mass (matrix) which slowly provides drug to the systemic circulation.
[0037] The drug, 1, for the purposes of the present invention refers to the parent drug and all pharmaceutically acceptable salts and prodrugs, thereof.
[0038] The term “mgA” refers to the number of milligrams of active drug based on the free base form of the drug.
[0039] The phrase “pharmaceutically acceptable” indicates that the substance or composition must be compatible chemically, physically, and/or toxicologically, with the other ingredients comprising a formulation, and/or the mammal being treated therewith.
[0040] The term “active ingredient” refers to a therapeutically active compound, as well as any prodrugs thereof and pharmaceutically acceptable salts, hydrates, and solvates of the compound and the prodrugs.
[0041] The term “appropriate period of time” or “suitable period of time” refers to the period of time necessary to achieve a desired effect or result. For example, a mixture may be blended until a potency distribution is reached that is within an acceptable qualitative range for a given application or use of the blended mixture.
[0042] As used herein, the term “unit dose” or “unit dosage” refers to a physically discrete unit that contains a predetermined quantity of active ingredient calculated to produce a desired therapeutic effect. The unit dose or unit dosage may be in the form of a tablet, capsule, sachet, etc. referred to herein as a “unit dosage form.”
DETAILED DESCRIPTION OF THE INVENTION
[0043] Procedures for making compound 1 are described in U.S. Pat. No. 6,410,550, the contents of which are hereby incorporated herein by reference, and the resolution of racemic mixtures thereof is described in WO01/62736. In accordance with the present invention, the CR pharmaceutical compositions of 1 can be desirably administered in doses ranging from about 0.1 mgA up to about 6 mgA per day, more preferably from about 0.5 to 4 mgA/day, and most preferably from about 1 to 4 mgA per day in single or divided doses, although variations will necessarily occur depending upon the weight and condition of the subject being treated. Depending on individual responses, dosage levels below the lower limit of the aforesaid range may be more than adequate, while in other cases still larger doses may be employed without causing any harmful side effects.
[0044] Although any pharmaceutically acceptable form of 1 may be used in connection with the present invention, it is preferable to use a salt form of the drug. A particularly preferred salt form of the drug is the L-tartrate salt.
[0045] To control nausea using a CR dosage form of 1, the release rate of the drug must be such that the drug is metered into the GI system in a form available for drug absorption at a rate significantly slower than that for the IR dosage form. Using divided IR dosages in a clinical trial, it was found that if the drug is released at a rate corresponding to about 12 mgA/hr (for a total dose of 3 mgA), the incidence of nausea reports exceeded 50% of the subjects tested. In contrast, at a dosing rate corresponding to about 8 mgA/hr (for a total dose of 2 mgA) the incidence level for nausea dropped to about 13%. This therefore determines an upper limit of 8 mgA/hr for the rate of drug administration needed for a CR dosage form to reduce nausea. In view of the present invention, it is anticipated that even greater improvement in nausea reduction will result by use of slower release rates. Oral CR dosage forms can generally be expected to undergo not more than about 18 hours of drug absorption, depending on the motility of the dosage form for the individual. Based on the blood levels of the drug needed for efficacy, it is anticipated that the total dose required for the drug is about 0.5 mgA to 6 mgA per day. Based on this, the lower limit on the rate of drug administration is approximately 0.03 mgA/hr. Although these extremes would certainly provide for the benefits described in the present invention, the inventors have found that to achieve the desired therapeutic blood levels while maintaining the nausea reduction, the drug is administered at a rate of between about 0.06 and 3 mgA/hr; and more preferably between 0.1 and 1 mgA/hr.
[0046] A number of means have been found to produce such a CR system to achieve the desired rate of drug administration. Examples of such means are set forth in International Patent Publications WO02/17918 and WO99/01121, both of which are hereby incorporated by reference. One such means is a matrix. In particular, a matrix tablet or matrix multiparticulates of 1 can be prepared in accordance with this invention. In the case of multiparticulates, the final presentation of the dosage form can be made by adding the particulates to a capsule or providing a sachet or other such presentation. These matrix dosage forms can be formed using traditional techniques such as by compression with a tablet press or by such processes as extrusion/spherinization, roto-granulation ormelt congealing. Multipartiulcates can also provide for controlled-release drug delivery behavior by coatings that control the diffusion of drug. Such coatings can restrict water and drug permeability or have solubilites such that they are removed after a particular time or at a particular pH. Two types of matrix dosage forms are appropriate for 1: hydrophilic and hydrophobic. A hydrophilic matrix matrix formulation generally consists of mixtures of high and low molecular weight water-soluble polymers. In particular, these matrix materials consist of combinations of different molecular weights of hydroxypropylmethylcellulose (HPMC), polyethyleneoxide (PEO), hydroxy-propylcellulose (HPC), polyacrylates, alginate, xantham gum and other such polymers. Particularly preferred polymers include HPMC and PEO. A particularly preferred formulation consists of a mixture of HPMC marketed under the tradename K4M Methocel™ (available from Dow Corp., Midland, Mich.) and calcium phosphate dibasic marketed under the tradename D-tab™ (available from Rhodia Inc., Cranbury, N.J.). Hydrophobic matrix formulations of 1 can be prepared by using hydrophobic materials to slow the rate that water comes in contact with 1, respectively. Particularly preferred hydrophobic materials include carnauba wax, glyceryl behenate and stearic acid. It will, however, be appreciated by those versed in the art that other similar waxy materials will function in an equivalent fashion.
[0047] Osmotic dosage forms can also provide the desired release rate for 1. One approach involves two-compartment systems (also known as “push-pull” systems). See, e.g., U.S. Pat. No. 4,111,202. In a push-pull system, the drug or drug formulation is present in one compartment and water-soluble or water-swellable auxiliaries (e.g. salts, sugars, swellable polymers and hydrogels) for producing an osmotic pressure are present in a second compartment. The two compartments are separated from each other by a flexible partition and sealed externally by a rigid water-permeable membrane. Fluids entering the second compartment cause an increase in volume of the lower compartment, which in turn acts on the expanding flexible partition and expels the contents of the drug compartment from the system. The preparation of push-pull systems is technically complicated. For example, a flexible partition consisting of a material different from that of the water-permeable membrane has to be incorporated into the dosage form. In addition, for sparingly soluble high-dosage drugs (e.g. more than 200 mg dose), a push-pull system would be voluminous thus making its ingestion difficult.
[0048] Push-pull systems for sparingly soluble drugs without a partition are disclosed in U.S. Pat. No. 4,327,725. A commercial embodiment of this system is known as GITS (gastro-intestinal therapeutic system) and is marketed in commercial products such as Procardia™ XL and Glucotrol™ XL (both available from Pfizer, Inc., New York, N.Y.). The core consists of two layers: one layer containing the drug and a second layer containing an osmotic driving member. A rigid water-permeable layer surrounds the core and contains a passageway in communication with the drug layer only. The osmotic driving member is a swellable polymer or hydrogel (e.g., polyethylene oxide). Absorption of fluid into the system causes the hydrogel in the second layer to expand thus forcing the contents of the drug layer through the passageway.
[0049] Another approach for delivering drugs in an osmotic tablet is the addition of a gas generating means to the tablet core. U.S. Pat. Nos. 4,036,228 and 4,265,874 disclose a single layer core containing a limited solubility drug, a gas generating means (e.g., effervescent couple), an osmagent and a surfactant having wetting, solubilizing and foaming properties (e.g., sodium lauryl sulfate). Fluids imbibing through a rigid water-permeable membrane surrounding the core causes the gas-generating means to produce a gas which creates a pressure sufficient to expel the drug through an orifice in the membrane.
[0050] Another method of delivering drugs osmotically involves the use of single layer osmotic tablets. Such tablets are described in G. Santus and R. W. Baker, J. Control. Rel., 1995, 35, 1-21, incorporated herein by reference. Other single-layer osmotic tablets are described in copending application PC11850, incorporated herein by reference. A particularly preferred osmotic dosage form for 1 is in the form of an AMT system, as described for example in U.S. Pat. Nos. 5,612,059 and 5,698,220. (See, also, S. M. Herbig, J. Control. Rel., 1995, 35, 127-136). Such systems provide for good control of the drug release throughout the GI system. The inventors have found that preferred formulations consist of cores made from the L-tartrate salt of the drug, mannitol, microcrystalline cellulose, dicalcium phosphate and magnesium stearate. These cores can be prepared by direct compression, wet granulation (with a high or low shear wet granulator or fluid bed granulator), extrusion granulation, rotogranulation or roller compaction. Roller compaction is especially preferred due to its ability to prevent drug segregation, while maintaining drug stability (in contrast to aqueous wet granulations which can lead to drug hydrate formation). The tablets can be prepared on standard tablet presses (rotary). The tablet cores are then coated using a pan coater. The coating favorably consists of a mixture of cellulose acetate (CA) and polyethylene glycol (PEG) coated from acetone and water. The ratio of components is selected such that the CA/PEG combination produce a porous, semipermeable coating which administers the drug through the pores in the GI tract at the desired rate. Most preferably, the ratio of CA to PEG is chosen such that the PEG is in a single phase with the CA since phase-separated PEG was found to lead to drug degradation at elevated temperatures in the final dosage form. Phase compatibility for the purpose of this invention can be determined using a standard differential scanning calorimeter on the desired CA to PEG blend. The absence of a PEG melt transition between 30° C. and 50° C. is an indication of a single phase, and therefore, an indication that such a ratio will form a preferred film. It is therefore most preferred that the CA/PEG ratio remain above about 4.
[0051] Non-oral CR systems can also provide nausea reduction while maintaining efficacy upon administration of 1. These systems include suppositories, transdermal systems, buccal systems, depots and implantable devices. In order to function to reduce nausea, these devices must provide controlled-release behavior as described previously. A particularly preferred non-oral dosage form is a transdermal dosage form.
[0052] With all the CR dosage forms, the drug is preferably delivered at a rate of between about 0.06 and 3 mgA/hr; and more preferably between 0.1 and 1 mgA/hr. Suitability for the present invention can be determined either by in vivo or in vitro testing. In particular, it is preferred that the average initial C max be reduced to achieve a value of 10 to 80% of that achieved with an average initial IR bolus administration; more preferred is between 30 and 70%. For T max , an increase in the average initial T max for a CR dosage form compared to an average initial IR bolus is preferred to be at least 50%. Preferred dosage forms for the present invention provide 50% w:w of the total dose into solution between about 1 and 15 hours; more preferably between 2 and 10 hours.
[0053] CR systems for the present invention can involve a delay or lag period between when the dose is administered and when drug is available for absorption. Such delays can be temporal or related to the position in the gastrointestinal tract. These systems will be effective for the purposes of the present invention as long as once they begin providing drug for absorption, the rate falls within the limits described above. A particularly preferred delayed release system is an enteric-coated tablet or multiparticulate. Preferred enteric systems can be prepared by coating tablets or multiparticulates with such materials as cellulose acetate phthalate or enteric polyacrylics such as those marketed under the Eudragit brand name (available from Rohm Pharmaceuticals).
[0054] Formulations useful for the present invention can be prepared using a wide range of materials and processes known in the art. The inventors have found, however, that the presence of reducing carbohydrates is detrimental to the drug stability on storage. In particular, CR formulations with less than 20% w/w of reducing carbohydrates are preferred; still more preferred are CR formulations with less than 10% w/w reducing carbohydrates; and most preferred are CR formulations with less than 5% w/w reducing carbohydrates. A particular reducing carbohydrate that is preferably avoided is lactose.
[0055] For preparation of the controlled release and immediate release dosage forms, the active ingredient may be used per se or in the form of its pharmaceutically acceptable salt, solvate and/or hydrate. The active ingredient may be used per se or in the form of its pharmaceutically acceptable salt, solvate and/or hydrate. The term “pharmaceutically acceptable salt” refers to non-toxic acid addition salts derived from inorganic and organic acids. Suitable salt derivatives include halides, thiocyanates, sulfates, bisulfates, sulfites, bisulfites, arylsulfonates, alkylsulfates, phosphonates, monohydrogen-phosphates, dihydrogenphosphates, metaphosphates, pyrophosphonates, alkanoates, cycloalkylalkanoates, arylalkonates, adipates, alginates, aspartates, benzoates, fumarates, glucoheptanoates, glycerophosphates, lactates, maleates, nicotinates, oxalates, palmitates, pectinates, picrates, pivalates, succinates, tartarates, citrates, camphorates, camphorsulfonates, digluconates, trifluoroacetates, and the like.
[0056] The final pharmaceutical composition is processed into a unit dosage form (e.g., tablet, capsule or sachet) and then packaged for distribution. The processing step will vary depending upon the particular unit dosage form. For example, a tablet is generally compressed under pressure into a desired shape and a capsule or sachet employs a simple fill operation. Those skilled in the art are well aware of the procedures used for manufacturing the various unit dosage forms.
[0057] The active blend of an immediate release dosage form generally includes one or more pharmaceutically acceptable excipients, carriers or diluents. The particular carrier, diluent or excipient used will depend upon the means and purpose for which the active ingredient is being applied. In general, an immediate release tablet formulation includes materials such as diluents, binders, lubricants, glidants, disintegrants and mixtures thereof. Although many such excipients are known to those skilled in the art, the inventors have found that only a sub-set of those provide for the most stable formulations. In particular, the inventors have found that preferred formulations contain less than about 20% w:w reducing carbohydrates. Reducing carbohydrates are sugars and their derivatives that contain a free aldehyde or ketone group capable of acting as a reducing agent through the donation of electrons. Examples of reducing carbohydrates include monosaccharides and disaccharides and more specifically include lactose, glucose, fructose, maltose and other similar sugars. The inventors have further found that formulations containing dicalcium phosphate are particularly stable. More specifically, stable formulations are produced with more than about 20% w:w dicalcium phosphate. Other acceptable excipients include starch, mannitol, kaolin, calcium sulfate, inorganic salts (e.g., sodium chloride), powdered cellulose derivatives, tribasic calcium phosphate, calcium sulfate, magnesium carbonate, magnesium oxide, poloxamers such as polyethylene oxide and hydroxypropyl methylcellulose. To ensure content uniformity of the blend, a volume mean diameter drug substance particle size of less than or equal to about 30 microns is preferably utilized. Preferred diluents are microcrystalline cellulose (e.g., Avicel® PH200, PH102 or PH101 available from FMC Pharmaceutical, Philadelphia, Pa.) and calcium phosphate dibasic, or dicalcium phosphate, (e.g. A-Tab® available from Rhodia, Chicago Heights, Ill.). The mean particle size for the microcrystalline cellulose generally ranges from about 90 μm to about 200 μm. Suitable grades of dicalcium phosphate include anhydrous (about 135 to 180 pm mean, available from PenWest Pharmaceuticals Co., Patterson, N.Y. or Rhodia, Cranbury, N.J.), and dihydrate (about 180 μm, available from PenWest Pharmaceuticals Co., Patterson, N.Y. or Rhodia, Cranbury, N.J.). Generally, the microcrystalline cellulose is present in an amount from about 10 wt % to about 70 wt % and the dicalcium phosphate is present in an amount from about 10 wt % to about 50 wt %, more preferably, microcrystalline cellulose is present in an amount of about 30-70 wt % and the dicalcium phosphate is present in an amount of about 20-40 wt %.
[0058] If desired, a binder may be added. Suitable binders include substances such as celluloses (e.g., cellulose, methylcellulose, ethylcellulose, hydroxypropyl cellulose and hydroxymethylcellulose), polypropylpyrrolidone, polyvinylprrolidone, gelatin, gum arabic, polyethylene glycol, starch, natural and synthetic gums (e.g., acacia, alginates, and gum arabic) and waxes.
[0059] A lubricant is typically used in a tablet formulation to prevent the tablet and punches from sticking in the die. Suitable lubricants include calcium stearate, glyceryl monostearate, glyceryl palmitostearate, hydrogenated vegetable oil, light mineral oil, magnesium stearate, mineral oil, polyethylene glycol, sodium benzoate, sodium lauryl sulfate, sodium stearyl fumarate, stearic acid, talc and zinc stearate. A preferred lubricant is magnesium stearate. The magnesium stearate is generally present in an amount from about 0.25 wt % to about 4.0% wt %.
[0060] Disintegrants may also be added to the composition to break up the dosage form and release the compound. Suitable disintegrants include sodium starch glycolate, sodium carboxymethyl cellulose, calcium carboxymethyl cellulose, croscarmellose sodium, polyvinylpyrrolidone, methyl cellulose, microcrystalline cellulose, powdered cellulose, lower alkyl-substituted hydroxypropyl cellulose, polacrilin potassium, starch, pregelatinized starch and sodium alginate. Of these, croscarmellose sodium and sodium starch glycolate are preferred, with croscarmellose sodium being most preferred. The croscarmellose sodium is generally present in an amount from about 0.5 wt % to about 6.0 wt %. The amount of disintegrant included in the dosage form will depend on several factors, including the properties of the dispersion, the properties of the porosigen (discussed below), and the properties of the disintegrant selected. Generally, the disintegrant will comprise from 1 wt % to 15 wt %, preferably from 1 wt % to 10 wt % of the dosage form.
[0061] Examples of glidants include silicon dioxide, talc and cornstarch.
[0062] A film coating on the immediate release dosage form can provide ease of swallowing, reduction in unpleasant taste or odor during administration, improved photostability through use of an opacifier, improved elegance, reduced friction during high-speed packaging, or as a barrier between incompatible substances (G. Cole, J. Hogan, and M. Aulton, Pharmaceutical Coating Technology , Taylor and Francis Ltd, Ch 1, 1995). When used, the inventors have found that coatings containing a majority of cellulosic polymers provide superior chemical stability for the drug. Cellulosics are polymers derived from cellulose. Examples of polymers include cellulosics such as hydroxypropyl methylcellulose, hydroxypropylcellulose, hydroxyethylcellulose, methylhydroxyethylcellulose, methylcellulose, and sodium carboxymethylcellulose. A preferred polymer is hydroxypropyl methylcellulose. Coatings of the present invention comprise a polymer, an opacifier, a plasticizer a pharmaceutically acceptable diluent/filler and optionally acolorant. An opacifier is an excipient that help decrease the transmission of light through the coating to the core of the tablet. Examples of opacifiers include titanium dioxide and talc. A preferred opacifier is titanium dioxide. A plasticizer is a material which lower the glass transition temperature of the polymer thereby typically improving physical properties. Examples of plasticizers include polyhydric alcohols such as glycerol and polyethylene glycols and acetate esters such as glyceryl triacetate (triacetin) and triethyl citrate. Optionally, the compositions of the present invention may include a colorant. Such colorants are available from a number of commercial vendors and are well known to those skilled in the art. Particularly preferred coating formulations comprise HPMC, triacetin and titanium dioxide or HPMC, PEG and titanium dioxide.
[0063] To achieve a uniform distribution of drug in a blend prior to tablet or capsule production, two methods have been invented. In the first method, a geometric dilution process is used. In this process, a pre-blend of the drug and a portion of the excipients is prepared and subsequently further diluted with the remaining excipients in 2-5 additional steps. In the first dilution step, drug is mixed with 10-30 wt % of the excipient(s). In the second dilution, the first pre-blend is further diluted with 10-40 wt % excipient(s). In the third to fifth dilutions, the second dilution blend is further diluted with 10-75 wt % excipient(s) to form the final blend. A preferred dilution scheme involves first diluting the drug with the dicalcium phosphate in two increments, then combining with a blend of the remaining excipients.
[0064] The second process for achieving uniform drug distribution involves blending the formulation with a particular level of shear. The inventors have found unexpectedly that shear the is too high or low results in poor uniformity or total potency. The inventors have found that the desirable shear is achieved using either a bin blender or a high shear blender operated at low shear conditions (less than 200 rpm). The typical blending time for the blending in the bin blender is from about 20 minutes to about 30 minutes. Although blending times greater than 30 minutes can be used, care should be taken not to demix the blend. After the initial blending step, the active blend may be sieved using a conical mill (Comil 197, Quadro Engineering, Inc., Waterloo, Ontario, Canada) fitted with a 0.8 mm screen. The lubricant is then added to the active blend and blended for about 3 minutes in the twin shell “V” or bin blender prior to dry granulating.
[0065] The processes described above provide efficient mixing and a more uniform distribution of the active ingredient without significant degradation of the active ingredient; however, the loss of active ingredient due to segregation or adherence of the compound to the metal surfaces of the equipment (e.g., screens and vessel surfaces) presented an additional challenge especially for low dosage formulations (e.g., less than 4 mg per unit dose). The inventors have found a third way of attaining acceptable blend potency involves the use of an abrasive excipient, such as dicalcium phosphate. More specifically, preferred formulations contain 10-50 wt % dicalcium phosphate.
[0066] The pharmaceutical composition can be used to produce unit dosage forms containing about 0.1 mg to about 10.0 mg active ingredient per unit dosage, preferably, about 0.2 mg to about 5.0 mg active ingredient per unit dosage. The tablet size (i.e., unit dosage form) is typically between about 100 mg and 600 mg.
[0067] The tablets are generally prepared by compression in a rotary press. However, the particular method used for tablet formation is non-limiting and is well known to those skilled in the art. After formation of the tablets, the tablets are often coated with one or more coatings. The tablet may be coated with a coating to mask flavor, to act as a sealant and/or to act as a receptor for printing a logo or trademark on the tablet surface. Alternatively, the tablet may be coated with a film-forming protecting agent(s) to modify the dissolution properties of the tablet. For example, the tablet may be coated with a film-forming coating that resists dissolution for a predictable period of time thus resulting in a delayed or prolonged release of the active ingredient. Suitable film-forming protecting agents include celluloses (e.g., hydroxypropyl-methylcellulose, hydroxypropyl cellulose, methylcellulose), polyvinyl pyrrolidone, and ethyl acrylate-methyl methacrylate copolymers. The coating formulations may also include additives such as plasticizers (e.g., polyethylene glycol or triacetin), preservatives, sweeteners, flavoring agents, coloring agents and other known additives to provide an elegant presentation of the drug. A preferred coating formulation contains 40-70 wt % cellulosic polymer(s). Preferably, the aqueous coating of the immediate release dosage form of the present invention comprises Opadry® (YS-1-18202-A) and Opadry Clear® (YS-2-19114-A) manufactured by Colorcon, West Point, Pa. Opadry ®, useful as an opacifying coat, contains hydroxypropyl methylcellulose, titanium dioxide, and polyethylene glycol or triacetin. Opadry Clear®), useful as a polish coat, contains hydroxypropyl methylcellulose and triacetin.
[0068] The inventors have found that preferred formulations consist of cores made from the L-tartrate salt of the drug, mannitol, microcrystalline cellulose, dicalcium phosphate and magnesium stearate. More preferred formulations consist of cores made from the L-tartrate salt of the drug, microcrystalline cellulose, dicalcium phosphate and magnesium stearate. Even more preferred formulations consist of cores made from the L-tartrate salt of the drug, microcrystalline cellulose, dicalcium phosphate, croscarmellose sodium, silicon dioxide and magnesium stearate. These cores can be prepared by direct compression, wet granulation (with a high or low shear wet granulator or fluid bed granulator), extrusion granulation, rotogranulation or roller compaction. Roller compaction is especially preferred due to its ability to prevent drug segregation, while maintaining drug stability (in contrast to aqueous wet granulations which can lead to drug hydrate formation). The tablets can be prepared on standard tablet presses (rotary). The tablet cores are then coated using a pan coater. The preferred coating consists of a mixture of hydroxypropyl methyl-cellulose, titanium dioxide, polyethylene glycol or triacetin, and optionally a colorant.
[0069] Alternatively, the active pharmaceutical blend may be filled into hard shell capsules, also referred to as the dry-filled capsule (DFC). The capsule formulation and manufacturing process is similar to the reported tablet core formulation and manufacturing process. A hard shell capsule could consist of gelatin and water or hydroxypropyl methylcellulose, water and a gelling agent (gelan gum or carageenan).
[0070] The pharmaceutical composition (or formulation) may be packaged in a variety of ways. Generally, an article for distribution includes a container that contains the pharmaceutical composition in an appropriate form. Suitable containers are well known to those skilled in the art and include materials such as bottles (plastic and glass), sachets, foil blister packs, and the like. The container may also include a tamper proof assemblage to prevent indiscreet access to the contents of the package. In addition, the container typically has deposited thereon a label that describes the contents of the container and any appropriate warnings or instructions.
[0071] The pharmaceutical compositions containing compound 1 described herein are useful in the treatment or prevention of inter alia inflammatory bowel disease (including but not limited to ulcerative colitis, pyoderma gangrenosum and Crohn's disease), irritable bowel syndrome, spastic dystonia, chronic pain, acute pain, celiac sprue, pouchitis, vasoconstriction, anxiety, panic disorder, depression, bipolar disorder, autism, sleep disorders, jet lag, amyotrophic lateral sclerosis (ALS), cognitive dysfunction, hypertension, bulimia, anorexia, obesity, cardiac arrhythmias, gastric acid hypersecretion, ulcers, pheochromocytoma, progressive supranuclear palsy, chemical dependencies and addictions (e.g., dependencies on, or addictions to nicotine (and/or tobacco products), alcohol, benzodiazepines, barbiturates, opioids or cocaine), headache, migraine, stroke, traumatic brain injury (TBI), obsessive-compulsive disorder (OCD), psychosis, Huntington's chorea, tardive dyskinesia, hyperkinesia, dyslexia, schizophrenia, multi-infarct dementia, age-related cognitive decline, epilepsy, including petit mal absence epilepsy, senile dementia of the Alzheimer's type (AD), Parkinson's disease (PD), attention deficit hyperactivity disorder (ADHD) and Tourette's Syndrome.
[0072] Accordingly, the pharmaceutical formulations containing compound 1 and processes described herein may be used in the manufacture of a medicament for the therapeutic applications described above.
[0073] A therapeutically effective amount of the manufactured medicament may be administered to a human in need of such treatment or prevention. As used herein, the term “therapeutically effective amount” refers to an amount of active ingredient which is capable of inhibiting or preventing the various pathological conditions or symptoms thereof and sequelae, referred to above. The terms “inhibit” or “inhibiting” refers to prohibiting, treating, alleviating, ameliorating, halting, restraining, slowing or reversing the progression, or reducing the severity of a pathological condition or symptom related to or resultant from the respective condition being treated. As such, the pharmaceutical formulations may be used for both medical therapeutic (acute or chronic) and/or prophylactic (prevention) administration as appropriate. The dose, frequency and duration will vary depending on such factors as the nature and severity of the condition being treated, the age and general health of the host and the tolerance of the host to the active ingredient. The pharmaceutical composition or medicament may be given in a single daily dose, in multiple doses during the day or even in a weekly dose. The regimen may last from about 2-3 days to several weeks or longer. Typically, the composition is administered to a human patient once or twice a day with a unit dosage of about 0.25 mg to about 10.0 mg, but the above dosage may be properly varied depending on the age, body weight and medical condition of the patient and the type of administration.
[0074] The following examples are provided for illustrative purposes and should not be construed to limit the scope of the present invention.
[0075] The following list of materials used in the Examples may be prepared or acquired from the corresponding source:
[0076] Compound 1 (L-tartrate salt) may be prepared by the methods described in patent applications WO9935131 A1 or WO01 62736A1, incorporated herein by reference.
[0077] Microcrystalline cellulose (Avicel™ PH200) available from FMC Pharmaceutical (Philadelphia, Pa.).
[0078] Mannitol (granular 2080) available from SPI Polyols, Inc. (New Castle, Del.).
[0079] Dialcium phosphate, anhydrous, (A-tab™) available from Rhodia Inc. (Chicago Heights, Ill.).
[0080] Croscarmellose Sodium (Ac-Di-Sol™) available from FMC BioPolymer (Philadelphia, Pa.).
[0081] Sodium Starch Glycolate (Explotab™) available from Penwest (Patterson, N.J.).
[0082] Silicon dioxide, colloidal (Cab-O-Sil™) available from Cabot Corporation (Boston, Mass.).
[0083] Silicified Microcrystalline Cellulose (ProSOlv™) available from Penwest (Patterson, N.J.).
[0084] Hydroxypropyl cellulose (Klucel™) available from Hercules, Inc. (Hopewell, Va.).
[0085] Lactose, anhydrous available from Quest International (Norwich, N.Y.).
[0086] Magnesium stearate, animal or vegetable source, available from Mallinckrodt (St. Louis, Mo.).
[0087] Film coatings, Opadry™ available from (Colorcon, West Point, Pa.).
[0088] Cellulose acetate (398-10 NF) available from Eastman Chemicals (Kingsport, Tenn.).
[0089] Polyethyleneglycol (PEG3350) available from Union Carbide Corp. (subsidiary of Dow Chemical Co., Midland, Mich.).
[0090] Hydroxypropyl methylcellulose (HPMC, K4M, methocel™) available from Dow Chemical Co., Midland, Mich.
EXAMPLE 1
Preparation of an AMT CR Dosage Form for the L-Tartrate Salt of 1
[0091] A 3 kg batch of tableting granulation was prepared as follows: 450 g of microcrystalline cellulose and 1602 g of calcium phosphate dibasic were mixed in an 8-quart V-blender fO min. Half the blend was discharged into a polyethylene bag, leaving half the blend remaining in the blender. To a 1250-cc glass bottle were added 450 g of mannitol and 10.3 g of the drug. The mixture was blended using a Turbula blender (available from Geln Mills Inc., Clifton, N.J.). This material was added to the V-blender containing the above listed materials. An additional 450 g of mannitol were added to the bottle followed by 5 minutes of Turbula blending to rinse any drug from the bottle. This material was also added to the V-blender, and the mixture was blended for 20 minutes. The material that had been discharged to the polyethylene bag was then added to the V-blender and the mixture was blended for an additional 20 min. A 22.5 g aliquot of magnesium stearate was then added to the V-blender and the mixture was blended for 5 min. The mixture was roller compacted using a TF-Mini roller compactor (available from Vector Corp., Marion, Iowa) with DSP rollers, using a roll pressure of 30 kg/cm 2 , a roll speed of 4.0 rpm and an auger speed of 15.6 rpm. The ribbons formed were milled using an M5A mill (available from Fitzpatrick Corp., Elmhurst, Ill.) with an 18 mesh Conidur rasping screen at 300 rpm. The powder was then placed back in the V-blender, and another 15 g of magnesium stearate were added, followed by an additional 5 min. of blending.
[0092] The granulation was tableted using a Kilian T100 (available from Kilian & Co. Inc., Horsham, Pa.) tablet press using 9/32″ (11 mm) SRC tooling to give tablets of 250 mg/tablet (0.5 mgA). The precompression force used was 2.8 kN, the main compression force was 8 kN, running at 74 rpm with a feed paddle speed of 20 rpm. The resulting tablets showed hardnesses of 7-9 kp, with no measurable friability.
[0093] The tablets were coated by first preparing a coating solution consisting of 538 g of cellulose acetate and 134.5 g of PEG in 4506 g of acetone and 1547 g of water. Coatings were carried out using an HCT-30EX Hicoater (available from Vector Corp., Marian, Iowa). A spray rate of 20.0 g/min was maintained with an outlet temperature of 28° C. until the target coating weight of 27.5% gain was achieved. The tablets were then tray dried in an oven at 40° C. for 24 hrs.
[0094] Tablets showed pH independent dissolution behavior in vitro using USP type II dissolution (37° C., paddles at 50 rpm, analysis by HPLC potency assay). The percent of drug dissolved as a function of time in the dissolution medium were as follows: 2 hrs, 1%; 5 hrs, 8%; 8 hrs, 35%; 10 hrs, 52%; 12 hrs, 65%; 16 hrs, 81%; 24 hrs, 95%. Thus the system delivers 0.03 mg/hr after a 5 hour lag.
EXAMPLE 2
Clinical Trial Results for Nausea using AMT from Example 1
[0095] In use of 1 in a clinical single dose study of the IR dosage form with fasting non-smokers, nausea was reported for 50% of subjects (2/4) at a dose of 1 mgA and 75% of subjects (3/4) at a dose of 3 mgA. With multidose studies, 1 mgA per day was well tolerated; however, persistent nausea was sufficiently bad (7/12 subjects) with 2 mgA/day that this study arm was discontinued. In a single dose test of fed, healthy smokers, nausea or related complaints were reported in 2 of 16 subjects given the maximum dose of 2 mgA for the IR. In contrast, a dose of 3 mgA and 4 mgA for the above AMT dosage form resulted in a similar levels of nausea as seen with a lower dose of the IR dosage form (2/16 for each case). In multidose studies, the levels of nausea for 3 mgA AMT tablets were comparable to 1 mgA IR tablets given twice a day, and significantly superior to 2 mgA IR tablets given once daily.
EXAMPLE 3
Preparation of Preferred AMT CR Dosage Form for the L-Tartrate Salt of 1
[0096] A 7 kg batch of tableting granulation was prepared as follows: 1050 g of microcrystalline cellulose and 3340 g of calcium phosphate dibasic were mixed in an 16-quart V-blender for 20 min. To an 8-quart V-blender were added 2450 g of mannitol and 71.8 g of the drug. The mixture was mixed for 30 min. This material was added to the 16-quart V-blender (with the blend from the first blending process) and the mixture was blended for 30 mins (blend can be used to rinse blender to assure complete transfers). A 52.5 g aliquot of magnesium stearate was then added to the V-blender and the mixture was blended for 5 min. The mixture was roller compacted using a TF-Mini roller compactor with DSP rollers, using a roll pressure of 30 kg/cm 2 , a roll speed of 4.0 rpm and an auger speed of 15 rpm resulting in ribbons with 0.06 to 0.08″ thickness. The ribbons were milled using an M5A mill (available from Fitzpatrick Corp., Elmhurst, Ill.) with an 18 mesh Conidur rasping screen at 300 rpm. The powder was then placed back in the V-blender, and another 35 g of magnesium stearate were added, followed by an additional 5 min. of blending.
[0097] The granulation was tableted using a Kilian T100 tablet press using 9/32″ (11 mm) SRC tooling to give tablets of 250 mg/tablet (1.5 mgA). The precompression force used was 1.2 kN, the main compression force was 8 kN, running at 74 rpm with a feed paddle speed of 20 rpm. The resulting tablets showed hardnesses of 5-8 kp, with no measurable friability.
[0098] The tablets were coated by first preparing a coating solution consisting of 4095 g of cellulose acetate and 405 g of PEG in 30.6 kg of acetone and 9.9 kg of water. Coatings on 40,000 to 48,000 tablets per batch were carried out using an HCT-60 Hicoater (available from Vector Corp., Marion, Iowa). A spray rate of 180 g/min was maintained with an outlet temperature of 27° C. until the target coating weight of 13% gain was achieved. The tablets were then tray dried in an oven at 40° C. for 16 hrs.
[0099] Tablets showed pH independent dissolution behavior in vitro using USP type II dissolution (37° C., paddles at 50 rpm, analysis by HPLC potency assay). The percent of drug dissolved as a function of time in the dissolution medium were as follows: 2 hrs, 5%; 5 hrs, 30%; 7 hrs, 50%; 10 hrs, 70%; 12 hrs, 80%; 24 hrs, 97%. Thus the system delivers 0.1 mg/hr after a 2 hour lag.
EXAMPLE 4
Preparation of a Hydrophilic Matrix CR Dosage Form for the L-Tartrate Salt of 1
[0100] HPMC K4M (45.000 g) and 50.575 g of calcium phosphate dibasic were Turbula blended in a bottle for 10 min. Approximately 10 g of this blend were combined with 3.425 g of the L-tartrate salt of 1 and Turbula blended for 10 min. Remaining powder from the first mix was then added to drug containing blend and the combination was Turbula blended for 20 min. Magnesium stearate (1.000 g) was then added and the combination was blended for an additional 3 min. Tablets were prepared using a Manesty™ F-Press (single-punch tablet machine available from Manesty Corporation, Liverpool, UK) using ¼″ SRC tooling. The average tablet weight was 102 mg/tablet corresponding to 0.5 mgA and the tablet hardness was 5-7 kp. In vitro dissolution experiments were carried out using simulated intestinal fluid (pH 6.8) at 37° C. using cages with sinkers on the tablets and paddles rotating at 50 rpm. The amount of drug dissolved over time was measured using an HPLC potency assay as follows: 2 hours, 59%; 4 hours, 85%; 8 hours, 94%; 16 hours, 97%. Thus the system delivered 0.10 mg/hour.
EXAMPLE 5
Preparation of a Hydrophobic Matrix CR Dosage Form for the L-Tartrate Salt of 1
[0101] A mixture of 0.86 g of 1 and 42.25 g of mannitol were passed through a #30 screen then Turbula blended for 2 min. Carnauba wax (6.04 g) and stearic acid (0.61 g) were added to a beaker and melted using a water bath at 90° C. While mixing, mannitol and drug blend were added to the melted wax and stearic acid mixture. The warm material was then screened through a #20 mesh screen, and then allowed to cool overnight. The material was combined with 0.09 g of silicon dioxide and Turbula blended for 2 min. Magnesium stearate (0.17 g) was added followed by an additional 0.5 min. Turbula blending. Tablets were prepared using {fraction (5/16)}″ SRC tooling using an F-press to give a tablet weight of 200 mg (2 mgA).
EXAMPLE 6
Process Selection Based on Tablet Stabilitv and Manufacturing Performance
[0102] This example compares conventional direct compression and wet granulation processes to dry granulation as the preferred method of processing. The dry granulation processing is presented using both a binary and ternary diluent formulation.
[0103] Dry Granulation:
[0104] The following ingredients were added to a bin blender, with drug layered in between excipients:
Diluent System Ingredient Binary Ternary 1-L-tartrate 0.87% 0.57% Mannitol 0% 26.02% Microcrystalline cellulose (PH200) 62.55% 33.33% Dibasic calcium phosphate 33.33% 33.33% Croscarmellose sodium 2.00% 5.00% Silicon dioxide (colloidal) 0.50% 0.50% Magnesium stearate 0.25% 0.75% Magnesium stearate 0.50% 0.50%
[0105] The mixture was blended for 30 minutes. Magnesium stearate was added to the mixture and then blended for 3 minutes. The lubricated blend was roller compacted into ribbons using a roll pressure of 30 kg f /cm 2 , a roll speed of 4 rpm and an auger speed of 15 rpm (using a TF-Mini Roller Compactor (available from Vector Corp., Marion, Iowa). The ribbons were milled through a 20 mesh screen (Vector Rotary Granulator) to produce the granulation. The granulation was blended for 10 minutes. The second portion of magnesium stearate was added to the granulation and blended for 3 minutes. The final blend was compressed into 200 mg tablets using a Kilian T100 tablet press (Kilian & Co., Inc., Horsham, Pa.) fitted with {fraction (5/16)} inch standard round concave punches.
[0106] Direct Compression (Comparative Process)
[0107] A binary diluent formulation (i.e. microcrystalline cellulose and dicalcium phosphate) was prepared with the levels listed below:
1-L-tartrate 8.68 g Microcrystalline cellulose 621.27 g Dibasic calcium phosphate 333.30 g Croscarmellose sodium 20.00 g Silicon dioxide (colloidal) 5.00 g
[0108] Two different blends were prepared and referred to as the “excipient pre-blend” and the “active pre-blend”. The “excipient pre-blend” consisted of microcrystalline cellulose, silicon dioxide, and croscarmellose sodium. These ingredients were added to a V-blender and blended for 20 minutes. The active pre-blend consisted of drug and one-half of the dicalcium phosphate. The active pre-blend ingredients were added to a V-blender and blended for 30 minutes and discharged. One-half of the “excipient pre-blend” was added to a suitably sized blender followed by addition of the entire “active pre-blend” and then blended for 20 minutes. The second part of dicalcium phosphate was added to the empty blender used to mix the “active pre-blend” and mixed for 5 minutes. This and the second half of the “excipient pre-blend” were added to the blender containing the active. The mixture was blended for 20 minutes. Magnesium stearate (5.00 g) was added to the mixture and then blended for 5 minutes. The final blend was compressed into 200 mg tablets using a Kilian T100 tablet press (Kilian & Co., Inc., Horsham, Pa.) fitted with {fraction (5/16)} inch standard round concave punches.
[0109] Wet Granulation (Comparative Formulations and Processes)
[0110] The wet granulation processing was evaluated with two different granulating agents, including water and isopropyl alcohol. The formulations prepared for each of the granulating agents are listed below:
Granulating Agent Ingredient Isopropyl 1-L-tartrate 5.70 g 5.70 g Mannitol 255.20 g 260.20 g Silicified microcrystalline cellulose 333.30 g — Microcrystalline cellulose (PH200) — 333.30 g Dibasic calcium phosphate 333.30 g 333.30 g Hydroxypropyl cellulose 10.00 g — Croscarmellose sodium 50.00 g 50.00 g Water 533.30 g — Isopropyl alcohol — 533.30 g Silicon dioxide (colloidal) 5.00 g 5.00 g Magnesium stearate 7.50 g 12.50 g
[0111] The inactive ingredients listed above the granulating agent (water or isopropyl alcohol) in the formulation table were added to a high shear blender and dry mixed for 1 minute at 100 rpm impeller speed. One half of the excipient blend was removed from the bowl, and the total quantity of 1-L-tartrate was added to the blender and covered with the removed blend. This blend was mixed for 1 minute at 100 rpm. While continuing to blend, the granulating agent was added over 1 minute with chopper speed of 1000 rpm and impeller speed of 300 rpm. The wet granulation was mixed an additional 15 seconds following addition of the water or isopropyl alcohol. The wet mass was dried in a 50° C. oven to a moisture level within 1% of the initial value prior to granulating. The dried granulation was milled through a conical mill (Comil, Quadro Engineering, Inc., Waterloo, Ontario, Canada) fitted with a 0.050 inch screen and round edge impeller set at 1770 rpm. Colloidal silicon dioxide was added to this granulation and blended in a V-blender for 20 minutes. Magnesium stearate was added to the blender and blended for 5 minutes. The final blend was compressed into 300 mg tablets using a Kilian T100 tablet press (Kilian & Co., Inc., Horsham, Pa.) fitted with {fraction (11/32)} inch standard round concave punches.
[0112] The blend uniformity of the direct compression and dry granulation processes is compared below. The batches utilized the same in-going bulk drug substance lot, drug loading (0.868%) and tablet size (200 mg). The potency and variability data are summarized in Table 5-1 below for the direct compression and dry granulation processes. The impact of dry granulating the formulation on blend uniformity is demonstrated by the reduction in blend variability from 8.0% to 1.8% RSD.
TABLE 6-1 Dry Granulation Direct Manufacturing Process (binary) Compression Percent Drug Load 0.868 0.868 Tablet Size (mg) 200 200 Final Blend Potency 99.2 99.4 (avg) Final Blend Potency 1.8 8 (% RSD)
[0113] The high variability (8% RSD) in the final blend potency prior to directly compressing the tablets was the basis for selecting dry granulation as the preferred process.
[0114] The wet and dry granulation processes were compared by manufacturing performance, in terms of granulation blend and tablet potencies and variabilities (percent relative standard deviation, or %RSD). These batches utilized the same in-going bulk drug substance lot, drug loading (0.57%) and tablet size (300 mg). The potency and variability data are summarized in Table 6-2 below for the three granulation processes evaluated here.
TABLE 6-2 Dry Wet Wet Granulation Granulation Granulation Manufacturing Process (ternary) with Water with IPO Percent Drug Load 0.57 0.57 0.57 Tablet Size (mg) 300 300 300 Granulation Potency (avg) 91.3 101.3 93.6 Granulation Potency (% RSD) 4.2 4.0 1.8 Tablet Potency (avg) Beginning 94.5 99.0 93.7 Middle 95.0 100.8 96.1 End 96.0 99.8 94.8 Tablet (% RSD) Beginning 1.2 2.5 2.3 Middle 0.4 0.9 0.4 End 1.2 2.6 1.0
[0115] Granulation and tablet potency values are closest to the intended 100% for the wet granulation process that used water as the granulating agent. The dry granulation and wet granulation with isopropyl alcohol processes resulted in similar manufacturing performance results.
[0116] Table 6-3 below summarized the stability results for tablets stored at the accelerated conditions for 6 weeks and analyzed by HPLC for the wet and dry granulation processes.
TABLE 6-3 Wet Dry Wet Granulation Manufacturing Process Granulation Granulation with Percent Drug Load 0.57 0.57 0.57 Tablet Size (mg) 300 300 300 Total Percent Impurities After 6 Weeks: At 5° C. ND 0.08 0.30 At 25° C./60% RH ND NA NA At 30° C./60% RH NA 0.10 0.35 At 40° C./75% RH 0 0.12 0.40 At 50° C./20% RH NA 0.20 0.35 Drug Form During Anhydrous Hydrate Anhydrous
[0117] Wet granulation using water as the granulating agent was found to be physically unstable due to a conversion from the anhydrous to hydrate state for the 1-L-tartrate. The hydrate was subsequently lost during the drying phase to form the anhydrous drug form. These physical stability changes during the wet granulation and drying process with water aided in the selection of the preferred process. Dry granulation and wet granulation with isopropyl alcohol are the preferred modes of processing for 1-L-tartrate tablets. The process that resulted in the lowest total impurity levels was dry granulation, followed by wet granulation with water and then wet granulation with isopropyl alcohol.
[0118] Therefore, the most preferred granulating process to make tablets of 1-L-tartrate based on stability, blend uniformity and manufacturing performance is dry granulation.
Example 7
[0119] Diluent Selection Based on Tablet Stability
[0120] The diluents used in making 1-L-tartrate tablets were selected based on the chemical stability and manufacturing performance. Three diluents (dicalcium phosphate, microcrystalline cellulose, and mannitol) were evaluated using the preferred dry granulation processing, and included two (binary) or three (ternary) diluents in the formulation.
Diluents Dical/MCC/ MCC/ Ingredient Mannitol Mannitol 1-L-tartrate 0.57% 0.57% Mannitol 26.02% 42.68% Microcrystalline cellulose (PH200) 33.33% 50.00% Dibasic calcium phosphate 33.33% 0.0% Croscarmellose sodium 5.00% 5.00% Silicon dioxide (colloidal) 0.50% 0.50% Magnesium stearate 0.75% 0.75% Magnesium stearate 0.50% 0.50%
[0121] Table 7-1 below summarizes the stability results for tablets prepared by dry granulation processing with either a ternary or binary (no dicalcium phosphate) formulation, stored for 3 months at accelerated conditions and analyzed by HPLC.
TABLE 7-1 Dry Granulation Dry Granulation (binary MCC/Mannitol - Manufacturing Process (ternary) no Dical) Percent Drug Load 0.57 0.57 Tablet Size (mg) 300 300 Total Percent Impurities After 6 Wks/3 Mos: At 5° C. ND/0 0/0.05 At 25° C./60% RH ND/0 NA At 30° C./60% RH NA 0.13/0.12 At 40° C./75% RH 0/0.10 0.28/0.34 At 50° C./20% RH NA 0.23/0.58
[0122] The formulation processed by dry granulation that resulted in the lowest total impurity levels utilized dicalcium phosphate. The preferred formulations prepared by dry granulation contain binary or ternary diluents of dicalcium phosphate, microcrystalline cellulose, and mannitol. The most preferred formulations prepared by dry granulation contain dicalcium phosphate as one of the major diluents.
[0123] Table 7-2 below summarized the stability results for tablets stored at the accelerated conditions for 6-12 weeks and analyzed by HPLC for the three binary diluent formulations to the ternary diluent formulation using the preferred dry granulation process.
TABLE 7-2 Ternary MCC/ Lactose/ (Dical/MCC/ Binary Diluents Dical Mannitol/Dical Dical Mannitol) Percent Drug Load 0.86 0.86 0.86 0.86 Tablet Size (mg) 200 200 200 300 Total Percent Impurities After 6 and 12 Weeks: At 5° C./75% RH 0/0 0/0 0/NA 0/0 At 30° C./60% RH 0.1/0.1 0/0 0.2/NA 0.1/0.1 At 40° C./75% RH 0.1/0.3 0.1/0.2 2.6/NA 0.1/0.3 At 50° C./20% RH 0.2/0.3 0.1/0.2 1.3/NA 0.2/0.3
[0124] The lactose/dicalcium phosphate binary diluent formulation was found to be less stable under accelerated temperature/humidity conditions. The microcrystalline cellulose/dicalcium phosphate and mannitol/dicalcium phosphate binary tablets exhibited similar total impurity levels as the original ternary formulation, as shown in Table 7-2. Therefore, the ternary and MCC/Dical and mannitol/Dical binary systems are preferred embodiments of this invention.
EXAMPLE 8
[0125] Diluent Selection Based on Tablet Manufacturing Performance and Content Uniformity
[0126] Based on chemical stability alone, the two binary formulations (MCC/Dical and mannitol/Dical) listed in Example 7 are suitable formulations of 1-L-tartrate. In order to select the more preferred composition, a manufacturing assessment was performed on a Kilian T-100 press with 3 stations of {fraction (5/16)} inch SRC tooling. Tablets were compressed at 4, 8, 12, 16, and 20 kN force and tested for weight, thickness, hardness, disintegration time and % friability at each condition. Those data are listed below in Table 8-1.
TABLE 8-1 Compression Disintegration Lot # Force (kN) Weight (mg) Thickness (in.) Hardness (kP) Time (min:sec) Friability (%) Mannitol/ 4.53 199.8 0.150 <1 00:17 35.48% (a) Dical 7.91 200.7 0.146 1.81 00:21 0.59% 11.65 200.1 0.141 2.73 00:19 0.34% 16.32 200.8 0.138 2.71 00:16 1.20% (b) 19.69 201.0 0.136 2.88 00:20 100% (c) MCC/ 3.94 201.5 0.156 <1 00:04 100% (d) Dical 7.89 201.8 0.146 3.05 00:09 0.21% 11.51 202.0 0.139 4.84 00:12 0.11% 16.08 202.7 0.136 7.17 00:23 0.14% 17.56 201.5 0.135 7.91 00:13 0.067%
[0127] The mannitol/dicalcium phosphate binary formulation exhibited severe capping issues and could not be tableted to a hardness above 3 kP, whereas the target range for this size tooling is 6-9 kP. At these hardnesses, the tablets had poor mechanical integrity based on the high % friability (desired less than 0.2%). Alternatively, the MCC/dicalcium phosphate binary tablet produced tablets with hardness and friability values within the target ranges. Therefore, the more preferred binary formulation based on the manufacturing assessment is microcrystalline cellulose/dicalcium phosphate. The ternary formulation is a preferred formulation based on stability and manufacturing, and is also an embodiment of this invention.
EXAMPLE 9
[0128] Disintegrant Selection Based on Tablet Stability
[0129] Tablets containing sodium starch glycolate (SSG) as a disintegrant were analyzed for purity and compared with croscarmellose sodium (CS) containing tablets. Tablets were placed 60 cc in HDPE/HIS bottles at 5° C./75% RH, 40° C./75% RH and 50° C./20% RH to be analyzed at 6 and 12 weeks. The 6 and 12 week purity results are shown in Table 9-1.
TABLE 9-1 Croscarmellose Sodium Starch Stability Condition Pull Point Sodium Glycolate 5° C./75% RH 6 Week 0% 0.3% 12 Week 0% 0.3% 40° C./75% RH 6 Week 0.1% 0.6% 12 Week 0.3% 0.9% 50° C./20% RH 6 Week 0.2% 0.9% 12 Week 0.3% 1.1%
[0130] The degradation of the SSG tablets (0.3 to 1.1%) is greater than was observed for tablets containing CS as the disintegrant. These CS-containing tablets never exceeded 0.3% total degradation when lactose was not present in the tablet at any condition at 6 or 12 weeks.
[0131] For this reason, croscarmellose sodium has been chosen as the more desirable disintegrant for 1-L-tartrate tablets based on the improved chemical stability compared to sodium starch glycolate.
EXAMPLE 10
[0132] Glidant Incorporated to Reduce Cohesivity of Blend
[0133] The impact of adding a glidant, colloidal silicon dioxide in this case, to the tablet formulation was evaluated using a standard powder avalanche test to characterize flow properties. For this evaluation, a placebo binary formulation was used since drug loading is less than 1%. The formulations are listed in Table 10-1. These tablets were prepared by the dry granulation method described in Example 6.
TABLE 10-1 Glidant Content Ingredient 0% 0.5% Microcrystalline cellulose (PH200) 63.42% 62.92% Dicalcium phosphate 33.33% 33.33% Croscarmellose sodium 2.00% 2.00% Silicon dioxide (colloidal) 0.0% 0.50% Magnesium stearate 0.75% 0.75% Magnesium stearate 0.50% 0.50%
[0134] Blend and granulation were sampled immediately before each of the lubrication steps for analysis. The cohesivity, flow variability and particle size were evaluated and the results appear in Table 10-2. Granulation particle size of the two lots was very similar and thus should have had no effect on the powder avalanche results. Cohesivity and flow variability were improved by the presence of silicon dioxide. Its addition reduced cohesivity from ‘low’ to ‘very low’ rating for the blends and from ‘high’ to ‘low’ rating for the granulations. The presence of 0.50% silicon dioxide also reduced the granulation flow variability category from moderate to low.
TABLE 10-2 0.5% Silicon 0% Silicon 0.5% Silicon Dioxide 0% Silicon Dioxide Property Dioxide Blend Granulation Dioxide Blend Granulation Cohesivity (s) 3.9 Very Low 4.5 Low 4.5 Low 6.1 High Cohesivity Cohesivity Cohesivity Cohesivity Flow 40.7 Moderate 31.1 Low Flow 41.0 Moderate 41.1 Moderate Variability Flow Variability Flow Flow Variability Variability Variability D[4, 3] 191.5□um 161.0□um 155.5□um 160.5□um
[0135] During tableting, the ejection force was monitored as a function of compression force. Table 10-3 lists the ejection forces resulting from compression forces in the range of 5-20 kN for the 0 and 0.5% silicon dioxide formulations.
TABLE 10-3 0% 0.5% Ejection Force Ejection Force Compression Force (kN) (N) (N) 6.3 29.56 8.9 27.47 12.2 25.88 14.3 21.08 18.6 21.56 5.7 16.64 9.1 25.40 11.4 22.58 15.0 19.97 18.6 23.56
[0136] The tablets containing 0.50% Cab-O-Sil showed a slightly lower ejection force over most of this compression range. Based on the positive attributes of reduced cohesivity, flow variability and ejection forces, 1-L-tartrate tablets containing a glidant is a more preferred formulation.
EXAMPLE 11
[0137] Film Coating Selection Based on Tablet Stability
[0138] The preferred white film coating for 1-L-tartrate tablets was selected based on chemical stability using accelerated challenge conditions. Four Opadry white film coating systems were applied onto one of the more preferred dry granulated tablet formulations.
[0139] The core tablets were made using a geometric dilution blending scheme prior to roller compacting, and contained the components listed below:
1-L-tartrate 10.62 g Microcrystalline cellulose 744.42 g Dibasic calcium phosphate 399.96 g Croscarmellose sodium 24.00 g Silicon dioxide (colloidal) 6.00 g Magnesium stearate 9.00 g Magnesium stearate 6.00 g
[0140] Two different blends were prepared and referred to as the “excipient pre-blend” and the “active pre-blend”. The “excipient pre-blend” consisted of microcrystalline cellulose, silicon dioxide, and croscarmellose sodium. These ingredients were added to a V-blender and blended for 20 minutes. The “active pre-blend” consisted of drug and one-half of the dicalcium phosphate. The “active pre-blend” ingredients were added to a V-blender and blended for 30 minutes and discharged. One-half of the “excipient pre-blend” was added to a suitably sized V-blender, followed by addition of the entire “active pre-blend” and then blended for 20 minutes. The second part of dicalcium phosphate was added to the empty blender used to mix the “active pre-blend” and blended for 5 minutes. This and the second half of the “excipient pre-blend” were added to the blender containing the active. The mixture was blended for 20 minutes. The first portion of magnesium stearate was added to the mixture and then blended for 5 minutes. The lubricated blend was roller compacted into ribbons using a roll pressure of 30 kg f /cm 2 , a roll speed of 4 rpm and an auger speed of 15 rpm (Vector TF-Mini Roller Compactor). The ribbons were milled through a 20 mesh screen (Vector Rotary Granulator) to produce the granulation. The granulation was blended for 10 minutes. The second portion of magnesium stearate was added to the granulation and blended for 5 minutes. The final blend was compressed into 200 mg tablets using a Kilian T-100 tablet press (Kilian & Co., Inc., Horsham, Pa.) fitted with {fraction (5/16)} inch standard round concave punches.
[0141] The qualitative compositions of the four coating systems are listed in Table 11-1. The coating composition listed as Lot Number A consisted of lactose, hydroxypropyl methylcellulose, or HPMC, titanium dioxide and triacetin. The main differences between the non-lactose coating systems, B through D, were the polymer type (hydroxypropyl methylcellulose, or HPMC, versus polyvinyl alcohol, or PVA) and the plasticizer type (polyethylene glycol, or PEG, and triacetin). The PVA coating also contained talc. The final dosage forms were coated to 4 wt % white coating and 0.5 wt % clear coating. Film coated tablets were placed in 60 cc HDPE/HIS bottles and challenged at 5° C. and 70° C./75% RH for 10 days and then evaluated for purity. Uncoated core tablets were also evaluated for comparison. Placebo tablets were prepared and analyzed for purity for the initial time point as a control. The purity results are shown in Table 11-2.
TABLE 11-1 Coating Lot Number Coating Components A Lactose Monohydrate Hydroxypropyl Methylcellulose Titanium Dioxide Triacetin B Hydroxypropyl Methylcellulose Titanium Dioxide Triacetin C Hydroxypropyl Methylcellulose Titanium Dioxide Polyethylene Glycol D Polyvinyl Alcohol Titanium Dioxide Polyethylene Glycol Talc
[0142] The non-lactose based film-coated tablets containing HPMC (B and C) were found to be more chemically stable than either the lactose/HPMC (A) or PVA (D) film coated tablet. The total degradation of the HPMC lots was found to range from 0.4-1.2% and 0.5-1.0% for PEG and triacetin plasticizer, respectively. Meanwhile, the total degradation for the lactose control and PVA lots were as high as 3.5% and 2.9%, respectively. Based on the improved chemical stability, the preferred film coatings consist of HPMC, titanium dioxide and either triacetin or PEG in Formulation B and C, respectively.
TABLE 11-2 Film Coating Uncoated Identification Placebo Tablet A B C D At 5° C. 0.0* 0.00 0.44 0.41 0.52 0.06 At 70° C./75% RH NA 1.07 3.54 1.29 0.96 2.95
EXAMPLE 12
[0143] Process—Content Uniformity of Dry Granulation
[0144] This example demonstrates the more preferred blending processing to achieve blend and tablet potency and uniformity. V-blending (with and without geometric dilution), bin blending (with and without baffles and with straight vs. angled rotation) and high shear blending were evaluated. The formulation was composed of a binary diluent system of dicalcium phosphate and microcrystalline cellulose, as listed below:
Component % by Weight 1-L-tartrate 0.885 Microcrystalline cellulose (PH200) 62.035 Dicalcium Phosphate dibasic (A-Tab) 33.330 Croscarmellose sodium 2.00 Silicon Dioxide (colloidal) 0.50 Magnesium stearate 0.75 Magnesium stearate 0.50
[0145] V-Blending with Geometric Dilution
[0146] Formulation and process description for core tablet provided in Example 11.
[0147] V-Blending in Single Step
[0148] The mixture (without lubricant) was blended for 30 minutes. The first portion of magnesium stearate was added to the mixture and then blended for 5 minutes. The lubricated blend was roller compacted into ribbons using a roll pressure of 30 kg f /cm 2 , a roll speed of 4 rpm and an auger speed of 15 rpm (Vector TF-Mini Roller Compactor). The ribbons were milled through a 20 mesh screen (Vector Rotary Granulator) to produce the granulation. The granulation was blended for 10 minutes. The second portion of magnesium stearate was added to the granulation and blended for 5 minutes. The final blend was compressed into 200 mg tablets using a Kilian T100 tablet press (Kilian & Co., Inc., Horsham, Pa.) fitted with {fraction (5/16)} inch standard round concave punches.
[0149] Bin Blending
[0150] The ingredients (without lubricant) were added to a bin blender with drug layered in the middle. The blender configuration (with or without baffles, and rotation straight or angled) was set-up. The mixture was blended for 30 minutes, the first portion of lubricant was added and blended for 5 minutes. The lubricated blend was roller compacted into ribbons using a roll pressure of 30 kg f /cm 2 , a roll speed of 4 rpm and an auger speed of 15 rpm (Vector TF-Mini Roller Compactor). The ribbons were milled through a 20 mesh screen (Vector Rotary Granulator) to produce the granulation. The granulation was bin blended for 10 minutes. The second portion of magnesium stearate was added to the granulation and blended for 5 minutes. The final blend was compressed into 200 mg tablets using a Kilian T100 tablet press (Kilian & Co., Inc., Horsham, Pa.) fitted with {fraction (5/16)} inch standard round concave punches.
[0151] High Shear Blending
[0152] The ingredients (without lubricant) were added to a high shear blender with drug layered in the middle. The mixture was blended for 10 minutes with the impeller at 200 rpm and the chopper at 0 rpm. The first portion of lubricant was added and blended for 5 minutes. The lubricated blend was roller compacted into ribbons using a roll pressure of 30 kg f /cm 2 , a roll speed of 4 rpm and an auger speed of 15 rpm (Vector TF-Mini Roller Compactor). The ribbons were milled through a 20 mesh screen (Vector Rotary Granulator) to produce the granulation. The granulation was blended in a V-blender for 10 minutes. The second portion of magnesium stearate was added to the granulation and blended for 5 minutes. The final blend was compressed into 200 mg tablets using a Kilian T100 tablet press (Kilian & Co., Inc., Horsham, Pa.) fitted with {fraction (5/16)} inch standard round concave punches.
[0153] The granulation and tablet potency and uniformity results are listed in Table 12-1. The V-blending in a single step and high shear blending processes resulted in the lowest granulation potency values. The more preferred blending process is blending with geometric dilution and bin blending with any configuration of baffles and rotation based on granulation and tablet potency and uniformity results. The high shear blender operated at low impeller speeds (low-to-moderate shear on this blender) is also a more preferred embodiment of this invention.
TABLE 12-1 Granulation Tablet Blending Process Potency % RSD Potency % RSD V-blending with Geometric 98.3 0.3 98.8 0.8 Dilution V-blending in Single Step 94.5 7.3 103.4 1.2 Bin blending; no baffles, 99.1 1.2 101.7 0.8 straight rotation Bin blending; baffles, straight 100.3 0.7 102.7 1.4 rotation Bin blending; baffles, angled 98.3 1.0 102.1 0.6 rotation High shear blending 91.1 0.4 96.2 2.3
EXAMPLE 13
[0154] Diluent Selection Based on Granulation Content Uniformity
[0155] The preferred diluent used in the “active pre-blend” for the geometric dilution blending process was selected based on granulation and tablet potency and uniformity. Two main diluents (dicalcium phosphate and mannitol) were investigated for their carrier excipient properties to aid in mixing of 1-L-tartrate within the formulation. The ingredients and levels used in the ternary tablet formulation (same composition as Example 7) were blended according to the geometric dilution scheme described in Example 11. The “active pre-blend” utilized either one half of the mannitol (13A) or dicalcium phosphate (13B). In this example, the drug was jet-milled to approximately half the original mean particle size prior to processing with excipients.
Diluent in “Active Pre-Blend” Mannitol Dicalcium Phosphate Ingredient (13A) (13B) 1-L-tartrate (jet milled) 0.86% 0.86% Mannitol 25.95% 25.95% Microcrystalline cellulose (PH200) 33.22% 33.22% Dibasic calcium phosphate (A-Tab) 33.22% 33.22% Coscarmellose sdium 5.00% 5.00% Silicon dioxide (colloidal) 0.50% 0.50% Magnesium stearate 0.75% 0.75% Magnesium stearate 0.50% 0.50%
[0156] For each tablet formulation, two different blends were prepared and referred to as the “excipient pre-blend” and the “active pre-blend”. The “excipient pre-blend” consisted of microcrystalline cellulose, silicon dioxide, croscarmellose sodium, and dicalcium phosphate or mannitol. These ingredients were added to a V-blender and blended for 20 minutes. The “active pre-blend” consisted of drug and approximately one-half of either mannitol (12A) or dicalcium phosphate (12B). The “active pre-blend” ingredients were added to a V-blender and blended for 30 minutes and discharged. One-half of the “excipient pre-blend” was added to a suitably sized V-blender, followed by addition of the entire “active pre-blend” and then blended for 20 minutes. The second part of mannitol or dicalcium phosphate was added to the empty blender used to mix the “active pre-blend” and blended for 5 minutes. This and the second half of the “excipient pre-blend” were added to the blender containing the active. The mixture was blended for 20 minutes. The first portion of magnesium stearate was added to the mixture and then blended for 5 minutes. The lubricated blend was roller compacted into ribbons using a roll pressure of 30 kg f /cm 2 , a roll speed of 4 rpm and an auger speed of 15 rpm (Vector TF-Mini Roller Compactor). The ribbons were milled through a 20 mesh screen (Vector Rotary Granulator) to produce the granulation. The second portion of magnesium stearate was added to the granulation and blended for 5 minutes. The final blend was compressed into 300 mg tablets using a Kilian T-100 tablet press (Kilian & Co., Inc., Horsham, Pa.) fitted with {fraction (11/32)} inch standard round concave punches. The final granulation and tablet potency and variability (in terms of %RSD) results are listed in Table 13-1.
TABLE 13-1 13A 13B Carrier Excipient Mannitol 2080, granular Dibasic Calcium Phosphate, Anhyd. Granulation Potency Overall: 95.9% Overall: 96.3% RSD: 0.2% RSD: 1.0% Tablet Potency Overall: 95.1% Overall: 97.2% RSD: 2.4% RSD: 0.8%
[0157] The granulation potency values are similar for both mannitol and dicalcium phosphate the “active pre-blend” diluent. However, the tablet potency values are increased from 95.1% to 97.2% when dicalcium phosphate replaced mannitol as the “active pre-blend” diluent used in the geometric dilution blending process. Therefore, the more preferred diluent used in the “active pre-blend” of the geometric dilution blending process is dicalcium phosphate.
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The present invention is directed to controlled-release (CR) oral pharmaceutical dosage forms of 5,8,14-triazatetracyclo[10.3.1.0 2,11 .0 4,9 ]-hexadeca-2(11),3,5,7,9-pentaene, 1, and pharmaceutically acceptable salts thereof, and methods of using them to reduce nicotine addiction or aiding in the cessation or lessening of tobacco use while reducing nausea as an adverse effect. The present invention also relates to an immediate-release (IR) low dosage composition having a stable formulation with uniform drug distribution and potency.
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This is a Continuation-In-Part of application Ser. No. 10/639,585 filed Aug. 13, 2003 now abandoned.
FIELD OF THE INVENTION
The present invention relates to therapeutic compositions and in particular compositions including honey or honey derivatives.
BACKGROUND OF THE INVENTION
Honey has been used as a natural remedy and therapeutic aid since ancient times. The anti-microbial properties of honey have long formed part of both folk and scientific knowledge. Applications for honey have included topical application for wounds, ulcers, burns and similar conditions. Honey has also been known to be used as a demulcent for use in the gastrointestinal tract for soothing or allaying irritation of inflamed or abraded surfaces. Therapeutic benefits of honey use are manifested by a reduction in inflammation, swelling and pain; prevention and control of infection in a wound; reduction in malodour and exudate; assisted debriding of wounds and improved granulation and epithelialisation of new tissue. These advantages help promote the rapid healing of a wound with minimal scarring.
Whilst these properties encourage the use of honey as a wound healing agent and provide a moist wound environment, regarded as beneficial to the healing of wounds, use has been mainly restricted to unadulterated honey which has been applied in various forms of wound dressings and treatments. Application of honey directly presents difficulties arising from some inherent properties of the material. Due to its relatively low viscosity and fluid nature, plus natural “stickiness”, honey tends to contaminate the local environment around a treatment region. The disadvantage of direct honey use is accentuated by the fact that honey at body temperature becomes reasonably fluid and migrates from a treatment site to further increase the chance of transfer to unintended areas. Use of honey can be time consuming, messy and impractical.
In using honey, the presence of wound fluid or exudate also dilutes the therapeutic agent exacerbating the problem of diminished contact time with the wound and diminished therapeutic efficacy. Attempts have also been made to address at least some of these problems by combination with other ingredients. Again the outcome has been variable in success rate. It is also recognised that to make clinical use of honey acceptable, it should be sterile (Postmes T, et. al., Experientia. 1995, 51(9-10), 986-9). Many of the antibacterial constituents of honey are sensitive to heat and so traditional pasteurisation techniques are not applicable. It has been demonstrated that the antibacterial activity of honey is not lost upon sterilisation by γ-irradiation (Molan P. C., and Allen K. L., J. Pharm. Pharmacol., 1996, 48, 1206-1209). However, it has been observed that the dosage of γ-irradiation required to effect sterilisation may cause breakdown or undesirable changes in the matrix of honey admixtures known to the art. Accordingly, while the therapeutic properties of honey are recognised and appreciated, there remain problems with the practicality of using honey on wounds.
SUMMARY OF THE INVENTION
In one form, although it need not be the only or indeed the broadest form, the invention resides in a composition comprising: a honey or honey derivative; a surfactant; and at least one topical carrier or vehicle selected from the group consisting of a fatty ester, a wax and wax-like compound; wherein the composition has been subjected to a sterilisation effective dosage of radiation, and wherein the topical carrier or vehicle, when subjected to that dosage, does not substantially modify the properties of the composition present before the sterilisation.
Suitably, the “properties” include but are not limited to rheology, consistency, tactility, and viscosity.
The honey may be a single type of honey or may be a combination of one or more honeys. The one or more honeys may be selected for therapeutic properties which may include anti microbial activities. The honeys may be substantially derived from the flowers of one or more Leptospermum species. In one embodiment, a honey derivative may be used. A honey derivative may be a modified form of honey formed by any one of various processes known to a skilled addressee. The honey derivative may include a modified honey where one or more components have been fully or partially removed. The honey or modified honey may have components added to it or treated in a manner to improve its functionality.
As defined herein, the term “fatty ester” refers to mono-ester of a fatty acid and accordingly excludes oils and fats (triglycerides), which are esters of glycerol (propane-1,2,3-triol).
The term “wax” typically refers to a solid, semi-solid material, and sometimes liquid derived from animal (eg. beeswax and lanolin), plant (eg. palm tree, candelilla, cotton and hemp wax) mineral/fossil/oil (eg. montan wax, rod wax, and microcrystalline wax) or synthetic origin (eg. polyethylene wax, ethylene copolymer wax, carbowax, halogenated hydrocarbon waxes, and synthetic mono esters of fatty acids). It is recognised that jojoba extract is a liquid wax, not an oil (Habashy, R. R., et. al., Pharmacological Research, 2005, 51, 95-105). The waxes listed above, do not necessarily form a chemically homogeneous group. A wax may made up of various substances including: hydrocarbons (normal or branched alkanes and alkenes), ketones, diketones, primary and secondary alcohols, aldehydes, sterol esters, fatty acids, terpenes and monoesters of fatty acids, typically with at least one long, or very long carbon chain (from 12 up to about 38 carbon atoms). In addition to mixtures, waxes may also be comprised of a single chemical compound, for example, a substantially pure ester of fatty acid (a fatty ester).
For the purposes of this specification, the term “wax” typically refers to a composition comprising about 50% or more by volume of fatty esters, wherein said compounds and compositions: (a) have the capacity to produce pastes or gels with suitable solvents or when mixed with other waxes or surfactants; (c) low viscosity at just above the melting point (distinction from resins and plastics); and (d) have a low solubility in solvents for fats at room temperature, and (e) are resistant to moisture.
In some embodiments the topical carrier or vehicle comprises an ester of a fatty acid and fatty alcohol (a fatty ester). Mixtures of fatty esters are naturally occurring constituents of many waxes. Substantially pure fatty esters and may be prepared by synthetic means. An example of a substantially pure fatty ester is myristyl myristate which has a melting point of about 37-39° C.
In some embodiments the topical carrier or vehicle comprises beeswax. Beeswax is comprised variously of n-alkanes, ketones, 1°- and 2°-alcohols and alkenols, ketones, aldehydes, alkenals, β-diketones, esters, alkanoic acids, dicarboxylic acids, alpha and omega-hydroxy acids, terpenes, oxygen-heterocycles and various aromatic compounds. Its main components are palmitate, palmitoleate, hydroxypalmitate and oleate esters of long-chain alcohols (C30-32) (about 70 to 80% of the total weight). Ethyl esters are also present, the most abundant species being ethyl palmitate, ethyl tetracosanoate, and ethyl oleate. Aliphatic hydrocarbons (from 10 to 18% of heptacosane and nonacosane and other species from 17 up to 35 carbon atoms), unsaturated hydrocarbons from 21 up to 35 carbon atoms with one or two double bonds, sterols (up to 2% as cholesterol, lanosterol, b-sitosterol), pheromones (geraniol, farnesol) and terpenoids are also found. The melting point of beeswax is typically in the range of 62-65° C.
In some embodiments the topical carrier or vehicle comprises Chinese wax. Chinese wax (insect wax) is generally secreted by insects ( Coccus ceriferus ) and laid on tree branches. Besides an important content in esters (about 83%), this wax includes some free acids, alcohols (up to 1%) and hydrocarbons (2 to 3%). Chemically, the esters are formed of chains with 46 up to 60 carbon atoms, the majority of alcohols and acids having 26 or 28 carbon atoms.
In some embodiments the topical carrier or vehicle comprises shellac wax also known as lac wax, which is produced by a cochineal insect ( Tachardia lacca ) native of India. It contains a majority of fatty esters (70-82%), free fatty alcohols (8-14%), acids (1-4%) and hydrocarbons (1-6%). The esters are formed of chains of 28 up to 34 carbon atoms.
In some embodiments the topical carrier or vehicle comprises a constituent of whale Spermaceti, which is extracted, for example, by cooling (11% of the initial oil) from adipose tissues and is also collected from a big cavity in the head of a cachalot ( Physeter macrocephalus ) known as a sperm whale. This product contained predominantly fatty esters (65-95%). The fatty esters were formed essentially of cetyl palmitate (C32) and cetyl myristate (C30). Its melting point is 42-50° C. Spermaceti, after the recent international regulation concerning whale capture, is no longer produced and sold. It is now replaced by synthetic spermaceti made of pure cetyl palmitate or mixtures based on jojoba.
In some embodiments the topical carrier or vehicle comprises epicuticular wax. In plants, the outer covering consists of a hydroxy fatty acid polymer called cutin. The underground parts and healed wound surfaces of plants are covered with an analogous substance, suberin. These substances are frequently mixed with other lipids and form a complex mixture called epicuticular wax. Cutins contain C16 and C18 families of acids. The former is more abundant in growing parts, the later is present in the cuticle of slower-growing plants. These acids may be saturated, unsaturated, mono- or di-hydroxylated. In the cutin structure, a polyester structure exists where cross-linking depends on the availability of secondary hydroxyl groups. In contrast, the major carbon chains of suberins are ω-hydroxy acids and dicarboxylic acids, all with very long chains (>20 carbon atoms). Among the least polar components of plant surface lipids hydrocarbons with the odd number carbon chains (C15 up to C33) are predominant. Aliphatic alcohols in the C20-C34 range are also widespread in plant surface lipids.
In some embodiments the topical carrier or vehicle comprises carnauba wax, which is secreted by leaves of a Brasilian palm tree ( Copernicia prunifera cerifera ), about 100 g for one tree in a year. It contains mainly fatty esters (80-85%), free alcohols (10-15%), acids (3-6%) and hydrocarbons (1-3%). Carnauba wax also contains esterified fatty dialcohols (diols, about 20%), hydroxylated fatty acids (about 6%) and cinnamic acid (about 10%). This last phenolic acid compound may be hydroxylated or methoxylated. This wax is the hard and high melting point wax (melting point: 78-85° C.). Ouricouri wax, which resembles camauba wax in its physical properties, was extracted from the ouricouri palm ( Syagrus coronata, Cocos coronata ) by scraping the wax from the leaf surface. Its melting point is 81-84° C.
In some embodiments the topical carrier or vehicle comprises Jojoba liquid wax, which is a polyunsaturated liquid wax very resistant to oxidation (melting point: about 7° C.), and is typically produced by pressing from seeds of the jojoba tree ( Simmondsia chinensis , Euphorbiacae). The wax is formed quite exclusively of alcohols esterified with long-chain fatty acids (more than 98%) with a typical total of 38 to 44 carbon atoms. The fatty acids are commonly 18:1 (about 10%), 20:1 (about 70%) and 22:1 (15-20%) while the fatty alcohols have predominantly 20 and 22 carbon atoms and one double bond. Derivatised forms of jojba liquid wax are also known to the art. (Harry-O'kuru, R. E., et. al., Industrial Crops and Products , received 17 Sep., 2003).
In some embodiments the topical carrier or vehicle comprises Montan wax. This wax is typically derived by solvent extraction of lignite or brown coal (sub-bituminous coal) and is a fossilised plant wax and accordingly has many characteristics of vegetal waxes. Typically, Montan wax is a mixture of long chain (C24-C30) esters (62-68 wt %), long-chain acids (22-26 wt %), and long chain alcohols, ketones, and hydrocarbons (7-15 wt %). Montan wax is hard and is one of the most resistant to oxidation.
In addition to the above-mentioned naturally occurring waxes, synthetic wax can be prepared by the reaction of a fatty acid with an alcohol to form a mono-ester of a fatty acid (a fatty ester as defined above). Typically the alcohol is a fatty alcohol. It is established that increasing the carbon chain length of a fatty ester by a carbon atom, has the effect of raising the melting temperature of the wax by 1-2° C. per carbon atom added. Additionally, it is known that symmetric wax esters (ie., whose alcohol and ester components have different chain lengths) typically have a higher melting point than their unsymmetrical counterparts of the same molecular weight. Further, the presence of an ester linkage in a hydrocarbon chain decreases the melting point by approximately 15° C. relative to hydrocarbons containing the same number of carbon atoms, as does the introduction of a methyl function. Similarly, introduction of a degree of unsaturation to the hydrocarbon chain will typically significantly decrease the melting point, with the introduction of a second degree of saturation further reducing the melting point, but not to the extent that the first degree of saturation. It has also been noted that more internally located double bonds and methyl groups tend to decrease the melting point of wax esters more than those same structural changes near the end of hydrocarbon chains. It has been proposed that these changes to the physical properties of wax esters may result from the disruption of lipid packing due to kinks formed in the hydrocarbon chains (Patel, S., et. al., Journal of Insect Science, 2001, 1.4, 7 pp).
Both the fatty acid moiety and the alcohol moiety may be substituted to impart desirable physico-chemical properties to the resulting ester. Mono-esters of fatty acids are described by formula II:
wherein:
R 1 is selected from a C 7-50 optionally substituted alkyl or alkenyl chain; and
R 2 is selected from an optionally substituted primary or secondary, optionally substituted alkyl or alkenyl chain, with the proviso that the total number of carbon atoms in the molecule is in excess of 11.
As defined herein “optionally substituted” refers to substitution by hydroxyl and/or methyl functional groups.
Also encompassed within the scope of the present invention are wax-like compounds which satisfy the property requirements of wax, whilst not chemically satisfying the compositional requirements of “wax” as defined above.
For example, “wax-like” materials from mineral oils may be derived from petroleum distillates or residues by treatments such as chilling, precipitating with a solvent, or de-oiling. The mineral wax ozocerite typically consists of hydrocarbons (C20-C32) and its melting point is about 90° C.
Another illustrative example of a wax-like compound is candelilla wax which is produced by small shrubs from Mexico, Euphorbia cerifera and E. antisyphilitica (Euphorbiaceae). The wax is extracted by boiling the plant (to separate the wax and the plant material). The wax floats to the top of the water and is skimmed off and processed. It contains hydrocarbons (about 50% of C29 to C33), esters (28-29%), alcohols, free fatty acids (7-9%), and resins (12-14% triterpenoid esters). Its melting point is 67-79° C. Candelilla has been used mainly mixed with other waxes to harden them without raising the melting point. This wax may be used to improve stability and texture as a substitute to beeswax (melting point: 66-71° C.).
In another example, the wax-like compound is Japan wax, which is a vegetable tallow found in the kernel and outer skin of the berries of Rhus and Toxicodendron species, including those yielding Japanese lacquer. It contains a high amount of palmitic acid triglycerides (93-97%), long chain dicarboxylic acids including C22 and C23 chains (4-5.5%) and free alcohols (12-1.6%). Its melting point is 45-53° C.
In yet another example, rice bran from the milling of rice, Oryza sativa , contains a “wax-like” material mixed with triglycerides which is known as rice bran oil. The melting point of the wax-like component is 75-80° C. The wax contains esters of fatty acids (26 to 30 carbon atoms) and long-chain alcohols (C26 to C30) and a large amount of unsaponifiable matter (55-67%).
It should be noted that the present invention is not dependent on any particular fatty esters, waxes or wax-like compounds and extends to any and all fatty esters, waxes or wax-like compounds with the desired properties irrespective of source. Particularly preferred fatty esters, waxes or wax-like compounds have a melting point in the range of about 37-45° C. and are stable to a sterilisation effective dose of radiation, especially γ-radiation.
As has been described, a wax composition is often composed of a plurality of constituents. It is also the case that a wax composition may be comprised or more volatile and less volatile components at room temperature. Indeed, it is evident that a combination of different waxes, wax-like compounds and fatty esters, each with different chemical properties, could provide a wax composition with sought after physical properties. Further, it is anticipated that it may be desirable to combine a range of waxes, wax-like compounds, and fatty esters with other components such as fatty alcohols, in order to provide “synthetic waxes” with certain desired properties.
For example, fatty esters such as myristyl myristate, cetyl myristate, or cetyl palmitate, and other waxes useful in the present invention may be formulated with each other, or with other chemical compounds such as volatile fatty acid mono-esters, fatty alcohols, liquid waxes (jojoba), hydrocarbons and the like, in order to modify the melting point, hardness, color, consistency, tactility, rheology, emollience, viscosity or bonding strength of the wax. By way of further example, fatty esters such as cetyl palmitate or cetyl myristate, which have a melting points in the range of about 43-53° C. and about 54-56° C. respectively, may be formulated with for example, jojoba liquid or lauryl laurate wax which have melting points of about 10° C. and about 24° C. respectively, in order to reduce the melting point of the final wax composition to the preferred range of about 37-45° C. Alternatively a fatty ester, such as cetyl palmitate, may be formulated with ethyl palmitate and myristyl alcohol to provide similarly, a formulation with the desired physico-chemical properties. In another embodiment, ethyl palmitate, which has a melting point of about 24-26° C., may be formulated with jojoba liquid wax and stearyl stearate in order to provide a wax composition with the desired physico-chemical properties. It is anticipated that certain esters, such as for example cetyl palmitate and cetostearyl stearate which are solid at room temperature, may be used to increase the viscosity of emulsions, whereas liquid branched chain esters, such as isopropyl myristate or cetostearyl ethylhexanoate, provide products with good spreading properties.
As noted above, both naturally occurring and synthetic waxes have a range of melting points. For example, beeswax melts at about 62-62° C., cetyl myristate melts at about 54-56° C., cetyl palmitate melts at about 43-53° C., ethyl palmitate (a constituent of beeswax) at about 24-26° C., and Carnauba wax at about 81-84° C. Of additional significance to the melting point, for the practice of the present invention, is the “set-point” of a wax. It is recognised that the melting point of a wax, and the point at which the wax resets, the “set-point” may be different. An intermediary transition phase, upon which the wax begins to become opaque but at which stage it is still mobile, is known as the “cloud point”. It is evident that by combining fatty esters, waxes and wax-like compositions, or other compounds with desired properties such as fatty alcohols, that a wax composition with a desirable set-point can thereto be derived, which would be within the skill of a person skilled in the art. In some embodiments, the set-point of a synthetic wax so derived, will be below about 45° C., with the melting point of the wax in excess of about 37° C.
The wax compositions of the present invention may comprise fatty esters such as myristyl myristate, dodecyl hexadecanoate (lauryl palmitate), cetyl palmitate, cetyl myristate, lauryl laurate, stearyl palmitate, stearyl behenate, stearyl stearate, ethyl palmitate, ethyl tetracosanoate, ethyl oleate, cetyl palmitoleate, cetyl laurate, cetyl oleate, jojoba liquid wax, and may further comprise fatty alcohols such as lauryl alcohol, myristyl alcohol, cetyl alcohol, stearyl alcohol, oleyl alcohol, linoleyl alcohol, isostearyl alcohol, palmitoleayl alcohol, with the proviso that the fatty alcohol content does not exceed 50% of the composition by volume.
In other embodiments, the compositions may contain compounds formulated in a manner to have a similar functionality as honey, yet contain little or no honey. In the International Honey Industry, a honey derivative is often applied to a product that is totally or substantially artificial honey and is sold as a honey substitute. These substances are known to a person skilled in the art.
Combinations of honey may include at least one honey with peroxide associated antibacterial activity and at least one other honey with non peroxide associated antibacterial activity. The honey or honeys may be selected on the basis of natural sugar levels to regulate natural crystal formation. The honeys may also be selected on the levels of physiologically active compounds including but not limited to flavonoids, alkaloids, growth regulators and compounds that cause stimulation of TNF-alpha release.
In certain embodiments, the honey or honeys constitute about 50% of the composition. Preferably the honey is present in the range of about 70-90% of the composition and most preferably is present in a concentration at or around about 80% of the composition. The percentage compositions in this specification are calculated on percentage weight/weight (% wt/wt).
Suitably, the wax or wax like material has a set-point of about 45° C. or less. Preferably, fatty ester, wax or wax-like compound has a narrow set-point range about 40° C. In some embodiments the wax may be a fatty ester or fatty alcohol. In specific embodiments, the wax is myristyl myristate, an illustrative example of which is Crodamol MM.
The fatty ester, wax or wax-like compound may be present in the range of 1-50% of the composition. Suitably, the fatty ester or wax or wax-like compound is present in the range of 10-30%. In a preferred embodiment the fatty ester, wax or wax-like compound is present at or about 15% of the ointment.
The surfactant may be a low irritant, mild non ionic surfactant. The surfactant may be ethoxylated oil, such as preferably ethoxylated sweet almond oil. The surfactant may alternatively comprise or include ethoxylated caster oil or ethoxylated evening primrose oil. The surfactant may be Crovol A70. The surfactant may be present in the range of 2-10%. Preferably the surfactant is present in the range of 2-7%. Most preferably the surfactant is present at or around 5% of the composition.
By “about” is meant quantity, level, value or amount that varies by as much as 30%, preferably as much as 20%, more preferably as much as 10% and even more preferably by as much as 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2% or 1% to a reference quantity, level value, or amount.
The articles “a” and “an” are used herein to refer to one or to more than one (i.e. to at least one) of the grammatical object of the article. By way of example, “a compound” means one compound or more than one compound.
In a further aspect the invention resides in a method of producing a therapeutic honey ointment, the method comprising the steps of:
heating honey to a temperature which is below a temperature that will cause degradation, complete or partial, of one or more functional enzymes in honey; combining the at least one topical carrier or vehicle and a surfactant by heating and mixing; cooling the mixture of at least one topical carrier or vehicle and surfactant until the mixture has a temperature similar to the temperature of the honey; and combining the honey with the carrier or vehicle and surfactant.
The “at least one topical carrier or vehicle” in this context includes fatty esters, waxes and wax-like compounds.
The one or more functional enzymes in honey may be glucose oxidase. The maximum temperature of the heated honey may be about 45° C.
The carrier or vehicle and surfactant mixture may be heated to a temperature range in which the wax is in a liquid phase.
The carrier or vehicle and surfactant mixture may be mixed through the honey with high shear mixing until homogeneous, preferably avoiding overheating of the mixture.
The method may include the step of sterilising the ointment. The ointment can be sterilised by applying one or more doses of gamma irradiation. The gamma irradiation may be provided at levels between 25-35 kGy.
The expression “ointment” in this specification may be understood to extend to any suitable physical state including, but not restricted to a gel, a paste, a cream, a lotion, a balm and a salve.
The method may further include the step of impregnating a bandage or dressing with the ointment for use on a subject.
The method may further include the step of packaging the ointment for distribution.
In a further aspect the invention extends to a method of treating a subject by applying one or more doses of an ointment made according to the above method or comprising the above described ingredients.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to an easy to use, effective and stable honey based composition preferably presented as an ointment. The ointment may be formed from a combination of honey or honey derivative, a surfactant and a wax or wax-like component or fatty ester.
The honey component of the ointment may include a combination of one or more honeys selected for their therapeutic properties. The honeys may be derived from the Australian or New Zealand Leptospermum species. The honeys may include a combination of two or more honeys selected for differing but preferably complementary physiological/therapeutic action including those with peroxide and non peroxide antibacterial activity. This combination may ensure a broad spectrum of antibacterial activity. There are many known types of honey. Illustrative examples are described in publications such as Honey and Pollen Flora , Clemson A, INKATA PRESS Pty Ltd, Melbourne, 1985 and similar reference works. Honeys may be selected on the basis of the presence of flavonoids which may act as an anti-oxidant resulting in inflammation reduction. Honeys may also be selected for the presence of growth factors which can assist with granulation, epithelialisation and the growth of new tissue to ensure a progressive and satisfactory healing process. The honeys may also be selected on the presence or levels of physiologically active compounds including but not limited to flavonoids, alkaloids, growth regulators and compounds that cause stimulation of TNF-alpha release.
The surfactant is preferably a low irritant, mild chemical. Preferably the surfactant is non ionic as, in general, this class of compounds is milder than ionic surfactants. A preferred surfactant is an ethoxylated triglyceride and in particular sweet almond oil or a derivative thereof. Alternatively it is possible to substitute ethoxylated castor oil or ethoxylated evening primrose oil, preferably in non ionic form.
An example of a commercially available product is CROVOL A70 which is derived from sweet almond oil in an ethoxylated form. The international nomenclature for cosmetic ingredients has allotted the name of PEG-60 almond glycerides to CROVOL A70. This product is a long chain ethoxylate and has been shown to have a very low tendency to irritation. CROVOL A70 has a chemical description as ethoxylated (70% by weight) sweet almond oil (CAS 124046-50-0) and may be obtained from Croda Australia, Villawood, Sydney.
An additional ingredient is at least one topical vehicle or carrier selected from the group consisting of a fatty ester, wax or wax-like compound. Preferably the fatty ester or wax has a melting point above about 37° C. and a set-point below about 45° C. The preferred melting point is selected so that the ointment is substantially non-running at the body temperature of a patient which is usually around 37° C. in a person but may be higher in domestic animals. In general however, the invention is suitable for both veterinary and human use. One means of assessing whether the ointment is non-running is to place a sample on a slope, preferably at 45°, and demonstrate that the sample does not freely flow down the incline at 25° C.
A preferred wax is Myristyl Myristate (CAS 3234-85-3). This is a wax with a low melting point, usually in the range of about 37-43° C. It has good skin softening and lubricating properties. Alternative ingredients may include any mixture of fatty esters, fatty alcohols and other hydrocarbons, that satisfies the condition of having a melting point above about 37° C. and a set-point below about 45° C. This temperature is above normal body temperature but it is also below the denaturing temperature of functional enzymes in honey which is generally accepted to be around 45° C. Most fatty esters have long hydro-carbon chains that are very stable. The ester group of the molecule also provides a stable and non-reactive aspect to the compound, making it safe to use for this application.
An example of a commercially available source of Myristyl Myristate is Crodamol MM which is available from Croda Australia, Villawood, Sydney.
In a preferred method of manufacture, honey is heated to a temperature that will not degrade the functional enzymes, such as glucose oxidase, which occur in honey. Preferably this temperature is about 45° C. Separately, the wax and surfactant are heated while being mixed until both are fully melted. The wax/surfactant mixture is allowed to cool to the temperature of the honey at which time it is added to the honey with high shear mixing until homogenous. The mixing period may be relatively brief. It is preferred to avoid heating honey above the upper identified temperature as such a process may lead to degradation of functional enzymes with resulting diminution of therapeutic effect.
The mixed ointment may then be allowed to cool and be packaged for distribution.
Preferably the ointment is also sterilised particularly to remove or reduce Clostridium sp spores and to provide an associated reduction in bioburden levels. The preferred method of sterilisation is through the use of gamma irradiation, preferably at levels between 25-35 kGy. One of the benefits of the present ointment is that it remains substantially stable and homogenous after irradiation at these levels. The current formulation may be described as a fine wax dispersion in a honey matrix. Without wishing to be tied to any one theory, it appears the surfactant acts to keep the wax particles small and enables them to be suspended and dispersed throughout the honey. It has been found that some emulsifiers including lanolin are prone to denaturing or breakdown under irradiation making them unsuitable for use in the present composition.
In one embodiment, the ointment is formulated according to the following proportions:
Ingredient
Range (% wt/wt)
Honey or honey derivative
50-97%
Myristyl Myristate
1-50%
Ethoxylated sweet almond oil
2-15%
Preferably honey is present in the range of about 75-84%. Myristyl Myristate may be the range of about 15-20% and ethoxylated sweet almond oil may be present in the range of about 1-7%.
In certain embodiments, the composition comprises about 80% honey, about 15% Myristyl Myristate and about 5% ethoxylated sweet almond oil.
It is envisaged that the present ointment may also be used for cosmetic rather than therapeutic purposes. In this case, selection of honeys with therapeutic characteristics is not essential. Honeys may be selected for cosmetic benefits such as providing a general moisturising action. Clearly, honeys may also be selected for the treatment of essentially aesthetic problems such as comedones or pimples. Selected honeys in these cases may be bacteriostatic.
Once produced, the ointment may be packaged and distributed in any suitable fashion. It may be dispensed into tubes. Alternatively it may be formed as part of a wound dressing by impregnation into a wound dressing material. The ointment may be packed into individual screw top containers or it may be delivered in sealed capsules or sachets for single use dispensing and treatment.
The ointment of the present invention may be applied in a wide range of situations and as already noted may be used in both human and veterinary medicine, as well as for human cosmetics. In its simplest form, the ointment may be applied topically to a lesion. The frequency of application may be varied to reflect the severity of the condition and the efficacy of the treatment. It is envisaged that an application rate of up to two to three times daily may be of benefit in some circumstances while application every 2-14 days may be suitable in other circumstances where the contact time is prolonged. The ointment is preferably of suitable viscosity that it may be dispensed or molded or pressed into shape using finger pressure to adopt a configuration suitable for a lesion. That shape may be retained while the ointment is fixed in position by a support bandage or similar.
The ointment may be beneficially utilised in post surgical wounds, sinus wounds, fistulae, burns, donor sites, infected wounds, pressure ulcers, venous ulcers, diabetic ulcers, trauma injuries, catheter exit sites, dental extraction sockets, fungating/malignant wounds, lesions, ophthalmology and surgical procedures. This list is not comprehensive. Viscosity may be selected so that the ointment is suitable for filling wound cavities. Some advantages of the composition will be demonstrated in the following non-limiting Examples.
EXAMPLE 1
Honey ointment according to the present invention was used to treat burns in paediatric patients. The ointment demonstrated an ability to deslough the wound, reduce the bacterial load and assist healing. One child had a deep partial thickness burn to the scalp that had become infected and a hard crusty eschar had formed over the wound. The honey ointment desloughed the wound, cleared the infection and the wound healed without the need for surgical debridement within five days. Another case involved a deep partial thickness burn on a child, that had become infected with bacteria that were resistant to other topical antibacterial products and oral antibiotics. After application of the honey ointment to the burn, the bacterial load was reduced within five days, allowing for successful skin grafting. The honey ointment was easy to apply to gauze dressings, which were then applied to the wounds. The honey ointment washed off easily in a shower. Dressings were changed daily over the period of treatment.
EXAMPLE 2
The honey ointment was tested in a microbiological laboratory against various bacterial organisms, including Pseudomonas sp isolated from wounds and resistant to antibiotics and other antibacterial products including silver sulfadiazine and povidone-iodine. The honey ointment proved very effective against all tested organisms.
EXAMPLE 3
Malodour associated with fungating tumours was reduced with the use of the honey ointment. The honey ointment was applied directly to a melolin dressing which was then applied to a fungating tumour external to the mouth cavity, which had become malodorous. Malodour was reduced within two days. The honey ointment was easy to apply and stayed in place on the wound.
EXAMPLE 4
Leg ulcers and skin tears are well suited to application of the honey ointment. One male patient with poor circulation and a difficult-to-heal leg ulcer infected with Pseudomonas sp and Staphylococcus sp was treated with honey ointment of the present invention. He had previously been on antibiotics, but as these had not helped clear the infection, he was taken off his oral antibiotics and the honey ointment was used. The honey ointment was applied directly to the wound then covered with either plain gauze or paraffin-impregnated gauze. The dressings were changed daily initially then when the wound was clean, dressings were changed every second day. The honey ointment cleared the infection and the wound was rendered clean and healing. Another male patient had a skin tear that was progressing towards an ulcerous condition and was treated with the honey ointment as described above. The wound healed within two weeks. Other ulcers and skin tears have also been treated successfully with the honey ointment.
EXAMPLE 5
A sacral area ulcer and an infected stump wound resulting from surgery were healed with the use of the honey ointment applied to a dry dressing (Combine™).
EXAMPLE 6
The honey ointment was applied directly to a partial amputation of the foot using a sterile tongue depressor and covered with a dry dressing (Combine™). The wound had been treated with pure honey but the patient had been complaining of leakage from the dressing. The treatment was changed to daily honey ointment dressings and the patient had no further complaints. Healing of the wound was subsequently uneventful.
A small and deep arterial leg ulcer infected with Methicillin-resistant Staphylococcus aureus (MRSA) was healed with the use of the honey ointment. Daily dressings of the honey ointment applied to a dry dressing (Combine™) helped clear the infection and heal the wound.
As a result of prior-wound management, a sacral wound on a patient had macerated edges and no granulation at the base of wound. A zinc-based cream was applied around the edges of the wound and the honey ointment was applied to the wound and covered with dry dressings (Combine™) and paraffin-based dressing (Adaptic™) and followed by a film dressing (Opsite™). Dressings were changed daily. Improved granulation of the wound bed was observed, the wound edges improved and the wound size decreased until the patient was sent to another clinical site.
EXAMPLE 7
The honey ointment has also been used to help reduce caesarean section scars. The honey ointment was applied directly to the week-old scar with no dressings required.
EXAMPLE 8
Diabetic wounds have also healed with the use of the honey ointment. The honey ointment was found to be easier to apply to these wounds than pure honey and the healing response was the same as or better than pure honey dressings.
The present ointment may be applied to mucous membranes and may be dispensed into bodily cavities for the treatment of mucous membranes. The ointment may be ingested for beneficial results in some circumstances. The composition of the ointment may be such that at body temperature, compared to room or storage temperature, it will soften and conform to a wound and surface to which it is applied and will remain in place for temperatures up to 37° and preferably up to 40°.
The present invention provides real benefits in the therapeutic use of honey. The use of 100% honey is, as noted above, somewhat problematic. Additionally the use of honey in known methods can be quite irritating particularly to sensitive wounds. The present invention incorporates ingredients which may be of natural origin and which do not have marked side effects such as may arise with mineral based products. The viscosity of the invention is such that it can be easily applied to a wide range of wounds some of which are painful to touch. As the surfactant can be a water soluble, vegetable derived emollient, the ointment can be easily washed off the body and can be irrigated out of body cavities. This advantage is of considerable significance as it provides easy clean-up of both patient and surrounding environments.
Manufacture of the ointment as described provides a product which can slowly dissolve over time in body fluid rather than be subject to immediate dilution and displacement by wound exudate. Additionally the ointment may be suitable for internal use and for effective gamma irradiation sterilisation. The nature of the product makes it practical for bulk manufacture and relatively easy dispensing into packages and containers.
The ingredients of the combination are known to be stable, inert, non irritating and safe to use in therapeutic applications. Further the composition is such that a stable and homogenous mix of ingredients is achieved within the manufacturing temperature restrictions. The present invention reduces the problems associated with raw honey used in the treatment of wounds which may cause stinging and sometimes painful sensations when applied to the wounds of patients. The ointment may be used for cosmetic purposes.
The honey ointment is preferably formulated with natural waxes and oils to provide a high viscosity gel that is easy to apply with good wash off characteristics when dressings are changed.
The honey ointment can be applied either directly to the wound or to the dressing. A thin absorbent dressing with a non/low adhering surface can be used to cover the honey ointment with additional absorbent secondary dressings applied as required.
The frequency of dressing changes required will depend on how rapidly the honey ointment is being diluted by exudate. Daily dressing changes are usual during the initial stages of wound healing. More frequent changes may be needed if the honey ointment is being diluted by a heavily exudating wound. When exudation is reduced, dressing changes can be less regular (2 to 3 days).
The honey present in the honey ointment will be gradually diluted by exudate and absorbed by the dressing. Waxes contained in the honey ointment will remain leaving a protective layer. These waxes can be washed away at each dressing change by rinsing with normal saline or similar products.
The honey ointment provides natural debridement of the wound through autolysis so the wound may appear deeper after the initial dressing changes. The debriding action may also be due to the strong osmotic potential of the honey.
It is within the scope of the invention to add other ingredients known to a skilled addressee for various additional characteristics.
Throughout the specification the aim has been to describe the preferred embodiments of the invention without limiting the invention to any one embodiment or specific collection of features. Those of skill in the art will therefore appreciate that, in light of the instant disclosure, various modifications and changes can be made in the particular embodiments exemplified without departing from the scope of the present invention. All such modifications and changes are intended to be included within the scope of the disclosure.
Throughout this specification, unless the context requires otherwise, the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element or integer or group of elements or integers but not the exclusion of any other element or integer or group of elements or integers.
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A therapeutic composition is described comprising honey or a honey derivative, a surfactant, and at least one topical carrier or vehicle selected from the group consisting of a fatty ester, a wax and a wax-like compound; wherein the composition has been subjected to a sterilization effective dosage of radiation, and wherein the topical carrier or vehicle, when subjected to that dosage, does not substantially modify the properties of the composition present before the sterilization.
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BACKGROUND OF THE INVENTION
This invention relates to a dispenser for drawing toothpaste from a squeeze-tube container and applying it to the top of a toothbrush with a vacuum pump of piston-cylinder construction, more particularly to a toothpaste dispenser with a vacuum pump of piston-cylinder construction whose discharge capacity can be adjustably predetermined.
The applicant is aware of the prior art proposed in Japanese Patent No. 50-3950 published in 1975 which discloses a dispenser for thick liquid material comprising a vacuum pump of piston-cylinder construction, a lever mechanism hinged to the piston thereof, a passageway for thick liquid material formed therein with the discharge port formed vertically downward, an inlet valve of ball type operating in direct contact with the end surface of the neck portion of the container, and an outlet valve formed integrally with the cylinder body.
Such a prior proposed dispenser may suffer from serveral disadvantages such as, for example, a rather imperfect sealing of the inlet valve because of the direct contact of the valve member with the end surface of the neck portion of the container of thick liquid material which by its nature is not intended to perform a valve function and the end surface of the neck portion may not be smooth enough to achieve the purpose of sealing when the valve is closed. Another disadvantage is that a rather incomplete construction of a piston-cylinder combination is formed which may lead to the leakage of the thick liquid material. A further disadvantage is an improperly arranged, vertically downward discharge port which tends to leave residuals of thick liquid material after the use of the dispenser. The leaks and residuals of thick liquid material not only waste the material but leaves the area around the apparatus messy, thus increasing the need for frequent cleaning.
SUMMARY OF THE INVENTION
In view of the aforesaid disadvantages or problems, the present invention discloses an improved toothpaste dispenser comprising a vacuum pump of piston-cylinder type with the piston provided with an elastic sealing sleeve, a mounting base formed with a passage in which an inlet valve of leaf type is provided to operate in cooperation with an elastic adapter for mounting and sealing the neck portion of the squeeze-tube container of toothpaste, an actuator connected to the end of the piston rod, and a supply amount adjusting bracket. The cylinder is formed with a discharge chamber in which an outlet valve is provided to operate in cooperation with the outlet port formed in the cylinder, and a cylinder chamber in which the piston is slidably inserted. An elastic discharge nozzle is provided at the end of discharge chamber and fastened with a sleeve nut.
The toothpaste is drawn into the cylinder chamber through an inlet valve, and discharged through an outlet valve, discharge chamber and the discharge nozzle that are arranged horizontally in line with the axis of the cylinder. The actuater connected to the piston rod is urged by a coil spring and normally kept in position at the end of a discharge stroke. The drawing, or suction, of the toothpaste is performed when the toothbrush is inserted through the opening in the front side of the mounting base to push the actuator inward, and the discharge of toothpaste is performed when the toothbrush is withdrawn and the actuator is pushed back outwardly by the spring. The stroke of the actuator can be adjustably predetermined by properly setting the supply amount adjusting bracket provided in the vicinity of the end of the inward stroke of the actuator so that the amount of toothpaste to be discharged each time can be adjusted as desired beforehand.
The main object of this invention is to provide an improved toothpaste dispenser which can supply a fixed amount of toothpaste to the toothbrush by a simple operation of pushing in and taking out the toothbrush.
Another object of this invention is to provide an improved toothpaste dispenser which cuts wastage from leaks, residuals or dripping.
Still another object of this invention is to provide an improved toothpaste dispenser with which the amount of toothpaste supplied each time can be adjustably predetermined.
DETAILED DESCRIPTION OF THE INVENTION
In order that this invention may be more readily understood, and so that the further features thereof may be appreciated, a particular embodiment of the toothpaste dispenser according to the invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a partial cut-away, perspective, sectional view of the toothpaste dispenser in accordance with the invention.
FIG. 2 is an oblique, exploded view of the major components of the toothpaste dispenser in accordance with the invention.
FIG. 3 is a longitudinal, sectional view of the toothpaste dispenser, showing the passage of toothpaste and the valves with the piston nearly at the end of the drawing or suction stroke.
FIG. 4 is a longitudinal, sectional view of the toothpaste dispenser, showing the passage of toothpaste and values with the piston nearly at the end of pumping or discharge stroke.
FIG. 5 is an enlarged, oblique view of the toothpaste supply amount adjusting bracket in accordance with the invention.
Referring now to the drawings, mounting base (100) is made of molded plastic, having a mounting plate (101) integrally formed therewith, a cylindrical upper boss (102) integrally formed with its axis vertically on the top side near the front end of said mounting plate (101), a base body (103) integrally formed on the bottom side near the front end of said mounting plate (101), said base body (103) being formed with a horizontal hole (104) whose front portion (105) has a larger diameter than that of the rear portion (106). The cylindrical upper boss (102) is formed with screw threads (108) on the outer peripheral surface and is also formed with a cylindrical cavity towards the bottom thereof, a cylindrical recess (109) at the bottom and another cylindrical recess (110) at the further bottom thereof. Between the front portion (105) of the horizontal hole (104) and the hollow portion of said recess (110) a passage (107) is formed; the axis of said passage is off the axis of said recesses (109), (110) and said cylindrical upper boss so that the inlet valve (200) having a lower tube portion (202) of eccentric center axis can be placed in position without rotational movement. Said mounting base (100) is further formed with lower case (180) as an integral part thereof, said lower case (180) being connected integrally to the front side of said base body (103) and having a front opening (181) formed on the front side thereof below the front side of said base body (103).
The adapter (120) is made of elastic material such as rubber in a cylinderical shape with the outer diameter approximately the same as the inner diameter of said cylindrical upper boss (102). Said adapter (120) is formed with a flange (123) protruding radially and outwardly on the top thereof, and a cylindrical flange (122) protruding axially, upwardly and slightly inwardly at the periphery of the upper end of the hollow portion of the diameter approximately the same as the outer diameter of the neck portion (11) of the squeeze-tube container (10) of the toothpaste. The bottom portion of said adapter (120) is formed with an inlet port (121) of diameter smaller than that of the hollow portion above. Said adapter (120) is inserted in said cylindrical upper boss (102) with the neck portion (11) of the squeeze-tube container (10) invertedly inserted in the hollow portion of said adapter (120) and is fastened tightly with a sleeve nut (150) to said cylindrical upper boss (102). The flanges (122), (123) are thus pressed to form an airtight joint, and the end surface (13) of the neck portion (11) of the squeeze-tube container (10) is pressed against the bottom of the adapter to form another airtight joint.
The inlet valve (200), as shown in FIG. 2, is made of molded plastic, comprising a valve leaf (201), a cylindrical valve body and a lower tube portion (202) formed integrally in one unit, said valve leaf (201) being molded at the periphery of said cylindrical valve body and being capable of swinging with resiliency with respect to the molded connection thereof, said lower tube portion (202) being formed with its own axis off the axis of said cylindrical valve body so that said inlet valve (200) is placed in the aforesaid recesses (109) and (110) and said lower tube portion (202) is inserted in said passage (107) correspondingly. Said inlet valve (200) is so arranged, that said valve leaf (201) comes in contact with the bottom surface of said adapter to close said inlet port (121) when it swings up, and open when it swings down so as to allow flow of the toothpaste in only the direction from the container to the cylinder. Furthermore, as said inlet valve (200) is put in place with its eccentric low tube portion (200) inserted in the passage (107), undesirable rotational movement is prevented positively.
The cylinder (300) is made of molded plastic, having the head portion (301) formed with screw threads on the outer peripheral surface thereof, the mid portion (302) with an outer diameter slightly larger than that of the cylinder body portion (303), said mid portion (302) being formed with a hole (304) in the upper wall. Said cylinder is inserted into the horizontal hole (104) in such a manner that said mid portion (302) fits the front portion (105) and said cylinder body portion (303) fits the rear portion of said horizontal hole (104) correspondingly, such that said head portion (301) protrudes outwardly from the front surface of the base body (103). The low tube portion (202) of said inlet valve (200) is so arranged to further extend into said hole (304) of said cylinder (300) and thus said cylinder (300) is positively positioned.
The outlet valve (400) is made of molded plastic, having a valve disc member (401), a resilient support member (403) formed in helical shape and a supporting ring (402) molded integrally in one unit, said resilient support member (403) being capable of compression when forced and expansion when the force is removed in axial direction. The outlet valve (400) is disposed in the discharge chamber (307) so that the valve disc member (401) is normally urged by the resilient support member (403) to close the outlet port (306) formed in the cylinder (300) and is allowed to move axially to open said outlet port (306) when forced by the outgoing toothpaste.
The discharge nozzle (500) is made of elastic material such as rubber in such a shape as shown in FIG. 2. The discharge nozzle is formed with a discharge port (501) of slit type which is normally closed by its own resiliency. When pressure is applied from within to expand the nozzle (500), the discharge port (501) opens, and when the pressure is removed as in the drawing or suction stroke, the discharge port (501) closes again by its own resiliency. The discharge nozzle is mounted at the front end of the cylinder (300) with a sleeve nut (570).
The piston (350) is made of molded plastic, having an elastic sleeve (352) securely mounted around the surface of the piston portion, said sleeve (352) being formed on the surface with a plurality of V shaped projections in ring shaped construction around the axis thereof. In the particular embodiment three projections a, b and c are formed as shown in FIG. 3, said projections being provided to seal the passage between the piston and cylinder to assure the perfect functioning of the drawing and discharge operations.
The piston (350) is so arranged that it is slidably inserted into the cylinder (300) with the end of piston rod portion protruding towards the rear end of the cylinder, the end of the piston rod portion being provided with a connection neck portion (353) where the extension portion (601) provided at the rear portion of an actuator (600) to be described below is connected.
The actuator (600) is made of molded plastic or sheet metal in a semi-cylindrical shape, having the bottom portion (603) extending toward the front side to form the toothbrush holder (604), and a stopper (605) formed to receive the round end (22) of the tooth brush (20). The actuator (600) is disposed underneath the base body (103) with the rear portion connected to the rear end of the piston rod portion of the piston (350) as described above, and is guided by the side and bottom panels of the lower case (180) so that it is capable of moving forward and backward in the lower case (180). A coil spring (610) is provided in the hollow portion of said actuator (600) with one end supported by a portion of the mounting bracket (190) and the other end in contact with the backside of said stopper (605) of the actuator (600) to urge the actuator (600) towards the front of the base body (103).
The aforesaid mounting base (100) is attached to the mounting bracket (190) with the rear edges of the mounting base (100) inserted into the grooves formed on the surface of said bracket (190), and is joined thereto with a conventional joining compound such as epoxy glue. The bracket is provided with screw mounting holes (191) for mounting the whole dispenser on a proper place such as bathroom wall.
The toothpaste supply amount adjusting bracket (800) is formed of molded plastic as shown in FIG. 5 in a shape of elongated loop, having a plurality of steps (801) in suitable height increments provided on each of the side members (802), and a latch (803) protruding inwardly toward each other on each of the side members (802). The toothpaste supply amount adjusting bracket (800) is mounted on a projection (192) formed on the lower portion of the mounting bracket (190), the projection (192) having a plurality of notches (193) formed on each of the two sides. The toothpaste supply amount adjusting bracket (800) is held in position by latches (803) which selectively engage with said notches (193). By pulling said toothpaste supply amount adjusting bracket (800) vertically upwardly or downwardly along the surface of the mounting bracket (190), the two side members (802) are forced to expand outwardly by the wedge effect between the latches (803) and the notches (193) and thus the latches (803) are disengaged from the notches (193) and moved to come in engagement with next notches by the resiliency of the toothpaste supply amount adjusting bracket (800) itself.
The toothpaste supply amount adjusting bracket (800) is arranged in the vicinity of the rear end of the actuator (600) towards the end of the inward stroke so that the stroke of the actuator is determined when the rear end of the actuator (600) hits one of the plurality of steps (801) formed on the toothpaste supply amount adjusting bracket (800), and thus determining the amount of toothpaste drawn to the cylinder. By pulling said toothpaste supply amount adjusting bracket (800) upwardly or downwardly to change its position in relation with the projection (192) as described above the step which the end of the actuator (800) hits is changed from one height to the other and thus the stroke is changed, and consequently the amount of toothpaste drawn to the cylinder, or supplied to the toothbrush, is changed.
The particular embodiment of the toothpaste dispenser according to this invention is further provided with an upper case (30) which is made of molded plastic and is detachably connected to the mounting base (100) with its lower edges engaged with the slot (not shown) formed on the upper surface of the mounting plate (101). The upper case (30) is arranged to conceal the toothpaste container (10) as mounted on the upper base (102), and is also provided with toothbrush hangers (31) capable of accommodating 4 or 5 toothbrushes on each side thereof. Each side of the upper case (30) is provided with a cover (32) detachably attached thereto with hook or snap-in joints, to form a toothbrush storage compartment. The covers (32) are made of molded plastic, preferably transparent, and are arranged to cover the brush portion of the toothbrushes stored thereon.
The operation of the embodiment according to this invention will now be described:
One of the toothbrushes stored on the hanger provided at the sides of the upper case (30) is taken and laid on the toothbrush holder (604), with the tip of the toothbrush laid against the stopper (605). The toothbrush is pushed into the front opening (181) and thus pushes the actuator (600) inwardly against the coil spring (610). The piston (350) is then pulled by the actuator (600) and by the extension rod (601) moves towards the rear end of the mounting base (100) and creates a vacuum in the cylinder (300). The leaf valve (201) of the inlet valve (200) then opens the port (121) as shown in FIG. 3, and the toothpaste is drawn from the tube container (10) into the interior of the cylinder (300). In the meantime the outlet valve disc (401) closes the outlet port (306) to maintain the vacuum in the interior of the cylinder (300).
As soon as the rear end of the actuator (600) hits the adjusting bracket (800), the backward movement of the piston (350) is stopped and the predetermined amount of toothpaste fills the cylinder (300).
Then the toothbrush is withdrawn and the actuator (600) is released from the pushing-in force and is then pushed forward by the coil spring (610) and the pressure is formed in the cylinder (300) by the forward movement of the piston (350). The inlet port (121) is then closed by the inlet valve leaf (201) and the outlet valve disc (401) is pushed by the toothpaste to open the outlet port (306). As the piston (350) continues to move forward by the force of the coil spring (610), the toothpaste in the cylinder (300) is discharged into the discharge chamber (307). The discharge nozzle is then opened by the pressure of the toothpaste and finally the toothpaste is supplied evenly to the toothbrush which is also moving outwardly. As soon as the piston (350) hits the outlet port (306), the forward movement of the piston (350) is stopped, pressure in the cylinder (300) and the discharge chamber (307) is relieved, and the outlet valve disc (401) is pushed by the resilient force of the helical support portion (403) to return to its originally closed position. In the meantime the discharge nozzle (500) is closed by its own resiliency without leaving residuals around the discharge nozzle.
In the case that a different amount of toothpaste is desired, the amount supplied can be selectively adjusted and predetermined by changing the position of the toothpaste supply amount adjusting bracket (800) as described previously.
It is readily apparent from the foregoing description that the toothpaste dispenser according to this invention is capable of supplying a preselected amount of tooth paste with simple operation of pushing the toothbrush into the dispenser and taking it out without leaving residuals in the area around the dispenser. Furthermore the toothpaste dispenser is provided with toothbrush storage compartments in one compact unit not only for easy access in use but also for better appearance as a bathroom utility unit.
The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. It is to be understood that the scope of the invention is defined by the appended claims hereof.
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A dispenser for drawing toothpaste from a squeeze-tube container and applying it to the top of a toothbrush with a vacuum pump of piston-cylinder construction which is so operated that the pump draws the toothpaste out of the squeeze-tube container when the toothbrush is pushed into the dispenser and discharges the same when the toothbrush is withdrawn. The toothpaste is pumped through a passage which is provided with an inlet valve which operates in cooperation with an elastic adapter used for mounting and sealing the neck portion of the squeeze-tube container, an outlet valve which operates in cooperation with a port formed in the cylinder, and an elastic discharge nozzle which opens when the toothpaste is being pumped and closes by its own resiliency when the toothpaste is being drawn out of the squeeze-tube container. The amount of toothpaste supplied each time by the dispenser can be adjustably predetermined as desired.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Nos. 60/979,022 and 60/979,025, both filed Oct. 10, 2007, which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO APPENDIX
[0004] Not applicable.
BACKGROUND
[0005] 1. Field of the Invention
[0006] The disclosure relates to oil field equipment, and particularly to oil field gate valves, such as those valves meeting pressurization specifications.
[0007] 2. Description of Related Art
[0008] As in most realms, the oil field market is influenced by safety concerns balanced against cost and value for products and services. To control the minimum safety requirements, regulations and specifications are promulgated in the oil field industry, so that customers can purchase equipment necessary for projects with the expectation that the equipment will meet certain standards. Known and respected specifications for oil field equipment are promulgated by the American Petroleum Institute (“API”) that requires valves to meet rigorous tests. A significant focus is on valves and similar control devices, because of the dangers of oil field wells that are controlled by valves. One specific specification is API 6A PSL-2 PR2 for product specification level and performance requirements. A valve has to pass certain tests as virtually leak proof for an extended period of time for a gaseous medium at elevated pressures (that is, generally 5,000 psi and above) and elevated temperatures (generally 250° F. and above). The challenge is to design a valve that can meet such rigorous tests in the industry that is affordable to customers and competitive to the marketplace.
[0009] Standard design engineering for such valves generally increases the overall cross-sectional diameters and thicknesses of the valve body to add mass to the valve for increased pressure requirements and performance. The valve acts as a pressure vessel and must withstand not only the pressure, but must be stiff enough to minimize the engineering strain at stress levels to maintain alignment of the valve components which must seal, connect, rotate, translate up and down, and otherwise function for their intended purpose all without leakage at critical junctures. Most valves in the market place reflect this standard practice of adding more mass to the overall size, even though a significant portion of the valve cost is directly related to simply the amount of material in the valve body. Another common practice is to increase larger cavities for larger seals, which in turn causes increased cross-sections of the valve body, which leads to the above referenced increase in material and costs. Another practice is to rely on metal-to-metal seals, because at PR2 pressures and temperatures, rubber and elastomeric seals may extrude and fail. However, as the valve ages, the surface finish of the mating surfaces deteriorates and the valves can leak, decreasing its useful life. The challenge is to include additional sealing while keeping costs to a minimum.
[0010] These challenges have been met in various ways by the industry. Generally, the remedy is to meet the engineering tests such as the API 6A PSL-2 PR2 referenced above even at an additional cost of materials, attempt to negotiate competitive prices from suppliers of the additional components, increase manufacturing efficiency, contract offshore to other suppliers, and demand an incremental price increase.
[0011] Therefore, there remains a need to provide an improved valve that can meet such specifications and tests that are still competitive in the marketplace.
BRIEF SUMMARY
[0012] The disclosure provides an efficient design for a pressure rated oil field gate valve that meets the challenges of providing a quality product with minimal increase in price due to the design. It minimizes weight increase in the valve body over valves not meeting strict pressure specifications, due to strengthening ribs at strategic places without having to increase the overall body size as in commonplace in the industry. It provides redundancy of seals with minimal costs and no change in seat pockets over valves not capable of meeting the higher standards. It provides multiple shear points along a valve stem that can still allow a user to operate the valve from external to the valve bonnet. It further provides for additional sealing of the valve bonnet to the valve body by using elasticity in metal over long lengths to maintain a compression seal between the bonnet and the body.
[0013] The disclosure provides a gate valve, comprising: a valve body having a flow passage from a first port to a second port with a gate cavity disposed between the first port and the second port, the gate cavity intersecting the flow passage; a valve bonnet coupled to the valve body with a bonnet opening; a gate slidably coupled to the valve body in the gate cavity, the gate adapted to slidably move at an angle to a centerline of the flow passage to block the flow when the gate is in a closed position to cover a cross-sectional area of the flow passage and allow flow when the gate is at least in a partially open position when the gate does not entirely cover the cross-sectional area of the flow passage; a stem rotatably coupled through the bonnet opening to the gate and adapted to move the gate reciprocally across the cross-sectional area of the flow passage between the closed and open positions; a seat pocket disposed on each side of the gate cavity in the valve body, the seat pocket having a bore that forms an outer perimeter of the seat pocket and a back face in the valve body distal from the gate cavity to create a stepped surface around the flow passage; and a seat disposed in each seat pocket and adapted to seal between the gate and the valve body. The seat comprises: a seat body having: a flow opening aligned with the flow passage; a gate face disposed toward the gate; a perimeter surface adapted to fit into the bore of the seat pocket; and a rear face disposed toward the back face of the seat pocket, the rear face comprising a first metal radial sealing surface having a shaped sealing surface and adapted to seal against the back face of the seat pocket in metal-to-metal contact.
[0014] The disclosure also provides a gate valve, comprising: valve body having a flow passage from a first port to a second port with a gate cavity disposed between the first port and the second port, the gate cavity intersecting the flow passage, the valve body further comprising at least two ribs extending from a portion of the valve body distant from the valve bonnet to a portion of the valve body external to the flow passage, a first rib being disposed toward the first port and a second rib being disposed toward the second port; a valve bonnet coupled to the valve body with a bonnet opening; a gate slidably coupled to the valve body in the gate cavity, the gate adapted to slidably move at an angle to the centerline of the flow passage to block the flow when the gate is in a closed position to cover a cross-sectional area of the flow passage and allow flow when the gate is at least in a partially open position when the gate does not entirely cover the cross-sectional area of the flow passage; a stem rotatably coupled through the bonnet opening to the gate and adapted to move the gate reciprocally across the cross-sectional area of the flow passage between the closed and open positions; a seat pocket disposed on each side of the gate cavity in the valve body, the seat pocket having a bore that forms an outer perimeter of the seat pocket and a back face in the valve body distal from the gate cavity to create a stepped surface around the flow passage; and a seat disposed in each seat pocket and adapted to seal between the gate and the valve body.
[0015] The disclosure further provides a gate valve, comprising: a valve body having a flow passage from a first port to a second port with a gate cavity disposed between the first port and the second port, the gate cavity intersecting the flow passage; a valve bonnet coupled to the valve body with a bonnet opening; a gate slidably coupled to the valve body in the gate cavity, the gate adapted to slidably move at an angle to a centerline of the flow passage to block the flow when the gate is in a closed position to cover a cross-sectional area of the flow passage and allow flow when the gate is at least in a partially open position when the gate does not entirely cover the cross-sectional area of the flow passage; a stem rotatably coupled through the bonnet opening to the gate and adapted to move the gate reciprocally across the cross-sectional area of the flow passage between the closed and open positions; a seat pocket disposed on each side of the gate cavity in the valve body, the seat pocket having a bore that forms an outer perimeter of the seat pocket and a back face in the valve body distal from the gate cavity to create a stepped surface around the flow passage; and a seat disposed in each seat pocket and adapted to seal between the gate and the valve body. The seat comprises: a seat body having: a flow opening aligned with the flow passage; a gate face disposed toward the gate; a perimeter surface adapted to fit into the bore of the seat pocket, the perimeter surface having a peripheral groove extending toward a centerline of the seat body; a rear face disposed toward the back face of the seat pocket; and a flexible castellated seal disposed in the peripheral groove of the seat body, the castellated seal having a series of castellations on a first face, the first face being disposed toward the gate face of the seat body of the seat.
[0016] The disclosure still further provides a gate valve, comprising: a valve body having a flow passage from a first port to a second port with a gate cavity disposed between the first port and the second port, the gate cavity intersecting the flow passage, the valve body further comprising at least two ribs extending from a portion of the valve body distant from the valve bonnet to a portion of the valve body external to the flow passage, a first rib being disposed toward the first port and a second rib being disposed toward the second port, wherein the ribs form an angled surface from a central portion of the valve body toward the first port and the second port at an angle to a centerline through the first port and second port; a valve bonnet coupled to the valve body with a bonnet opening; a gate slidably coupled to the valve body in the gate cavity, the gate adapted to slidably move at an angle to the centerline of the flow passage to block the flow when the gate is in a closed position to cover a cross-sectional area of the flow passage and allow flow when the gate is at least in a partially open position when the gate does not entirely cover the cross-sectional area of the flow passage; a stem rotatably coupled through the bonnet opening to the gate and adapted to move the gate reciprocally across the cross-sectional area of the flow passage between the closed and open positions; a seat pocket disposed on each side of the gate cavity in the valve body, the seat pocket having a bore that forms an outer perimeter of the seat pocket and a back face in the valve body distal from the gate cavity to create a stepped surface around the flow passage; and a seat disposed in each seat pocket and adapted to seal between the gate and the valve body. The seat comprises: a seat body having: a flow opening aligned with the flow passage; a gate face disposed toward the gate; a perimeter surface adapted to fit into the bore of the seat pocket, the perimeter surface having a peripheral groove extending toward a centerline of the seat body; a rear face disposed toward the back face of the seat pocket, the rear face comprising a rear cylindrical groove and a first metal radial sealing surface formed on the rear face adjacent the rear cylindrical groove, the first metal radial sealing surface being adapted to seal against the back face in metal-to-metal contact as a first seal, and the rear face further comprising a second metal radial sealing surface formed on the rear face adjacent the rear cylindrical groove and distal from the first metal radial sealing surface relative to the rear cylindrical groove, the second metal radial sealing surface adapted to seal against the back face in metal-to-metal contact as a second seal, wherein at least one of the metal radial sealing surfaces comprises a shaped sealing surface; and a peripheral step formed in the perimeter surface adjacent the rear face; a rear flexible seal disposed in the cylindrical groove of the rear face and adapted to seal against the back face as a third seal; and a flexible castellated seal disposed in the peripheral groove of the seat body, the castellated seal having a series of castellations on a first face, the first face being disposed toward the gate face of the seat body of the seat, the flexible castellated seal forming a fourth seal.
[0017] The disclosure provides a gate valve, comprising: a valve body having a flow passage from a first port to a second port with a gate cavity disposed between the first port and the second port, the gate cavity intersecting the flow passage; a valve bonnet coupled to the valve body with a bonnet opening; a gate slidably coupled to the valve body in the gate cavity, the gate adapted to slidably move at an angle to a centerline of the flow passage to block the flow when the gate is in a closed position to cover a cross-sectional area of the flow passage and allow flow when the gate is at least in a partially open position when the gate does not entirely cover the cross-sectional area of the flow passage; a stem rotatably coupled through the bonnet opening to the gate and adapted to move the gate reciprocally across the cross-sectional area of the flow passage between the closed and open positions; a seat pocket disposed on each side of the gate cavity in the valve body, the seat pocket having a bore that forms an outer perimeter of the seat pocket and a back face in the valve body distal from the gate cavity to create a stepped surface around the flow passage; and a seat disposed in each seat pocket and adapted to seal between the gate and the valve body. The seat comprises: a seat body having: a flow opening aligned with the flow passage; a gate face disposed toward the gate; a perimeter surface adapted to fit into the bore of the seat pocket; a rear face disposed toward the back face of the seat pocket; and a peripheral step formed in the perimeter surface adjacent the rear face; and a flexible peripheral seal disposed around the peripheral step formed in the perimeter surface. The flexible peripheral seal comprises: a jacket having a heel portion of flexible material of a longitudinal thickness and a groove formed in an outer periphery of the jacket, having at least two peripherally extending seal arms; and a peripheral spring disposed in the jacket groove, the peripherally extending seal arms being biased to a width, measured from an outside surface of one seal arm to an outside surface of the other seal arm, that is greater than the heel longitudinal thickness.
[0018] The disclosure also provides a gate valve, comprising: a valve body having a flow passage from a first port to a second port with a gate cavity disposed between the first port and the second port, the gate cavity intersecting the flow passage, the valve body further comprising at least two ribs extending from a portion of the valve body distant from the valve bonnet to a portion of the valve body external to the flow passage, a first rib being disposed toward the first port and a second rib being disposed toward the second port, wherein the ribs form an angled from a central portion of the valve body toward the first port and the second port at an angle to a centerline through the first port and second port; a valve bonnet coupled to the valve body with a bonnet opening; a gate slidably coupled to the valve body in the gate cavity, the gate adapted to slidably move at an angle to the centerline of the flow passage to block the flow when the gate is in a closed position to cover a cross-sectional area of the flow passage and allow flow when the gate is at least in a partially open position when the gate does not entirely cover the cross-sectional area of the flow passage; a stem rotatably coupled through the bonnet opening to the gate and adapted to move the gate reciprocally across the cross-sectional area of the flow passage between the closed and open positions; a seat pocket disposed on each side of the gate cavity in the valve body, the seat pocket having a bore that forms an outer perimeter of the seat pocket and a back face in the valve body distal from the gate cavity to create a stepped surface around the flow passage; and a seat disposed in each seat pocket and adapted to seal between the gate and the valve body. The seat comprises: a seat body having: a flow opening aligned with the flow passage; a gate face disposed toward the gate; a perimeter surface adapted to fit into the bore of the seat pocket, the perimeter surface having a peripheral step formed in the perimeter surface adjacent the rear face; a rear face disposed toward the back face of the seat pocket, the rear face comprising a rear cylindrical groove and a first metal radial sealing surface formed on the rear face adjacent the rear cylindrical groove and adapted to seal against the back face in metal-to-metal contact as a first seal, and the rear face further comprising a second metal radial sealing surface formed on the rear face adjacent the rear cylindrical groove and distal from the first metal radial sealing surface relative to the rear cylindrical groove, the second metal radial sealing surface adapted to seal against the back face in metal-to-metal contact as a second seal, wherein at least one of the metal radial sealing surfaces comprises a shaped sealing surface; and a rear flexible seal disposed in the cylindrical groove of the rear face and adapted to seal against the back face as a third seal; and a flexible peripheral seal disposed around the peripheral step formed in the perimeter surface adjacent the rear surface, the flexible peripheral seal forming a fourth seal. The flexible peripheral seal comprises: a jacket having a heel portion of flexible material of a longitudinal thickness and a groove formed in an outer periphery of the jacket, having at least two peripherally extending seal arms; and a peripheral spring disposed in the jacket groove, the peripherally extending seal arms being biased to a width, measured from an outside surface of one seal arm to an outside surface of the other seal arm, that is greater than the heel longitudinal thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic cross-sectional view of an exemplary embodiment of a gate valve described herein.
[0020] FIG. 2 is a schematic cross-sectional view of a portion of a valve body of the gate valve of FIG. 1 illustrating valve seat pockets.
[0021] FIG. 3 is a schematic cross-sectional assembly view of an exemplary embodiment of a valve seat.
[0022] FIG. 3A is a schematic cross-section view of a portion of a seat body.
[0023] FIG. 3B is a schematic cross-section view of a portion of an alternative seat body.
[0024] FIG. 4 is a schematic perspective view of the assembled valve seat.
[0025] FIG. 5 is a schematic cross-sectional view of the valve body with the valve seats installed in the valve seat pockets.
[0026] FIG. 6 is a schematic cross-sectional assembly view of another exemplary embodiment of a valve seat.
[0027] FIG. 6A is a schematic cross-sectional view of a portion of a flexible peripheral seal.
[0028] FIG. 7 is a schematic perspective view of the assembled valve seat shown in FIG. 6 .
[0029] FIG. 8 is a schematic cross-sectional view of the valve body with the valve seats installed in the valve seat pockets.
[0030] FIG. 9 is a schematic side view of the valve body illustrating ribs.
[0031] FIG. 10 is a schematic partial cross-sectional view from an end illustrating the ribs.
[0032] FIG. 11 is a schematic bottom perspective view of the valve body of FIGS. 9 and 10 .
[0033] FIG. 12 is a schematic cross-sectional view of the valve bonnet with a stem assembled therein.
[0034] FIG. 13 is a schematic top perspective assembly view of the valve body and valve bonnet with extended bonnet bolts.
DETAILED DESCRIPTION
[0035] The Figures described above and the written description of specific structures and functions below are not presented to limit the scope of what Applicants have invented or the scope of the appended claims. Rather, the Figures and written description are provided to teach any person skilled in the art to make and use the inventions for which patent protection is sought. Those skilled in the art will appreciate that not all features of a commercial embodiment of the inventions are described or shown for the sake of clarity and understanding. Persons of skill in this art will also appreciate that the development of an actual commercial embodiment incorporating aspects of the present inventions will require numerous implementation-specific decisions to achieve the developer's ultimate goal for the commercial embodiment. Such implementation-specific decisions may include, and likely are not limited to, compliance with system-related, business-related, government-related, and other constraints, which may vary by specific implementation, location and from time to time. While a developer's efforts might be complex and time-consuming in an absolute sense, such efforts would be, nevertheless, a routine undertaking for those of skill in this art having benefit of this disclosure. It must be understood that the inventions disclosed and taught herein are susceptible to numerous and various modifications and alternative forms. Lastly, the use of a singular term, such as, but not limited to, “a,” is not intended as limiting of the number of items. Also, the use of relational terms, such as, but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,” “side,” and the like are used in the written description for clarity in specific reference to the Figures and are not intended to limit the scope of the invention or the appended claims.
[0036] FIG. 1 is a schematic cross-sectional view of an exemplary embodiment of a gate valve described herein. The gate valve 2 generally includes a body 4 having a pair of flanges 6 , 8 at each end of the body. A first port 10 is formed on one end of the body and a second port 12 is formed on another end. Generally, the ports are aligned and, in any case, form a flow passage 13 therebetween having a centerline 31 . The flanges include a seal surface 14 for placement of a flange seal (not shown) to enable sealing between an adjacent flange and connecting equipment. Other types of connections can be formed, although flanges are common for the pressure ratings of such valves. The valve body 4 includes a gate cavity 16 disposed between the first port and the second port, so that the gate cavity intersects the flow passage 13 . Generally, the gate cavity 16 is disposed perpendicular to the flow passage 13 , although other angles can be used. The gate cavity contains a gate 30 to be described below that blocks the flow passage and controls flow therethrough. To effectively block flow through the flow passage, a seat 20 is generally disposed on each side of the gate cavity and gate. A seat pocket 18 is formed in the flow passage 13 to contain the seat 20 . Generally, the seat 20 will have an opening size commensurate with the flow passage 13 . In the orientation of the exemplary embodiment shown in FIG. 1 , a seat pocket 18 A is formed on a left side of the gate cavity 16 and a seat pocket 18 B is formed on a right side of the gate cavity, so that the gate can translate up and down in the gate cavity between the seats 20 A and 20 B, respectively, disposed therein. Further details of the seat and seat pocket will be described below.
[0037] Relative to the orientation in FIG. 1 of the valve, an upper portion of the valve is generally termed a bonnet 22 . The bonnet 22 is attached to the valve body 4 through a plurality of bonnet bolts 24 . A bonnet cavity 108 is created between the valve body and the internal portion of the bonnet that is fluidicly coupled to a gate cavity 16 . A bonnet opening 26 is formed in the bonnet 22 through which a stem 28 is assembled. The stem 28 can be rotated in the bonnet 22 and move the gate 30 up and down in the gate cavity 16 . The movement is caused by rotation of a threaded surface 32 formed between the gate and the stem such that rotation of the stem effectively moves the gate along the threaded surfaces in a translating motion. In the embodiment shown, the movement of a gate is at a perpendicular angle to the centerline 31 formed through the flow passage 13 , although the angle can vary if so designed. The stem can be rotated by an actuator 34 . Generally, an actuator can be a hand wheel, level, motor-driven gear, or other movable elements. A bonnet-to-body seal 36 is disposed between the bonnet 22 and the valve body 4 to generally eliminate leakage to the outside of the valve. A packing 38 is disposed around the stem 28 to generally eliminate leakage upward through the opening 26 in the bonnet 22 . A cap 40 is mounted over the stem with one or more other seals between the bonnet 22 and the stem 28 . A grease fitting 42 is generally included in the cap 40 to lubricate bearings, the stem, various contact surfaces, and the like.
[0038] A shear pin 44 is inserted through an opening in the stem 28 and a bearing adjacent the stem. The shear pin 44 helps to protect the stem from breaking internal to the bonnet 22 when extraordinarily high stresses are placed on the stem. Generally, a smaller cross-sectional area of the stem is created in manufacturing the threaded engagement surface 32 on the stem due to a thread relief This smaller cross-section creates a weakened section in the stem from the manufacturing process. The shear pin 44 is designed to fail in shear to protect the stem 28 from breaking at the thread relief 46 internal to the bonnet 22 , where the shear pin can be more readily accessed through the cap 40 and replaced as necessary. The exemplary embodiment of the valve includes a further groove, herein a stem groove 48 , to further protect the stem from breakage, if the stem shear pin 44 does not break in accordance with its design load. More details are provided below.
[0039] Further, the valve body 4 includes ribs 50 , described in more detail below, that help stiffen the valve body to maintain alignment of various valve components and structure under high stress loads. These ribs are provided in contrast to generally accepted teachings for valve design by not significantly increasing the overall mass of the valve body to create such stiffness.
[0040] FIG. 2 is a schematic cross-sectional view of a portion of a valve body of the gate valve of FIG. 1 illustrating valve seat pockets. The valve 2 and particularly the valve body 4 , includes the flow passage 13 with a centerline 31 formed therethrough. The seat pocket 18 , such as a first seat pocket 18 A and a second seat pocket 18 B, is formed along the flow passage in the valve body on both sides of the gate cavity 16 . For purposes herein, the seat pocket 18 includes a bore 52 with an outer perimeter and a back face 54 , where the term “rear” is intended to include a surface distal from the gate or gate cavity, and the term “forward” is intended to include a surface toward the gate or gate cavity.
[0041] FIG. 3 is a schematic cross-sectional assembly view of an exemplary embodiment of a valve seat. FIG. 3A is a schematic cross-section view of a portion of a seat body. FIG. 3B is a schematic cross-section view of a portion of an alternative seat body. The figures will be described in conjunction with each other. The seat described can meet the API 6A tests for at least a 5,000 PSI rated pressure valve. The seat 20 generally includes a seat body and various seals assembled thereof In the orientation shown in FIG. 3 , the seat 20 corresponds to the orientation of the seat 20 A described and shown in FIG. 1 . The seat 20 B is generally a mirror image of the seat 20 A with the orientation reversed, so that corresponding surfaces face forward toward the gate to interact therewith. The seat 20 includes a seat body 60 of generally a cylindrical shape having an inner perimeter 61 forming a flow opening 62 approximately equal to the flow passage 13 along the centerline 31 shown and described in FIG. 1 . The seat body generally includes a gate face 64 disposed toward the gate 30 described in FIG. 1 . The seat body further includes a perimeter surface 66 that is disposed radially outward toward the outer perimeter of the bore 52 described in FIG. 2 . The seat body 60 further includes a rear face 68 disposed toward the back face 54 of the seat pocket 18 , also shown in FIG. 2 .
[0042] More specifically, the gate face 64 includes a gate cylindrical groove 74 formed in the gate face. A gate flexible seal 76 is assembled and mounted to the gate face in the gate cylindrical groove 74 . The gate flexible seal 76 can be made of a variety of materials and generally of materials that reduce the slidable friction between the seat 20 and the gate 30 . One exemplary and non-limiting material is PTFE, also known as Teflon. An outer metal surface 78 disposed radially outward from the gate cylindrical 74 forms an axial stop to the movement of the seat to the gate along the centerline 31 . A portion 82 of the outer metal surface 78 can be tapered or formed with a radius to help guide the gate 30 as it translates up and down past the seat 20 in the orientation shown. An inner metal surface 80 , disposed radially inward toward the centerline 31 can be further to used to support the flexible seal 76 in a perimeter and provide a stop to the relative movement between the seat and the gate.
[0043] The perimeter surface 66 of the seat body 60 includes a peripheral groove 70 formed in the perimeter surface and having walls on either side of the groove from the seat body. Further, a peripheral step 72 is formed toward the rear face 68 and intersects the rear face, so that the peripheral step has one wall of the seat body in the direction of the gate face. A groove 84 can also be formed in the peripheral surface of the seat body for maintenance purposes, mainly, to assist in disassembly of the seat 20 from the seat pocket 18 , shown in FIG. 1 .
[0044] The rear face 68 includes a rear cylindrical groove 86 , so that a rear flexible seal 88 can be disposed therein. The rear flexible seal 88 forms a flexible seal that can enable sealing even if the back face 54 of the seat pocket 18 should become rough from use and deterioration, or contaminants be disposed thereon. A metal radial sealing surface 90 is disposed radially around the rear face. Without limitation, the metal radial sealing surface 90 can be formed outward from the rear cylinder groove 86 away from the centerline 31 . The metal radial sealing surface 90 forms a metal seal by establishing metal-to-metal contact with the back face 54 of the seat pocket 18 . Similarly, a second metal radial sealing surface 92 can be similarly formed around the rear face. Without limitation, the metal radial sealing surface 92 can be formed inward from the rear cylinder groove 86 toward the centerline 31 .
[0045] One or more of the metal radial sealing surfaces 90 , 92 can be shaped to establish one or more shaped sealing surfaces 132 , 134 , respectively. The shaped sealing surfaces can be formed with a radius R, as shown in FIG. 3A , or tapered at an angle β, as shown in FIG. 3B . For example and without limitation, the radius R can be 1″-2″ from a center point aligned with the middle of the rear cylindrical groove 86 , more advantageously 1.4″-1.6″, and an angle β can be 2°-10°, more advantageously 3°-5°, and any radius or angle therebetween inclusively. The resulting leading edges 148 , 150 of the shaped sealing surfaces 132 , 134 can first contact the back face 54 to establish a concentrated load and a more effective seal over a smaller cross-sectional area than without the shaped sealing surfaces. The contacting area of a shaped sealing surface that contacts the back face of the seat pocket can be self-adjusting by deforming the leading edge as necessary under high stress loads until the contacting surface area has deformed enough to support a sealing load caused by the contact force between the metal sealing surface and the back face to establish an equilibrium condition, and yet minimize the contacting area required to support the load to help maintain an effective seal.
[0046] In FIG. 3 , a flexible castellated seal 94 is sized to be disposed into the peripheral groove 70 formed in the perimeter surface 66 of the seat body. The castellated seal with castellations 102 having merlons 106 adjacent crenels 104 will be described in more detail in reference to FIG. 4 and its function in FIG. 5 . A wave spring 96 can be disposed in the peripheral step 72 . The wave spring 96 biases the seat 20 away from the back face 54 of the seat pocket 18 and toward the gate 30 disposed in the gate cavity 16 , shown in FIGS. 1 and 2 .
[0047] FIG. 4 is a schematic perspective view of the assembled valve seat. The seat body 60 and the assembled seals form the seat 20 . The gate face 64 is disposed toward the gate 30 in FIG. 1 and provides a smooth surface for the gate to translate across the gate space. The perimeter surface 66 contains one or more seals, such as the flexible castellated seal 94 , and the rear face 68 generally includes one or more metal-to-metal seals through one or more metal radial sealing surfaces and the rear flexible seal 88 to further enhance sealing for deteriorated surfaces.
[0048] The castellated seal 94 includes one or more castellations 102 . A castellation is formed by an axially extended portion known as a merlon 106 adjacent a crenel 104 and generally between two crenels. The castellations of the castellated seal are disposed on a forward facing surface 100 that is disposed toward the gate face 64 of the seat 20 and the gate 30 of FIG. 1 . The rear surface 98 of the castellated seal 94 that is disposed toward the rear face 68 of the seat 20 generally includes a smooth seal that is noncastellated. As will be described in FIG. 5 , the castellated seal effectively creates an inexpensive one-way seal that allows upstream leakage and downstream sealing for the gate valve.
[0049] FIG. 5 is a schematic cross-sectional view of the valve body with the valve seats installed in the valve seat pockets. FIG. 5 illustrates the relative flow with the sealing functions of the seats disposed on both sides of the gate 30 . As described above, the valve body 4 includes a gate 30 that translates across the flow passage 13 to control the flow through the flow passage 13 . To meet the required standards, such as the API 6A specifications referenced above, the seat 20 must seal between the seat pocket and the gate under rigorous conditions. While certain third party designs have offered various solutions, the solutions generally are an expensive arrangement. The present system is a simplified and inexpensive solution.
[0050] In general, the seat 20 A is disposed in the seat pocket 18 A on the left side of the gate 30 and seat 20 B is disposed on the right side of the gate in the seat pocket 18 B, using the orientations for illustrative purposes shown in FIG. 5 . With a gate in a downward position, so that it blocks the flow passage 13 and fluid 110 therethrough, a small amount of fluid at pressure P 1 leaks past the seat 20 A into the bonnet cavity 108 . This intentional leakage helps equalize the forces on both sides of the seat 20 A in the seat pocket 18 A and reduces a sealing force from the upstream seat to the gate 30 . The reduced sealing force on the upstream side of the gate at the higher pressure P 1 allows a lower force to open the gate as it slides across the face of the seat 20 A. Further, the pressure P 1 equalizes (with relatively minor pressure drops) with the pressure P 2 in the bonnet cavity 108 . The bonnet cavity 108 is fluidly coupled to the right side of the gate above the seat pocket 18 B, so that the pressure P 2 on the right side of the gate in FIG. 2 is equal to the pressure P 2 on the left side. The mirror image orientation of the seat 20 B in the seat pocket 18 B and the reverse orientation of the seals compared to the seat 20 A creates a seal so that the fluid at pressure P 2 is prevented from leaking downstream of the seat 20 B into the downstream portion of the flow passage 13 at pressure P 3 .
[0051] Thus, the upstream seat 20 A leaks intentionally and the downstream seat 20 B seals intentionally (in the orientations of the fluid flow shown). If the flow was reversed, so that seat 20 B became the upstream seat and seat 20 A became the downstream seat, the result would be the mirror image where the upstream seat 20 B would leak and the downstream seat 20 A would seal. The simplicity of this design and yet the ability to seal in such fashion is caused by astute orientation and selection of the various components described here.
[0052] More specifically, the pressure P 1 in conjunction with the action of the wave spring 96 forces the seat 20 A toward the gate 30 . The metal-to-metal contact of the metal radial sealing surface 90 or the metal radial sealing surface 92 or both is not effectively engaged to seal against the back face 54 . Similarly, the rear flexible seal 88 is not effectively engaged to seal against the back face 54 and thus fluid at pressure P 1 leaks past the three seals. The fluid at pressure P 1 then encounters the flexible castellated seal 94 . However, with the orientation shown in FIG. 4 , the rear surface 98 is pushed away from the adjacent wall of the peripheral groove 70 and does not seal in the groove 70 , and allows fluid at pressure P 1 (ignoring any losses in pressure along the way) to flow through the castellations 102 , specifically, the crenels 104 , of the castellated seal 94 and leak past the castellated seal 94 . The crenels 104 cannot seal because the merlons 106 keep the crenels 104 from sealing against adjacent wall of the peripheral groove 70 . Thus, the fluid at pressure P 1 leaks past the seat 20 A into the bonnet cavity 108 at substantially the same pressure to established pressure P 2 downstream of the seat 20 A.
[0053] However, on the right side of FIG. 5 , the downstream seat 20 B, effectively seals the fluid at pressure P 2 from flowing farther downstream into the remaining flow path. The fluid flows at pressure P 2 along the surfaces between the bore 52 and the perimeter surface 66 of the seat 20 B. However, this time due to the mirror image placement of the seals, the flow passes first through the crenels 104 of the castellations 102 and encounters the rear surface 98 of the castellated seal 94 . The pressure P 2 forces the rear surface 98 against the downstream wall of the peripheral groove 70 and effectuates a seal thereon. The flow is stopped. If any flow should inadvertently leak past the seal 94 on the rear surface 98 , the fluid will encounter a metal radial sealing surface 90 that is sealing in metal-to-metal contact against the back face 54 of the seat pocket 18 B. The metal-to-metal contact is enhanced by the pressure P 2 forcing the seat 20 B against the back face 54 of a seat pocket 18 B. Further, the rear flexible seal 88 is also being forced against the back face 54 for another sealing surface. Finally, the metal radial sealing surface 92 that is disposed radially inward from the seal 88 is also being forced against the back face 54 of the seat pocket 18 B. Thus, the seat 20 B in one embodiment includes four sealing surfaces to help prevent leakage of fluids downstream of the seat 20 B.
[0054] FIG. 6 is a schematic cross-sectional assembly view of another exemplary embodiment of a valve seat. FIG. 6A is a schematic cross-sectional view of a portion of a flexible peripheral seal. FIG. 7 is a schematic perspective view of the assembled valve seat shown in FIG. 6 . The figures will be described in conjunction with each other. This embodiment of the valve seat 20 is designed for higher pressures than the seat shown in FIGS. 3-5 . Because of the higher pressures, a different design can be utilized more efficiently. Higher pressures include 10,000 PSI and qualify for meeting the API 6 A test described above for a 10,000 PSI rated pressure valve. The seat body 60 includes an inner perimeter 61 that forms a flow opening 62 through the seat 20 . The seal body 60 includes a gate face 64 , perimeter surface 66 , and rear face 68 . The gate face 64 generally includes a metal surface that is disposed adjacent the gate 30 described above. The gate face 64 can include a tapered or radius portion 82 to assist in aligning the gate as the gate encounters the gate face 64 in its traversal. A groove 84 can be included for disassembly on the perimeter surface 66 . A peripheral step 72 can be formed in the perimeter surface 66 adjacent to the rear face 68 . In this seat body 60 , the peripheral step 72 can be used to efficiently support a peripheral seal 112 that can seal to the periphery of the seat pocket 18 and/or the back face 54 of the seat pocket. The seat body 60 can further include a rear cylinder groove 86 formed in the rear face 68 . A metal radial sealing surface 90 disposed radially outward from the rear cylindrical groove 86 can form a metal-to-metal seal against the back face 54 of the seat pocket 18 described above. Similarly, a metal radial sealing surface 92 can form a metal-to-metal seal against the back face 54 in additional to or in lieu of the metal radial sealing surface 90 . The seat shown in FIG. 6 is aligned according to the orientation of the seat 20 A described above. A rear flexible seal 88 can be disposed in the rear cylindrical groove 86 to similarly seal as described above for the seat of FIGS. 3-5 .
[0055] The peripheral seal 112 generally includes a jacket 114 of flexible material. The jacket 114 includes an inner peripheral surface 116 that is sized to fit over the diameter of the peripheral step 72 . The jacket generally includes a cross-sectional shape that has a radial portion termed a “heel” 118 . The heel 118 has a longitudinal thickness “T” relative to the centerline 31 . A groove 120 is formed in the peripheral seal 112 radially outward from the heel 118 . The groove 120 can form a U-shaped cross-section so that a peripheral spring 126 that can be stretched and assembled thereto. The peripheral spring 126 can be a coil spring. The peripheral spring 126 can also be a spring with a cross-section generally in the shape of a “U”. Generally, the open portion of the “U” will be placed facing radially away from the centerline of the seal. The groove 120 formed in the peripheral seal 112 creates a first arm 122 and a second arm 124 with the spring disposed at least partially therebetween. The arms 122 and 124 peripherally extend radially outward from the heel 118 . The arms are biased to a width W that is greater than the thickness T of the heel, when the width is measured from an outside surface 128 of one arm to an outside surface 130 of the other arm 124 . The outward bias assists in biasing the seat 20 toward the gate 30 described above.
[0056] FIG. 8 is a schematic cross-sectional view of the valve body with the valve seats of FIG. 6 installed in the valve seat pockets. The flow in FIG. 8 is similar to the flow described above for FIG. 5 and has similar results in that the upstream seat is designed to bypass a certain amount of fluid under pressure to equalize the pressure between the gate 30 and the upstream seat 20 A, and yet restrict pressure from passing downstream of the downstream seat 20 B. More specifically, the valve body 4 includes a seat body 18 A into which a seat 20 A is disposed, and a seat pocket 18 B into which a seat 20 B is disposed. In the flow direction 110 illustrated in FIG. 7 from left to right, the seat 20 A is the upstream seat and the seat 20 B is the downstream seat. The seats are mirror images of each other, so that the gate face of each as described above faces the gate from opposite directions. The pressure P 1 of a fluid upstream of the upstream seat 20 A exerts pressure against the seat 20 A and leaks past the rear flexible seal 88 and metal radial sealing surfaces 90 , 92 , as described above in FIG. 5 , encounters the peripheral seal 112 . The fluid flowing in this direction collapses the arms toward each other and leaks past the peripheral seal 112 and into the bonnet cavity 108 to stabilize the pressures that the pressure P 2 is approximately equal to the pressure P 1 . The left side of the bonnet cavity 108 illustrated in FIG. 8 is fluidicly coupled to the right side of the bonnet cavity 108 , so that fluid at pressure P 2 encounters the downstream seat 20 B. As the fluid passes between an annulus created between the outer periphery of the seat 20 B and the bore 52 of the seat pocket, the fluid encounters the peripheral seal 1 12 . However, from this direction, the fluid at the pressure P 2 energizes the arms 122 , 124 of the seal 112 by forcing them away from each other and forces the seat 20 B against the wall of the peripheral step 72 on one side and the back face 54 of the other side. The arms seal so that the fluid at pressure P 2 does not leak past the peripheral seal 112 . If any fluid leaks past the seal 112 , it encounters the metal radial sealing surface 90 which seals in a metal-to-metal fashion against the back face 54 by the fluid at pressure P 2 , forcing the seat against the back face 54 . Further, any fluid leaking past the metal-to-metal seal created by the metal radial sealing surface 90 further encounters the rear flexible seal 88 . The rear flexible seal 88 on the downstream seat 20 B is pressed against the back face 54 and seals against the back face 54 . Further, the other metal radial sealing surface 92 creates a seal against the back face 54 , as the seat 20 B is pressed against the back face 54 . Thus, the seat 20 B in one embodiment includes four sealing surfaces to help prevent leakage of fluids downstream of the seat 20 B.
[0057] Thus, the system intentionally allows fluid to flow past an upstream seat (such as 20 A in the above example) and conversely seal when flowing past a downstream seat (such as 20 B in the above example). If the flow 110 was reversed, the seat 20 B would become the upstream seat and would allow pressures to stabilize by allowing fluid to seep past the seals in a downstream position, and the seat 20 A would be downstream and seal the fluid from leaking past the seat with its respective seals.
[0058] FIG. 9 is a schematic side view of the valve body illustrating ribs. FIG. 10 is a schematic partial cross-sectional view from an end illustrating the ribs. FIG. 11 is a schematic bottom perspective view of the valve body of FIGS. 9 and 10 . The figures will be described in conjunction with each other. The valve body 4 is generally a nonsymmetrical valve body between the upper portion and the lower portion relative to the centerline 31 of the flow passage 13 . The nonsymmetrical nature of the valve is generally due to the bonnet being coupled to the upper portion in which additional material is unnecessary and would otherwise add to the cost. Thus, the valve body portion 138 adjacent the bonnet has less material than the valve body portion 140 distal from the bonnet. Since the valve body portion 138 has less material, the valves and particularly the ends, flexes in a non-coplanar fashion when pressurized, so that the flanges 6 , 8 bend at angles α 1 and α 2 relative to their orientation in a nonpressurized state. The nonsymmetrical portions of the valve cause the valves ends when the valve is under pressure to be deformed by being nonsymetrically stressed. Such movement (engineering “strain”) is calculable due to stress-strain curves at given stress levels for given metals. If the connections to other equipment are sufficiently rigid, the connections may reduce the deflection. However, the valve is in a strained condition.
[0059] Typical valve engineering practices would dictate adding a significant amount of bulk material to the valve to be able to withstand the stress and strain. However, as discussed above, the additional bulk material adds significant cost as well. In contrast to the typical engineering practice, the inventors realize that selective positioning of relatively thin, minute amounts of material could make a significant difference in the overall stiffness and rigidity of the valve body. Thus, in contrast to standard engineering practice, the valve disclosed herein can add one or more ribs 50 A, 50 B (collectively, ribs 50 ) to the valve body to provide sufficient rigidity for the elevated pressures, and still retain a lower material cost than in standard engineering practice. More specifically, the valve having a valve body portion 142 A external to the flow passage 13 can have a rib 50 A coupled between the valve body portion 140 and the valve body portion 142 A. Similarly, the valve can have a rib 50 B disposed between the valve body portion 140 and the valve body portion 142 B external to the flow passage 13 .
[0060] As shown in FIG. 9 , the ribs 50 can have an angled surface 146 between the valve body portion 140 and the valve body portions 142 A, 142 B. The term “angled” is used broadly and includes sloped and curved surfaces. In some embodiments, the rib can have an opening formed therethrough to lessen the material and weight, depending on manufacturing.
[0061] As shown in FIG. 10 , the rib 50 can have a rib thickness T R . In the embodiment shown, the rib thickness can be a consistent thickness other than allowances for radii where the ribs join the valve body passage 142 or other transitions. In other embodiments, the rib thickness can vary, depending on manufacturing complexities and costs.
[0062] FIG. 12 is a schematic cross-sectional view of the valve bonnet with a stem assembled therein. The bonnet 22 includes an opening 26 through which the stem 28 can be inserted. The stem 28 is threadably coupled to the gate 30 as described above for actuating the gate up and down in the gate cavity 16 by rotating the stem 28 by an actuator 34 . Under certain conditions, the stem 28 can be overstressed and fail, generally by excess torque from the actuator 34 , creating a shear failure. A shear pin 44 coupled from the stem 28 to a bearing 56 provides a protective mechanism to overstressing the stem and possibly breaking the stem at a less desirable location. However, sometimes, the shear pin can be replaced with an improperly rated shear pin and not shear, and the stem can be sheared at a weak point. One weak point is a thread relief 46 that is created in forming the threads 32 along the portion of the stem that engages the gate described above. If the stem fails at the thread relief 46 , the valve is generally taken offline and dissembled which could interrupt production flow and create a significant expenditure. Thus, the inventors have provided another safety device that supplements the shear pin 44 . Specifically, the stem 28 in at least one embodiment can provide a weakened point in the stem at a stem groove 48 . The stem groove 48 is formed external to the bonnet 22 and generally external to the cap 40 of the bonnet. If the stem fails to shear the shear pin when excess torque is applied, it can shear at the thread groove 48 instead of the thread relief 46 . If the stem shears at the stem groove 48 , there can still be sufficient length on the stem 28 external to the bonnet to be engaged by a pipe wrench or other device for rotating the valve, independent of the actuator 34 . In general, the diameter D G of the stem groove 48 will be less than the diameter D T of the thread relief 46 , so that the smaller and weaker cross-section will be the thread groove 48 . More specifically, the stem groove 48 establishes a smaller cross-sectional area in the stem 28 than a cross-sectional area at a thread relief 46 on the stem. In turn, the cross-sectional area of the stem groove 28 has a greater shear strength than a shear strength of the shear pin 44 inserted through the stem. Thus, the shear pin should fail first, then the stem groove 48 , and both fail before the thread relief 46 fails.
[0063] FIG. 13 is a schematic top perspective assembly view of the valve body and valve bonnet with extended bonnet bolts. An additional feature of an embodiment of the valve disclosed herein is the use of significantly longer bonnet bolts to act as metal “springs” on the bonnet-to-body seal 36 . It is typical that a bonnet bolt will be a relatively short, stubby bolt. The inventors have realized as an added advantage to the design shown herein, that a much longer bonnet bolt can be used as a mechanical “spring” to maintain pressure under varying conditions on the bonnet-to-body seal 36 . Specifically, the length L of the bonnet bolt 24 can be multiples of length of a standard bonnet bolt. In at least one embodiment, the length L of the bonnet bolt 24 can be 2× to 6×, and more preferably 4×, of a standard length of bonnet bolt. The invention can use the modulus of elasticity (Young's Modulus) of a stress-strain curve for the particular metal to determine that under a given stress, the metal will be deformed a certain length (“strained”) and thus stretched to create a metal “spring” that can absorb varying stresses and still maintain a tight seal on the bonnet-to-body seal 36 . A longer bolt can accommodate a longer strain for a given stress and effectively operate more as a spring with a lower spring constant for increased flexibility in sealing to the bonnet-to-body seal 36 .
[0064] The bolts are generally coupled to valve body bolt holes 154 in the valve body 4 . The bonnet 22 can be assembled with the stem 28 and other associated components, and inserted over the bonnet bolts 24 , so that the bolts travel through bonnet bolt holes 156 . The bonnet bolts are then pre-stressed to a certain torque using nuts and other fasteners, so that the bolts are strained (that is, stretched in tension) for a given stress in an elastic engineering mode without incurring plastic permanent deformation. The engineering strain creates a “spring” loaded force on the lower bonnet sealing surface 158 , also shown in cross-sectional view in FIG. 1 . The lower bonnet sealing surface 158 engages the bonnet-to-body seal 36 that creates a tight seal between the bonnet 22 and the valve body 4 under varying stress loads.
[0065] Other and further embodiments utilizing one or more aspects of the inventions described above can be devised without departing from the spirit of the invention. For example, the cables could be chains, the motive forces could be gears and sprockets, and other variations. Further, the various methods and embodiments of the translating movement that shifts the pile and launches the piles can be included in combination with each other to produce variations of the disclosed methods and embodiments. Discussion of singular elements can include plural elements and vice-versa.
[0066] The order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Similarly, elements have been described functionally and can be embodied as separate components or can be combined into components having multiple functions.
[0067] Unless the context requires otherwise, the word “comprise” or variations such as “comprises” or “comprising,” should be understood to imply the inclusion of at least the stated element or step or group of elements or steps or equivalents thereof, and not the exclusion of a greater numerical quantity or any other element or step or group of elements or steps or equivalents thereof. The term “couple”, “coupled,” “coupling,” “coupler,” and like terms are used broadly herein and may include any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, directly or indirectly with intermediate elements, one or more pieces of members together and may further include without limitation integrally forming one functional member with another in a unity fashion. The coupling may occur in any direction, including rotationally.
[0068] The systems and methods herein have been described in the context of various embodiments and not every embodiment has been described. Apparent modifications and alterations to the described embodiments are available to those of ordinary skill in the art. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the concepts of the Applicants, but rather, in conformity with the patent laws, Applicants intend to protect all such modifications and improvements to the full extent that such falls within the scope or range of equivalent of the following claims.
[0069] Further, any references mentioned in the application for this patent, as well as all references listed in the information disclosure originally filed with the application, are hereby incorporated by reference in their entirety to the extent such may be deemed essential to support the enabling of the concept. However, to the extent statements might be considered inconsistent with the patenting of the concept, such statements are expressly not meant to be considered as made by the Applicant(s).
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The disclosure provides an efficient design for a pressure rated oil field gate valve that meets the challenges of providing a quality product with minimal increase in price due to the design. It minimizes weight increase in the valve body over valves not meeting strict pressure specifications, due to strengthening ribs at strategic places without having to increase the overall body size as in commonplace in the industry. It provides redundancy of seals with minimal costs and no change in seat pockets over valves not capable of meeting the higher standards. It provides multiple shear points along a valve stem that can still allow a user to operate the valve from external to the valve bonnet. It further provides for additional sealing of the valve bonnet to the valve body by using elasticity in metal over long lengths to maintain a compression seal between the bonnet and the body.
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TECHNICAL FIELD
This invention relates in general to a method of manufacturing electrically conductive high aspect ratio holes in a substrate carrying printed circuits on both sides.
BACKGROUND
Printed circuit boards (PCB) are manufactured using a large number of complex steps and processes. Basically, the PCB is made by laminating thin sublayers together. Copper clad laminates are normally used to make the etched circuitry layers, and are bonded together with prepreg or bonding sheets. The resulting single strong panel may optionally have internal etched copper layers centrally embedded in the resin. The panel is then drilled, and the drilled holes are metallized to provide the electrical connections between the inner and the outer layers. The outer two layers are then etched to make the circuitry patterns. The resulting structure is the well-known plated through hole, shown in FIG. 1. Note that the interior layers are connected to the metallized hole, which also further connects them to the exterior two layers.
Artisans have sought to use ever-decreasing hole diameters in order to reduce the real estate on the board surface. However, it is costly to produce small diameter plated through holes with guaranteed electrical continuity, because plating metal in these tiny holes is not a reproducible process. The quality of the connection between the hole plating and the internal layers can only be checked by destructive microsectioning. One alternative to small-hole PCB technology is multilayer ceramic. The substrates for these modules have many (up to 23) layers, and each layer begins as a part of a continuous cast sheet of ceramic material, cut into pieces 175 mm square, then punched with holes so that electrical connections could later be made between layers. Conductive paste is then extruded onto the green sheets through metal masks, forming a wiring pattern unique to a given layer. Stacks of these sheets, with the required configurations of conducting line and insulating layers, layer-to-layer connections, and reference and power planes, were laminated together and trimmed to form individual modules, which were then fired in a furnace to harden the ceramic. The resulting small diameter via contains a conductive media that forms the side to side connection.
Clearly, a need exists for a better, more efficient way to create small diameter plated through holes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a plated through hole as practiced in the prior art.
FIGS. 2, 3 and 4 are cut-away isometric views showing the various stages of the method of manufacturing high aspect ratio holes in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A method for providing conductive through holes to make electrical connection as required from the circuit on the front side of a PCB to the circuit on the back side is disclosed. This method is particularly appropriate to the use of additive circuit manufacturing methods starting with vacuum deposited copper as the base layer for electroplating. Very thin base metal layers are a necessity for fabrication of high density circuits, lines less than 75 micrometers in width with spaces less than 75 micrometer between the lines, for example. Vacuum deposition of this thin metal layer, rather than conventional electroless copper plating, might be appropriate in many situations. For example, DC sputtering results in improved metal adhesion on certain substrate materials.
Referring now to FIG. 2, a substrate 10 is first provided. The substrate is typically a fiberglass reinforced organic material such as the well-known FR-4 epoxy laminate. Other types of resins can also be substituted, such as polyimide, polytetrafluoroethylene, polyester, polyetherimide, etc. The substrate 10 typically has a center core 12, made of the fiberglass reinforced organic material that is clad on one or both sides with a layer of copper 14. To make connection between the circuit traces which will subsequently be created on opposite sides of the clad substrate, a hole 16 is drilled through the substrate 10 perpendicular to the two opposing faces. The present invention is particularly applicable to the case where the substrate thickness (t) is substantially greater than the diameter (d) of the drilled holes (although, for clarity, the diameter (d) is shown in greatly exaggerated scale in the drawing figures). This condition is known as `high aspect ratio`, and in this context typically is greater than 3/1, where the ratio is defined as the ratio of the substrate thickness to diameter (t/d) of the hole. Typically, high aspect ratio holes for which the invention is applicable are in the range of 5/1 to 15/1, and have hole diameters less than 0.5 millimeters.
After the holes have been drilled in the substrate, a very thin layer of copper 20 is applied to the substrate by vacuum deposition (FIG. 3). The preferred method of vacuum deposition is DC sputtering, though other methods such as evaporation and RF sputtering can be employed. This vacuum deposited layer forms on all exposed exterior surfaces of the substrate, including the two faces, the edges, and on the interior walls of the drilled hole 16. In an alternate embodiment, a thin adhesion promoting layer such as 500 Å of chromium might first be sputtered, followed by the copper layer. In any event, the copper layer is applied so that the thickness on the face of the substrate is in the range of 4000 Å to 20,000 Å, with 5000 Å to 15,000 Å being preferred. Sputtering copper at this thickness results in a macroscopically continuous conducting layer on both faces of the substrate, while a macroscopically discontinuous layer of copper is deposited in the high aspect ratio through holes. We postulate that this is because the drilled holes 16 are very narrow when compared to the depth of the hole, and it is difficult for a significant amount of copper atoms to find their way deep into the interior of the hole. However, due to the statistics of the sputtering process, some small amount of copper atoms apparently are deposited in the far interior of the high aspect ratio hole walls, forming a discontinuous island type of structure, the islands acting as nucleation sites that can later be used to advantage in a plating process. Due to the very small diameter (high aspect ratio) of the drilled holes, sputtering additional copper thickness has not been found to substantially improve the continuity of the film deposited inside the high aspect ratio holes. To reiterate, the vacuum deposition process results in a thin film of about 5000 Å to 15,000 Å of copper deposited on the face 22 of the substrate and on the walls of the drilled hole walls near the outer edges 24, but the measured copper thickness continues to decrease as one travels along the hole wall towards the center 26 of the substrate, until the copper film deposited in this area changes from macroscopically continuous to macroscopically discontinuous. Those skilled in the art have known that it not possible to sputter metal deep into high aspect ratio apertures, because the metal does not reach the interior, and thus they have avoided using high aspect ratio holes. However, we have discovered that even though the copper cannot be visually detected, and even though electrical probing shows that the hole is not electrically continuous from one side of the substrate to the other, some small (previously considered to be insignificant or non-existent) amount of metal is apparently deposited in the deep interior wall 26 of the hole. This small deposition apparently forms what we refer to as a `macroscopically discontinuous` film less than 100 Angstroms thick, which serves as an anchor for metal deposited by conventional plating processes in a later step.
Referring now to FIG. 4, after vacuum deposition, the substrates are immersed in an electroless copper plating bath. This bath deposits additional copper 30 on the sputtered surfaces and in the holes using an autocatalytic reaction, and the vacuum deposited copper serves as the `seed` layer for the electroless deposition. With most standard electroless bath chemistries, 5 to 10 minutes of immersion is sufficient to achieve complete continuity of the through holes from front to back. One type of plating bath found to be suitable is an alkaline solution of copper, formaldehyde and EDTA. Typically, one also finds trace quantities of palladium, tin or reaction byproducts of palladium, tin or copper in these types of plating baths. It should be noted that only one wet chemistry bath is required for the plating operation in the instant invention, whereas, in the prior art, 5 or 6 baths are typically used to catalyze and plate electroless copper on bare (i.e. no metal) substrate surfaces.
The PCB can then be completed using standard additive methods of photodefining the circuit, electroplating the circuit on the surface and in the holes, and then etching the sputtered metal from the two faces to separate the circuit traces as desired. These additional steps are well known to those skilled in the art of PCB and hybrid circuit manufacturing, and do not need to be further elaborated upon here. Obvious variations of these additional steps are considered to fall within the scope and spirit of the invention, and the invention is not intended to be limited except as by the claims.
In summary, we have discovered that numerous conventional steps (as practiced in the prior art) of preparing the surface of a drilled hole in a PCB for electroless plating can be eliminated by a single step of properly sputtering a layer of copper or chrome and copper. The sputtered copper forms a macroscopically discontinuous film on the interior walls of the high aspect ratio hole, deep within the hole. This film is then used as a novel seed layer for subsequent electroless copper plating. The electroless copper catalytically plates on this seed layer, forming a usable layer of plated copper in the high aspect ratio hole. Thus, holes with aspect ratios greater than previously attainable can now be made. While the preferred embodiments of the invention have been illustrated and described, it will be clear that the invention is not so limited. Numerous modifications, changes, variations, substitutions and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as defined by the appended claims.
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A method of manufacturing high aspect ratio plated through holes in a circuit carrying substrate. High aspect ratio apertures or holes (16) are formed in a substrate (10). A thin film of copper (20) is sputtered onto the substrate and in the apertures that a macroscopically discontinuous copper film (26) is formed on part of the aperture walls. The macroscopically discontinuous copper film is substantially thinner than the copper film that is deposited on the surface. A catalytic copper coating (30) is plated directly on the vacuum deposited thin film of copper by electroless copper plating in a manner sufficient to form a macroscopically continuous copper layer on the aperture walls.
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This application is a division of application Ser. No. 07/701,503, filed May 16, 1991 now U.S. Pat. No. 5,205,612.
BACKGROUND OF THE INVENTION
This invention relates to transport apparatus.
This invention has particular but not exclusive application to excavating apparatus, and for illustrative purposes reference will be made to such application. However, it is to be understood that the transport apparatus of this invention could be used in other applications, such as cross-country transport.
A continuous mining machine typically comprises a mining head supported by a head transport apparatus which guides the mining head in a desired direction of excavation and provides the stabilizing forces necessary to resist the cutting forces applied at the mining head, as the latter must of necessity overhang the front of the transport apparatus.
Where the cutting forces are relatively light, such as in the mining of soft materials like coal, the transport apparatus may include a pair of crawler tracks, and the dead weight of the transport may be sufficient to prevent it from overbalancing. Where the cutting forces are relatively high, such as in the mining of hard rock, it becomes necessary to provide further stabilization for the transport apparatus, such as may be obtained by clamping it against the walls of the tunnel being out.
DISCUSSION OF THE PRIOR ART
Continuous mining machines intended for the cutting of hard rock have been developed over a number of years. A number of these have utilized the principle of cutting with cutters disposed about a cutting wheel rotated about a transverse axis and slewed transversely about a vertical axis to form a tunnel with a flat floor or roof and curved side walls. Seberg (U.S. Pat. No. 976,703) discloses such a cutting wheel supported on a pair of spaced supporting trucks, while App (U.S. Pat. No. 1,290,479) utilizes a chain-driven cutting wheel supported on a rail-mounted carriage. Auger-type cutters supported on a crawler-undercarriage form the basis for the mining machine disclosed by Bradthauer (U.S. Pat. No. 3,290,095). Fink (U.S. Pat. No. 4,035,024) utilized roller-type cutters mounted on the periphery of a horizontal cutting wheel to cut a shallow trench in hard rock. While such roller-cutters are more effective and longer-lasting than picks in cutting hard rock, the cutting wheels could not slew, and the carriage supporting the wheels advanced against a support frame clamped to the walls of the trench.
Sugden, et al (U.S. Pat. No. 4,548,442) discloses a mining machine utilizing a cutting wheel rotatable about a horizontal axis and supporting a plurality of roller-cutters around its periphery. The cutting wheel is supported by a slewable boom, permitting the cutting wheel to excavate a tunnel with a flat floor and roof and elliptical side walls. The slewable boom is supported on a carriage which may slide longitudinally relative to an undercarriage to urge the cutting wheel into the advancing face of the tunnel. The undercarriage includes crawler tracks for accommodating advancing of the complete machine, and upper and lower jacks for clamping the undercarriage between the tunnel roof and floor.
In practice, this arrangement produced a workable mining machine, but the flexibility of the structure supporting the cutting wheel resulted in high levels of vibration between the roller-cutters and the mining face, reducing the effectiveness of the cutting process. In addition, the rolling cutters were distributed over a plurality of cutting planes, emulating to some degree the spaced relationship employed on tunnel boring machines, in which application rolling cutters were first utilized. Such a cutter distribution is wasteful when applied to a slewing cutting wheel however, as only cutters in the leading plane perform useful work when the cutting wheel slews across an excavation face.
SUMMARY OF THE INVENTION
The present invention aims to alleviate the above disadvantages and to provide excavating apparatus which will be reliable and efficient in use. Other objects and advantages of this invention will hereinafter become apparent.
With the foregoing and other objects in view, this invention in one aspect resides broadly in a mobile mining machine suitable for cutting a tunnel in rock, said mobile mining machine including:
an elongate main beam supported at longitudinally spaced locations by first beam support means and second beam support means, said first beam support means including a travel assembly adapted for relatively free longitudinal movement along the floor of the tunnel and said second beam support means including clamping means which may be selectively clamped to the walls of said tunnel;
a boom pivot adjacent said first beam support and having a substantially vertical pivot axis substantially perpendicular to then longitudinal axis of said main beam assembly;
a boom assembly attached to said boom pivot for pivotal movement thereabout;
slewing means extending between said boom assembly and said main beam assembly for controlling pivotal movement of said boom assembly about said boom pivot;
a cutting wheel assembly supported at the free end portion of said boom assembly, said cutting wheel assembly having an axis of rotation substantially co-planar with said longitudinal axis and substantially perpendicular to said boom pivot axis and having a plurality of roller-cutter assemblies mounted about its periphery;
drive means for rotating said cutting wheel assembly, and
advancing means for longitudinally advancing said main beam assembly relative to said second beam support means. The clamping means may be selectively clamped to the vertical or horizontal walls of the tunnel.
Preferably, the travel assembly includes a transversely-spaced pair of crawler tracks joined to the main beam assembly through transverse crawler pivots such that the main beam may tilt within a longitudinal vertical plane about said crawler pivots for alterations to the vertical alignment of the cutting wheel. The travel assembly may also include substantially vertical steering pivots whereby the crawler, wheels or the like may be steered relative to the main beam assembly for enhanced manoeuverability of the mining machine. Of course, if desired, the travel assembly may include road wheels or rollers, or track wheels running on tracks laid along the tunnel floor. The travel assembly may also include travel drive operable to assist advancing said cutting wheel against the advancing face of the tunnel.
The clamping means may include horizontal actuators for moving the adjacent portion of said main beam transversely relative to the tunnel and vertical actuators for moving the adjacent portion of said main beam vertically relative to the tunnel, whereby control may be exercised over the horizontal and vertical alignment of the tunnel being out by altering the alignment of the cutting wheel relative to the travel assembly.
A preloading assembly may be provided, and may be attached to the main beam assembly for selective engagement with the roof of the tunnel such that the location of the boom pivot may be held relative to the tunnel against disturbing forces in excess of those which may be resisted by the weight of the mining machine alone. The preloading assembly include an actuator adapted for applying a predetermined level of force to the tunnel roof, and may include a crawler assembly, a wheel, a roller or a slide assembly such that the main beam may advance along the tunnel while maintaining the desired level of preload.
The mobile mining assembly may further include a rear auxiliary assembly comprising a rear frame supported on a rear travel assembly and attached to the rear portion of the main beam assembly through a rear pivot such that the mining machine may be relocated by travel on the assembly and the rear auxiliary assembly with the clamping frame detached from the tunnel walls. Suitably the rear pivot includes a ball or universal joint such that the main beam assembly and the rear auxiliary may articulate relative to one another and substantially vertical-axis steering slide such that unevenness in the tunnel floor may be accommodated. Steering means may be associated with the vertical steering slide such that pivoting of the rear auxiliary assembly relative to the main beam may be achieved for steering purposes.
In a further aspect of this invention, a transport assembly is disclosed, comprising:
an elongate main beam assembly supported at longitudinally spaced locations by first beam support means and second beam support means, said first beam support including a travel assembly adapted for relatively free longitudinal movement and said second beam support includes a rear travel assembly attached to the rear portion of said main beam assembly through a rear pivot. The rear pivot may include a ball joint supporting a vertical steering slide, and steering means for rotating the rear travel assembly about the ball joint relative to the main beam assembly such that steering of the transport assembly may be accomplished. Preferably, the travel assembly includes a pair of transversely-spaced crawler tracks for movement over uneven ground, and the rear travel assembly may also include crawler tracks if desired.
In a further aspect, this invention resides in a cutter wheel assembly including a cutting wheel having a peripheral wheel rim supporting a plurality of main wheel cutters having cutting rims disposed substantially within a single cutting plane, and vertical to the cutter wheel axis. Preferably a plurality of gauge wheel cutters are disposed on either side of the plane of the cutting rims and the gauge axes about which said gauge wheels rotate are substantially inclined to said main cutting plane. In this way, a substantially continuous cut may be achieved on an excavation face by the operation of successive cutters as the cutting wheel rotates. This minimizes power demand relative to excavated volume, or cutting efficiency, as the spacing of successive cuts formed across a mining face may be controlled to its maximum possible value for the prevailing conditions, minimizing the degree of rock crushing required for excavation. The cutting efficiency may further enhanced by arranging the main wheel cutters and gauge wheel cutters such that the proportion of the width of the cut excavated by the gauge cutters is minimized, since their cutting efficiency is low relative to that of the main wheel cutters. In particular, the gauge wheel cutters should be mounted as close as possible along the axis to the main cutting plane, consistent with producing a cut which will provide the necessary clearance for the wheel rim and other rotating components, as well as for the re;levant boom-mounted components such as the cutting wheel drive means. Thus it is important that the wheel rim be as narrow as possible to minimize the clearance cut which needs to be excavated by the gauge cutters. In a preferred embodiment, the wheel rim is enclosed between a pair of opposed cones having a common base circle joining the portions of the cutting rims furthest from the cutting wheel axis in which the included angles at the apexes of the cones are maximized, and are at least one hundred and twenty degrees. In order to minimize the proportion of the excavating carried out by the gauge wheel cutters, the spacing between a pair of planes perpendicular to the cutter wheel axis and enclosing the cutting portions of the gauge wheel cutters should not exceed one-sixth, and preferably be less than one-tenth, of the diameter of the common base circle.
The gauge wheel cutters may be arranged for cutting at a smaller radius relative to the cutting wheel axis than the primary cutters such that the gauge cutters may engage with the mining face only at the extremities of the slewing travel of the cutting wheel while rotating clear of the excavation face formed by the main wheel cutters. Suitably, the inclination between said cutting wheel axis and said gauge axes is greater than twenty-five degrees.
Preferably, the cutting wheel is supported on a boom assembly for slewing motion about a slewing pivot axis, the slewing pivot axis being substantially perpendicular to the cutter wheel axis and coplanar with the cutting plane such that cutting forces produce minimal torque reaction about the slewing pivot axis.
The cutting wheel body is suitably formed to include a hub portion joined to a circumferential rim only by a pair of spaced frusto-conical web portions. The thickness of the web portions is set to a level adequate to withstand transverse (axial) forces applied to the cutting wheel such that transverse stiffeners are not needed. This simplifies the construction of the cutting wheel and minimizes the extent of regions of stress concentration typically associated with stiffeners.
In another aspect this invention provides a method of cutting a tunnel, including:
providing a mobile mining machine comprising an elongate main beam assembly supported at a pair of spaced longitudinal locations by a travel assembly adapted for relatively free longitudinal movement along the floor of a tunnel and a clamping frame which may be selectively clamped to the walls of said tunnel and selectively moved along said main beam, said beam assembly supporting at its front end adjacent said first beam support a boom pivot, the boom pivot axis being substantially perpendicular to the longitudinal axis of said main beam assembly, a boom assembly attached to said boom pivot for rotational movement thereabout and supporting at its free end portion a wheel pivot, the wheel pivot axis being substantially co-planar with said longitudinal axis and substantially perpendicular to said boom pivot axis, slewing means attached between said boom assembly and said main beam for controlling rotational movement of said boom assembly about said boom pivot, a cutting wheel assembly mounted to said wheel pivot for rotation thereabout and having a plurality of roller-cutter assemblies mounted about its periphery, and wheel drive means for rotating said cutting wheel assembly;
energizing said clamping means to force said clamping assembly into frictional engagement with the tunnel walls;
energizing said advancing means to force said main beam forward along the tunnel relative to said clamping means;
energizing said slewing means to sweep said cutting wheel assembly across the advancing face of the tunnel;
energizing said wheel drive means to rotate said roller-cutter assemblies about said wheel pivot axis;
de-energizing said clamping means to release said clamping assembly from the tunnel walls;
energizing said advancing means in reverse function to draw said clamping assembly forward relative to said main beam and the tunnel.
In another aspect this invention includes a method of forming a mobile mining machine, including:
providing an elongate main beam assembly supported at a pair of spaced longitudinal locations by a travel assembly adapted for relatively free longitudinal movement along the floor of a tunnel and clamping means which may be selectively clamped to the walls of said tunnel and selectively moved longitudinally relative to said main beam by advancing means, said main beam assembly supporting at its front end adjacent said first beam support a boom pivot, the boom axis of rotation of said boom pivot being substantially perpendicular to the longitudinal axis of said main beam assembly;
providing a boom assembly attached to said boom pivot for rotational movement thereabout, said boom assembly supporting at its free end portion a wheel pivot, the wheel axis of rotation of said wheel pivot being substantially co-planar with said longitudinal axis and substantially perpendicular to said boom pivot axis;
providing slewing means attached between said boom assembly and said main beam assembly for controlling rotational movement of said boom assembly about said boom pivot;
providing a cutting wheel assembly mounted to said wheel pivot for rotation thereabout and having a plurality of roller-cutter assemblies mounted about its periphery;
providing wheel drive means for rotating said cutting wheel assembly; and
assembling said main beam assembly, said boom assembly, said slewing means, said cutting wheel assembly and said wheel drive means to form said mobile mining machine.
In a further aspect, this invention resides in a method of controlling a mobile mining machine of the type having a cutting wheel rotatable about a horizontal axis by wheel drive means and traversable across a mining face in order to maximize its mined output consistent with maintaining cutter wheel power below a desired limit, including selectively controlling the kerf depth and kerf spacing such that the kerf ratio of kerf depth to kerf spacing approaches the optimum value for the rock being cut by continuously monitoring the wheel drive means power input and altering the speed of the slewing means to vary the traversing speed and thus the kerf spacing to maintain said power input close to a predetermined level. The method may further include the monitoring of changes in rock properties transversely across a rock face by storing kerf-spacing information for a traverse of said cutting wheel and utilizing said kerf-spacing information to control the kerf spacing or the kerf depth during successive traverses.
Force-measurement transducers may be provided for monitoring selected forces applied to the cutting wheel by the cutting process, and the output from the force-measurement transducers may be applied to the feedback control system for reducing the speed of the slewing means as required to maintain the selected forces below pre-determined limits such that the method of control may not result in the application of undesirable levels of force to the mining machine.
The gripper assembly may include traverse means for moving the portion of the beam member engaged therewith, whereby the excavation head may be steered vertically and/or horizontally as desired for excavating a tunnel of a desired curvature.
An auxiliary transport assembly may be attached to the free end portion of the beam member by connection means and may be powered for urging the excavation apparatus forward or rearward as desired, such as when moving the excavation apparatus to or from an excavation site. Suitably, the connection means includes a ball joint in series with a vertical slide such that the inclination of the beam member in the vertical plane may be controlled by interaction with the gripper assembly while permitting the second transport assembly to align itself independently with the floor of the tunnel.
In another aspect, this invention resides in a method of forming an excavating apparatus, including:
providing an excavating head for excavating material from an excavating face;
providing a transport assembly adapted for supporting said excavating head for movement towards the excavated face;
providing biasing means for biasing said excavating head into engagement with the excavated face;
providing traversing means for moving said excavating head across the excavated face such that material may be excavated progressively from selected portions of the excavated face, and
assembling said excavating head, said transport assembly, said biasing means and said traversing means to form said excavating apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In order that this invention may be more easily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention, wherein:
FIG. 1 is a side view of a mobile mining apparatus according to the invention;
FIG. 2 is a top view of the mobile mining apparatus shown in FIG. 1;
FIG. 3 is a partial side view of the mobile mining apparatus;
FIG. 4 is a partial top view of the mobile mining apparatus;
FIG. 5 is a cross-sectional view of the gripper assembly of the mining apparatus;
FIG. 6 is a block diagram of the apparatus for optimizing pitch and swing typifying the present invention;
FIGS. 7A-7P is a flow chart of the P.L.C. program;
FIGS. 8A-8B is a flow chart of the optimization program;
FIG. 9 is a flow chart of the start sweep subroutine of the optimization program;
FIG. 10 is a flow chart of the matrix subroutine of the optimization program;
FIG. 11 is a flow chart of the machine dat subroutine of the optimization program;
FIGS. 12A-12B is a flow chart of the ramp subroutine of the optimization program;
FIG. 13 is a flow chart of the mode 1 subroutine of the optimization program;
FIG. 14 is a flow chart of the mode 2 subroutine of the optimization program;
FIG. 15 is a flow chart of the mode 3 reduce subroutine of the optimization program; and
FIG. 16 is a flow chart of the mode 3 increase subroutine of the optimization program.
The mobile mining apparatus 10 shown in FIGS. 1, 2, 3 and 4 comprises a front travel assembly 11 and a rear travel assembly 12 joined at a coupling 13. The front travel assembly 11 is constructed around a main beam assembly 14 which is supported at its front end on crawler assemblies 15. The front portion of the main beam assembly 14 includes a vertical-axis boom pivot 16 to which a boom assembly 17 is pivoted for traversing motion from side to side. Directly behind the upper portion of the vertical boom pivot 16, a vertical preload cylinder 20 is formed in the main beam assembly 14 and supports a preload assembly 21 including a preload crawler 22.
The main beam assembly 14 terminates rearwardly in a longitudinal guide tube 23, to the free end of which the coupling 13 is attached. A gripper assembly 24 is mounted slidably about the guide tube 23, and a two-axis gimballed yoke assembly 25 mounted to the gripper assembly 24 slides on the guide tube 23. The gripper assembly 24 has a gripper body 26 to the sides of which opposed pairs of upper gripper cylinders 27 and lower gripper cylinders 30 are attached. The free ends of the latter are joined to the outer ends of a floor gripper 31, while the upper gripper cylinders 27 terminate at their free ends in individual roof grippers 32. The gripper body 26 is coupled to the main beam assembly 14 via substantially horizontal plunge cylinders 33.
The boom assembly 17 comprises a boom 34 supporting a planetary reduction gearbox assembly 35 about which a cutting wheel 36 revolves, the gearbox assembly 35 being driven by two cutting wheel drive motors 37 through fluid couplings 40, clutches 41 and bevel input drives 42. The rim 43 of the cutting wheel 36 supports a ring of roller cutter assemblies 44 all disposed substantially in a plane normal to the cutting wheel axis, and outer rings of gauge cutter assemblies 45. Each roller cutter assembly 44 comprises a roller trunnion 46 within which a roller 47 including a central cutting flange 50 may rotate about an axis parallel to the cutting wheel axis. All of the roller cutter assemblies 44 are mounted with their cutting flanges 50 within a common plane perpendicular to the cutting wheel axis. Gauge cutter assemblies 45 comprise gauge trunnions 51 within each of which a gauge roller 52 studded with high-hardness "buttons" 53 may rotate about a gauge axis disposed at a substantial angle to the cutting wheel axis. If desired, the gauge cutters may utilize disc cutters similar to the roller cutter assemblies 44.
The rim 43 and other rotating components are fully enclosed within a pair of cones 92 which share a base circle 93 joining the portions of the cutting flanges 50 which are furthest from the cutting wheel axis, and have included angles at their apexes which are greater than one hundred and twenty degrees, minimizing the clearance necessary outside the portion of the face 76 which is out by the cutting flanges 50. The gauge cutters 45 are contained between a pair of planes 94 which are perpendicular to the cutting wheel axis and are spaced apart by a distance which is less than one-tenth of the diameter of the base circle 93. These proportions provide adequate clearance for the operation of a cutting wheel 36 of the proportions defined by the cones 92, while minimizing the excavation which must be performed by the gauge cutters.
Swing cylinders 54 are connected between boom lugs 55 formed on the sides of the boom 34 and beam lugs 56 formed on the main beam assembly 14 for rotating the boom assembly 17 about the vertical pivot 16. Crawler drive motors 57 are attached to the frames of the crawler assemblies 15 and drive the crawler idlers 60 through drive chains 61. Scraper plates 62 attached to the main beam 14 and shaped to fit the tunnel bored by the mining apparatus 10 confine cut rock to the region ahead of the crawler assemblies 15. A primary conveyor 63 transports cut rock from ahead of the scraper plates 62 into the lower portion of a carousel conveyor 64 which discharges it onto a secondary conveyor 65 running above the main beam assembly 14 to the rear of the mining apparatus 10 where it may be discharged into a bulk transport vehicle 66.
The rear assembly 12 is supported on rear crawlers 67, and the coupling 13 includes a ball joint 70 permitting articulation in both horizontal and vertical directions, and a vertical slide-pivot 71, permitting the rear travel assembly 12 to move up or down independently of the motion of the main beam assembly 14, and to pivot transversely relative thereto. The crawler assemblies 15 and 67 may include transverse gripper treads for enhancing the traction when driven, but it is preferred that they include plain crawlers, and that the desired traction be attained as a result of generating a desired level of preload on the crawler.
The rear travel assembly 12 carries hydraulic pumps 72 for operating the hydraulic cylinders and electrical control cubicles 73 for controlling the operation of electric equipment including the cutting wheel drive motors 37. The control cubicles 73 also house a programmable logic controller (PLC) for controlling the overall operation of the mining apparatus 10.
Swing cylinder length transducers 75a are attached to the swing cylinders 54 and are wired to the PLC 74 to allow the transverse horizontal inclination of the boom assembly 17 relative to the main beam 14 to be monitored. Cylinder length transducers 75a (boom swing cylinder position transducers) are preferably Temposonics linear displacement transducers manufactured by Temposonics, Research of Triangle Park, N.C. Additional transducers include beam propel cylinder position transducers 75b, which measure cylinder extension (which relates directly to beam position). Beam propel cylinder position transducers 75b are also preferably Temposonics linear displacement transducers, described above. Also, boom pivot pin strain gauge 75c, which measures boom force, may be employed. Boom pivot pin strain gauge 75c is preferably a Series 125 strain gauge manufactured by Micro-measurements of Raleigh, N.C. Boom swing cylinder pin strain gauge 75d measures swing cylinder force, and is preferably a Micro-measurements Series 125 strain gauge discussed above. Boom swing pressure transducer 75e measures the swing system hydraulic pressure and is preferably a model 811 FMG transducer manufactured by Sensotec of Columbus, Ohio. Cutterhead drive motor current sensor 75f measures cutterhead motor current, which relates to power, and is preferably model CT5-005E manufactured by Ohio Semitronics, Inc. of Columbus, Ohio.
To excavate a face 76 at the end of a tunnel 77, the cutting wheel 36 is rotated by the cutting wheel drive motors 37, and the gripper assembly is clamped rigidly between the floor 80 and the roof 81 of the tunnel 77 by extending the gripper cylinders 27 and 30. The cutting flanges 50 of the roller cutter assemblies 44 are urged into engagement with the face 76 to be excavated by extending the plunge cylinders 33. The swing cylinders 54 are then operated to traverse the boom assembly 17 about the boom pivot 16, and the cutting flanges 50 of the rollers 47 score cutter path lines in the face 76, and, provided that the cutter path lines are deep enough relative to their spacing, the material between adjacent cuts will break away from the face 76. As the boom assembly 17 traverses to the desired extent of tunnel width on one side, the gauge cutter assemblies 45 engage with the face 76, forming the edge of the tunnel. The plunge cylinders 33 are extended to advance the rollers 47 into the face 76, the traversing direction of the boom 17 is then reversed, and the excavation process continues, extending the tunnel 77. The length by which the plunge cylinders 33 are extended each cycle is controlled to a pre-determined value by the PLC 74 using length information fed to it from the beam propel cylinder position transducers 75b, and the cutterhead motor current from cutterhead motor current transducer 75f.
When it is desired to alter the vertical direction in which the mobile mining apparatus 10 is excavating along the tunnel 77, the upper and lower gripper cylinders 27 and 30 are selectively actuated to move the gripper body 26 relative to the tunnel 77. This tilts the main beam assembly 14 through the interaction of the yoke assembly 25 and the guide tube 23. When it is desired to alter the transverse direction in which mining is to occur, the transverse yoke cylinders 82 are selectively activated to move the guide tube 23 transversely relative to the tunnel 77, rotating the main beam assembly about a vertical axis. The mobile mining apparatus 10 may be steered while being moved to a further mining location along a tunnel by retracting the gripper cylinders 27 and 30 to free the gripper assembly from the floor 80 and roof 81, and utilizing steering means 83 to vary the steering angle formed between the main beam assembly 14 and the rear travel assembly 12 at the vertical slide-pivot 71.
As illustrated in the diagram of FIG. 6, the PLC 74 may be programmed to continuously monitor the cutter wheel drive motor power using the output from the cutter wheel drive motor current transducer 75f, which provides a reasonably accurate measure of motor power input for a constant-voltage supply. The measured power level is compared with the maximum power level which may be safely utilized by the cutter wheel drive system. From the swing cylinder length transducers 75a, the PLC 74 can also determine the angular position and slew rate of the boom assembly 17. If the measured power level is significantly lower than the maximum power level and the slew rate is below the pre-determined maximum value, the PLC 74 may control a proportional control value controlling a swing pump feeding oil to the swing cylinders 54 to increase the slew rate. As the cutting wheel 36 rotates at a relatively constant speed in this embodiment, this has the effect of increasing the pitch of the spiral lines scribed in the rock (kerf spacing) by the cutting flanges 50 during successive rotations of the cutting wheel 36. This effect increases the force applied to the cutting flanges 50 by the rock and thus increases the power demand of the cutting wheel drive motors 37. The volume of rock cut from the face 76 also increases with increased kerf spacing, and thus the output of the mobile mining apparatus may be optimized for rock with particular cutting properties. Should the cutting wheel 36 encounter harder rock as it slews across the face 76, the power demand of the cutting wheel drive motors 37 will rise, and the PLC 74 will reduce the slew rate of the boom assembly 17 until the maximum sustainable production rate consistent with the cutting wheel power limit is again reached. This form of production optimization is particularly applicable to a cutting wheel in which all of the cutting flanges 50 are co-planar and thus scribe a single spiral line across the face 76, whereby all kerf spacings are dependent only on the slew rate of the boom assembly 17 relative to the rotational speed of the cutting wheel 36.
The PLC 74 may also monitor the swing cylinder oil pressure through the boom swing hydraulic pressure sensors 75e to give a measure of the transverse loading on the cutting wheel 36, the boom pivot pin strain gauge 75c to give further information on both horizontal and vertical forces on the cutting wheel 36, and the cutter shaft strain gauges 75g (discussed below) to provide a measure of the direct load on one or more roller cutter assemblies 44. The computed forces are compared with predetermined limits, and the slew rate of the boom assembly 17 may be reduced below the optimum value for maximizing production to a value at which excessive stress levels are not generated on the cutters or within the structure of the mobile mining apparatus 17.
If desired, the PLC 74 may be programmed to monitor changes in rock properties, such as rock hardness, relative to cutter wheel location across the face 76 using data including the cut spacing produced by the cutter power optimization algorithm. The rock hardness map so produced from one traverse of the cutting wheel may be utilized to program controlled variations in cut spacing for a succeeding traverse. Such a hardness map may also be used to detect a substantially vertical join between an ore body and surrounding rock of differing hardness, and may be utilized to control the extent of traverse of the cutting wheel to one side such that the ore body may be selectively mined.
The PLC 74 may be further programmed to monitor the cutting forces of individual cutters, such as by the use of strain transducers or the like, and the rotational position of the cutting wheel whereby the variation in rock properties along a cutter path line may be monitored and utilized for mapping the vertical variation in rock properties of the face 76. These transducers are cutter shaft strain gauges 75g, preferably Series 125 strain gauges manufactured by Micro-measurements of Raleigh, N.C.
It is readily apparent that the above description pertains to optimization of rock cutting by optimization of cutterhead plunge and cutterhead sweep. This optimization of cutterhead plunger and cutterhead sweep allows fine-tuning of machine performance in various rock conditions and maximizes penetration rate without exceeding either the cutterhead drive torque limit or the cutterhead bearings load capacity. In addition, control over both the cutter penetration and the cutter path spacing gives control of the average contract stress between the rock and the cutter edges, thus improving cutter ring life. This PLC 74 monitors machine performance and derives the optimum cutter penetration and cutter path spacing that will maximize performance.
Spacing between cutter paths is a function of the number of cutters in assemblies 44 and 45 on cutter wheel 36, the revolutions per minute of cutter wheel 36 and the slew rate. Thus, the spacing between cutter paths can be changed by varying the slew rate. Specifically, an increase in the slew rate causes a proportional increase in the spacing between cuts.
Direct control over the spacing between cuts allows the cutting performance to be optimized.
In soft rocks, for example, both a large plunge and fast swing rate can be used without over loading either the cutterhead power or cutter bearings. In hard rock, on the other hand, both the plunge and swing rate can be reduced to prevent high cutter loads and edge stresses.
Referring again to FIG. 6, PLC 74 includes a processor 85 which is preferably an Allen-Bradley Model PLC-5/25 Processor with 21K of memory. PLC 74 also has an optimization module 87, preferably an Allen-Bradley 1771 DB Basic Module.
PLC 74 also includes discrete input/outputs 89 which are preferably Allen-Bradley Model 1771-IMP, Model 1771-OMD, Model 1771-IBD and Model 1771 CBD, and which access discrete controls 91 such as hydraulic pumps, hydraulic values, pressure sensors, component status sensors, and electric motors known in the art. The A/D inputs and D/A outputs 95 of PLC 74 are preferably Allen-Bradley Model 1771-IFE and Model 1771-OFE, and access transducers 75a-75g discussed above. Processor 85 is connected to optimization module 87, discrete input/outputs 89, A/D inputs and D/A outputs 95, and is controlled by PLC program 7000 to be explained in further detail below. Optimization module 87 is controlled by optimization program 8000, discussed in detail below.
PLC 74, and specifically processor 85 in conjunction with PLC program 7000, controls the following functions of mobile mining apparatus 10: tramming from site to site, conditioning the face, overcutting the back for cutter replacement, unattended operation through one propel stroke, regrip at end of propel stroke, horizontal and vertical steering, curve development, fire detection and suppression, cutterhead boom swing angle, cutterhead boom swing rate, and cutterhead plunge depth.
Optimization module 87, in conjunction with optimization program 8000, analyzes machine data performance sent by processor 85. Specifically, processor 85 sends data based on cutterhead drive motor amperage, swing cylinder extension cutter loads and boom forces to optimization module 87.
From this data optimization module 87 will calculate the cutter penetration (plunge) and the spacing between cuts (swing rate) required to maximize machine performance in the rock being mined. In weak rocks, this will be the deepest plunge and highest slew rate that fully utilizes the available cutter wheel drive power without exceeding the maximum allowed slew angle (the angle between the cutter paths and the vertical). In hard rocks, limitations such as the bearing load capacity of the cutters are expected to restrict the penetration and slew rate, causing the machine to operate below the maximum cutter head power.
For optimization module 87 to send updated plunge depth and swing rate instructions to processor 85, optimization program 8000 uses equations that define the relationships between the cutter penetration and spacing between cuts, and the resulting cutter loads, edge stresses and cutterhead power. Such equations will allow the machine to respond quickly to changing rock conditions and, thus, will allow it to achieve maximum penetrations rates over most of the cutting time.
The machine performance data that will be used by the optimization program 8000 for calculating the maximum operating conditions include the cutterhead motor amperage, cutter normal force (optional), the plunge at the beginning of each slew, and the extension of the swing cylinders. During a slew the cutterhead motor amperage, cutter normal force, and the swing cylinder extensions will be sent to the optimization module 87 at fixed intervals (presently set at 5 degrees). The motor amperage will be used to calculate the cutterhead torque and the cylinder extensions will be used to calculate the slew angle and slew rate.
The average cutter normal force (Fn) for each 5 degree slew for example will be either calculated by the optimization module 87 from the average cutterhead torque and cutter penetration as determined from the plunge and slew angle or measured directly. Normal force calculations from the cutterhead torque will be done by calculating the average tangential force on the cutters (Ft-rolling force) from the cutterhead torque and the average cutter coefficient (Ft/Fn) based on the cutter penetration. By multiplying these two values, the cutter normal force (Fn) can be determined. The cutter edge loads (i.e. force per unit contact length between the cutter and rock) can also be determined either from the cutter rolling force and cutter penetration or from the measured cutter normal force.
After the average cutter normal force, cutter edge load and cutter head drive power are known, the cutter penetration and spacing between cuts (slewing rate) that will produce the maximum machine performance can be calculated using the relationships defined by the predictor equations. This will be done with the following limitations being observed: bearing capacity of the cutters, cutterhead power limit, cutter edge load limit, and slew angle limit.
The cutter edge load limit is used to protect the cutters from excessively high edge stresses that might occur in hard rock and cause catastrophic brittle failure. It also helps to reduce the cutter wear rates caused by small scale chipping at the cutter edges and high abrasion rates. The slew angle limit is used to protect the cutters from excessively high sides loads caused by slewing and protects the cutter rings from excessive abrasive wear due to cutter skidding.
In the first mode of operation (Mode 1), the optimization module 87 and optimization program 8000 will send a new plunge rate, plunge depth, and a new average slew rate to the processor 85 once at the end of each slew. All calculations for maximizing performance will usually be made during the time that the cutterhead is ramping down just prior to contact with the side wall of the tunnel, and the new plunge and slew rate value will be passed to the processor 85 usually just prior to the start of the next swing. In this mode, the slew rate of the cutterhead will not be varied during a swing unless some overload of the cutterhead power occurs causing the processor 85 to take corrective action by slowing the slew rate or, if the overload is extremely severe, shutting down the machine. Optimum plunge depth and plunge rate are derived for each entire slew and do not change unless overload occurs.
In a second mode of operation (Mode 2) optimization module 87 and optimization program 8000 will map the tunnel face using the input data, and from this map calculate a matrix of slew rate values as a function of the slew angle. This mode of operation is useful in mixed rock conditions where the cutter loads will vary across the face. Under such conditions, reducing the slew rate over the hard rock portions of the face helps to reduce these loads by reducing the spacing between cuts. Optimum plunge depth and plunge rate are derived for each entire slew and do not change during the slew unless overload occurs.
In Mode 3, optimization module 87 and optimization program 8000 make substantially real time corrections to the slew rate during a swing. This requires substantially continuous communication (such as at 5 degree increments) between optimization module 87 and processor 85. Optimum plunge depth and plunge rate are derived for each entire slew and do not change unless overload occurs.
Now described is PLC program 7000 of FIGS. 7A-7P, this program controls the functioning of processor 85.
Referring first to block 7001, at this block certain preexisting conditions must be met before the program is initiated. Specifically, the cutterhead motors must be running, all the safety circuits of the machine must be satisfied, the survey data should be entered, the steering data must be entered, and the tunnel width or the face width must be entered. Also, based on the above conditions, the end-of-swing cylinder extensions will be calculated by another program.
Next, at block 7002, processor 85 is programmed to run the program 7000. At block 7003, the right hand swing cylinder extension is compared to the end-of-swing that was previously calculated. Block 7004 is a decision block at which it is ascertained whether or not the right hand cylinder extension is greater than or equal to end-of-swing. If the answer is "yes", the program proceeds to block 7005 at which the left hand swing cylinder extension data taken from the transducer is loaded to a file. Next, at block 7006, a bit indicating the program is reading the left hand cylinder extension is set at 0 in the status word. The program next proceeds to block 7007 which is label 1-2. From Label 1-2 the program then proceeds to block 7013 to be described in further detail below.
Now referring again to block 7004, a decision block, if the answer is in the negative, the program proceeds to block 7008 at which the left hand swing cylinder extension is compared to the end-of-swing. Block 7009 is a decision block at which it is ascertained whether the left hand cylinder extension is greater than or equal to the end-of-swing. If the answer is "no", the program proceeds to block 7010. At block 7010, the operator is prompted with the message "condition the face". From block 7010, the program proceeds to an end-of-program designation where the program then preferably proceeds to an alarm and warning subroutine, either proprietary or known in the art. From the alarm and warning subroutine, the program then loops to the start of the main program, controlling PLC program 7000.
Referring again to decision block 7009, if, on the other hand, the answer is "yes", the program proceeds to block 7011. At block 7011, the right hand swing cylinder extension data is sent to a file. Next, at block 7012, a bit is set in the status word indicating that the program is reading the right hand cylinder extension. From block 7012, the program proceeds to block 7007, which is label 1-2 described above. From block 7007, the program proceeds to block 7013 where it is determined whether the auto-enable bit is equal to 1. If the answer is "yes", the program proceeds to block 7014, which is label 1-4. From block 7014, the program proceeds to block 7045 to be described in further detail below.
Again referring to decision block 7013, if the decision is "no", the program proceeds to 7015 where the data from the previous swing is stored. Next the program proceeds to block 7016 at which the operator is shown the data retrieved from the previous swing. Block 7017 is a decision block at which the operator decides whether or not to choose current data. If the answer is "yes", the program proceeds to block 7018. Block 7018 is a decision block at which the operator decides whether or not to enter 1. If the decision is "no", the program proceeds to the end designation previously described. If, on the other hand, the answer at block 7018 is "yes", the program proceeds to block 7019, which is label 2-3. From label 2-3, the program then proceeds to block 7042 to be described in further detail below.
Referring again to decision block 7017, if, on the other hand, the decision is "no", the program proceeds to decision block 7020. Block 7020 is a decision block at which the operator later decides whether to enter 0. If the operator does not enter 0, i.e., if the decision is "no", the program proceeds to the end of program designation, as previously described above. If, on the other hand, the operator does enter 0, i.e., the decision is "yes", the program proceeds to block 7021. Block 7021 prompts the operator with the message "enter swing rate".
Block 7022 is a decision block at which it is ascertained whether the operator has entered the swing rate. If the answer is "no", the program proceeds to the end of program designation as described above. If, on the other hand, the answer is "yes", the program proceeds to decision block 7023. Decision block 7023 ascertains whether the swing rate chosen is within the machine limits. If the answer is in the negative, the program proceeds to block 7024 at which the program prompts the message "invalid data" to the operator. At block 7024, the program then proceeds back to block 7021 described above.
Referring again to block 7023, if, on the other hand, the answer is "yes", the program proceeds to block 7025. At block 7025, the swing rate chosen is loaded into memory. Block 7026 prompts the operator with the message "enter plunge rate". The program then continues to block 7027, which is a decision block.
Block 7027 determines whether the operator has entered the plunge rate. If the answer is "no", the program continues to the end designation as described above. If, on the other hand, the decision was "yes", the program continues to block 7028, which is a decision block. Block 7028 determines whether the rate chosen was within the machine limits. If the answer is "no", the program proceeds to block 7029. Block 7029 prompts the operator with the message "invalid data". The program then proceeds to block 7026 described previously.
Referring back to block 7028, a decision block, if the answer is "yes", the program proceeds to label 1-3 which is block 7030. The program continues from label 1-3 or block 7030 to block 7031. Block 7031 loads the chosen plunge rate into memory. Block 7032 prompts the operator with the message "enter plunge depth".
The program then proceeds to block 7033, which is a decision block. Block 7033 determines whether the operator has entered the plunge depth. If the answer is "no", the program continues to the end designation as previously described above. If the answer from block 7033 is "yes", the program proceeds to block 7034, a decision block.
Block 7034 determines whether the plunge depth is within the machine limits. If the answer is "no", the program proceeds to block 7035. Block 7035 prompts the operator with the message "invalid data". The program then proceeds to block 7032 previously described.
If the answer from the decision made in block 7034 is "yes", the program proceeds to block 7036, "load plunge depth". Block 7037 prompts the operator with the message "enter optimization code".
The program then proceeds to block 7038, a decision block. Block 7038 determines whether the operator has entered the optimization code. If the answer is "no", the program proceeds to the end of program designation as previously described above.
If the answer to decision block 7038 is "yes", the program proceeds to block 7039, a decision block. Block 7039 determines whether the operator has entered a valid optimization code. The valid numbers are 0, 1, 2, or 3. Optimization code 0 indicates that the program will bypass the optimization program 8000 and run strictly off of operator input. Optimization codes 1, 2 and 3, pertain to mode 1, mode 2 and mode 3 of operation, respectively.
If the answer to decision block 7039 is "no", the program continues to block 7040. Block 7040 prompts the operator with the message "invalid code". The program then continues to block 7037 previously described above.
If, on the other hand, the answer to decision block 7039 is "yes", the program proceeds to block 7041. Block 7041 loads the previously chosen optimization code to the status word. The program then continues to block 7042. Block 7042 displays the message "data OK, press start". Block 7042 is also in the path of the program coming from label 2-3 which is block 7019 previously described. The program then continues to block 7043, which is a decision block. Block 7043 determines whether the start button has been pressed. If the answer to the decision in block 7043 is "no", the program continues to the end designation as previously described above. If the answer, on the other hand, is "yes", the program proceeds to block 7044.
Block 7044 sets the "first pass bit" to "1". The program then continues to label 1-4, which is block 7014 previously described. The program continues from block 7014 to block 7045. Block 7045 reads the upper right propel cylinder extension and loads it to memory.
The program continues to block 7046, which reads the lower left propel cylinder extension and loads it to memory. Block 7047 subtracts the upper right propel cylinder extension from the maximum propel cylinder extension distance determined by the physical length of the propel cylinder. The program continues to block 7048, a decision block.
Block 7048 ascertains if the difference between the upper right propel cylinder extension and the maximum propel cylinder extension is greater than the plunge depth entered above. If the answer to this question is "no", the program continues to block 7049. Block 7049 prompts the operator with the message "regrip required". Block 7050 resets the "first pass" and the "auto-enable" bits to "0". From block 7050, the program goes to the end of program designation as previously described above.
If the answer to the decision in block 7048 is "yes", the program proceeds to block 7051. Block 7051 subtracts the lower left propel cylinder extension from the maximum propel cylinder extension determined by the physical length of the cylinder. The program continues from block 7051 to block 7052, a decision block. Block 7052 ascertains if the difference derived in block 7051 is greater than the plunge depth. If the answer to this decision is "no", the program proceeds to block 7049 previously described.
If the answer to decision block 7052 is "yes", the program proceeds to label 1-5, which is block 7053. The program continues from label 1-5 or block 7053, to block 7054. Block 7054 adds the plunge depth to the right propel cylinder extension and stores this new value to memory. Block 7055 adds the plunge depth to the left propel cylinder extension and stores this new number to memory. Block 7056 calculates the output voltage to the propel cylinder proportional valve and the time that the signals will be present at the valve. This is calculated from the relationship of the plunge depth and plunge rate to the valve, operational amplifier, and cylinder characteristics, plus a correction factor derived from the actual extension and the desired extension.
Block 7057 loads the output voltage determined in block 7056 to memory. It also loads the time, also calculated in block 7056 to memory. The program continues to label 2-5, which is block 7058.
The program then continues to block 7059, a decision block. Block 7059 ascertains if the plunge timer has been set. If the answer to this question is "no", the program proceeds to block 7060. Block 7060 starts a timer known as the "plunge timer". The plunge timer accumulates time until the plunge cycle is complete. The program continues from block 7060 to label 2-5 which is block 7058 previously described.
If the answer to the decision block 7059 is "yes", the program proceeds to block 7061, a decision block. Block 7061 determines if the time calculated in block 7056 is greater than or equal to the accumulated time from the plunge timer. If the answer to this decision is "no", the program proceeds to label 1-6, which is block 7064. Block 7065 obtains the voltage level determined in block 7056 and sends it to the analog output module to energize the propel cylinder proportional valve.
Block 7066 reads and averages the cutterhead motor amperage and loads this to memory. Block 7067 reads and averages the boom swing cylinder force and loads this to memory. Block 7068 reads and averages the beam propel thrust force and loads this to memory. The program then continues to label 2-5, which is block 7058, previously described.
If the decision required from block 7061 is "yes", the program continues at block 7063, which is a label identified 2-6. The program continues from label 26, or block 7063, to block 7069. Block 7069 sends a voltage level of 0 to analog output module thereby de-energizing the propel cylinder proportional valve. The program continues from block 7069 to label 1-7, which is block 7070. The program continues from block 7070 to block 7071, a decision block.
Decision block 7071 determines if the "plunge write" bit has been set to "1". If the answer to the decision in block 7071 is "no", the program proceeds to block 7073. Block 7073 reads the present position for the upper right hand propel cylinder and subtracts the previous right hand propel cylinder extension distance and loads this new number which is the actual plunge depth for the right hand propel cylinder in memory. Block 7074 reads the actual value of the lower left hand propel cylinder and subtracts the previous position of the lower left hand propel cylinder and loads this new number which is the actual plunge depth for the left hand cylinder into memory. Block 7075 compares the actual plunge depth to the programmed plunge depth and calculates a new correction to be used in the next plunge. Block 7076 sends a block of information to the optimization module 87 for use in the optimization program 8000. This information consists of the machine status word, the true plunge depth, the cutterhead amperage, a bit signifying whether the left or right hand swing cylinder is extended, and the tip ration. The tip ratio is a cutter wear factor that is derived from empirical data. Also included in this packet of information is the left hand and right hand swing cylinder extension values. The program continues from block 7076 to label 1-8, which is block 7077. From block 7077, the program goes to block 7062. Block 7062 sets the "plunge write" bit to "1". The program continues from block 7062 to label 1-7, which is block 7070, previously described.
If the answer to decision block 7071 is "yes", the program continues to label 2-8, which is block 7072. The program goes from block 7072 to block 7078. Block 7078 calculates the output voltage determining the swing rate which will be sent to the swing pump proportional control valve. This is determined from relationships of the valve operational amplifier and cylinder characteristics, and a correction factor derived from empirical data. This output voltage value is then stored to memory.
The program continues from block 7078 to block 7079, a decision block. Block 7079 ascertains if the first pass bit has been set to "1". If the answer to this decision is "yes", the program continues to block 7080. Block 7080 calculates at what point during the swing the swing speed should be reduced to an extremely slow swing rate. This point typically occurs near the end of the swing cycle. The program continues from block 7080 to label 3-8, which is block 7081. The program continues from block 7081 to block 7082, a decision block which is described below.
Returning to block 7079, a decision block, if the decision reached in this block is "no", the program continues to label 3-8, which is block 7081 previously described. Block 7082, a decision block, determines if the "swing timer" has been turned on. If this answer to the decision is "no", the program continues to block 7083. Block 7083 turns on the swing timer. The program then continues from this block to label 3-8, which is block 7081, previously described.
If the answer to the decision in block 7082 is "yes", the program continues to label 1-9, which is block 7084. From block 7084, the program continues to block 7085, a decision block. Block 7085 ascertains if the "ramp down bit" has been set to "1". If the answer to the decision in block 7085 is "yes", the program continues to block 7086, a label identified as 2-11. From label 2-11 or block 7086, the program continues to block 7115, which will be described below.
If, on the other hand, the decision at block 7085 is "no", the program continues to block 7087. Block 7087 writes the voltage level determined in block 7078 above to the proportional control valve which controls the swing pump. Block 7088 reads and averages the cutterhead motor amps and stores these in memory. Block 7089 reads and averages the boom swing cylinder force and stores this number in memory. Block 7090 reads and averages the beam propel thrust force and stores this value to memory. Block 7091 loads a bit to the status word to indicate the start of the swing cycle. The program continues from block 7091 to label 1-10, which is block 7092. The program continues from label 1-10, block 7092, to block 7093, a decision block.
Block 7093 ascertains if the swing is going from the left to the right. This information was loaded into the status word in block 7006 or in block 7012 previously described. If the answer to this decision is in the affirmative, i.e., "yes", the program continues to block 7101. Block 7101 energizes the left hand swing cylinder solenoid valve and causes the cylinder to extend. The program then continues to block 7102, a decision block. The decision block 7102 ascertains if the memory word, which for the purposes of clarity will be referred to as "SWG", has a value of "0". If the answer to this decision is "yes", the program continues to block 7103. Block 7103 gets the left hand cylinder extension distance that was saved to memory in block 7008 previously described and adds to it a swing cylinder extension distance of approximately 5° in millimeters. This new value is then saved as "SWG". The program then continues to block 7104 to be described below.
If, on the other hand, the decision reached at block 7102 is "no", the program proceeds directly to decision block 7104. Decision block 7104 ascertains if the value in the register "SWG" is less than or equal to the actual left hand swing cylinder extension. If the answer to this decision is "no", the program then proceeds to decision block 7105 to be described below. If the answer to decision block 7104 is "yes", the program continues at block 7100 to be described below.
Returning to decision block 7093, if the answer to this block is "no", the program proceeds to block 7094. Block 7094 causes the right hand swing cylinder solenoid valve to energize, thereby extending the right hand swing cylinder. The program continues to block 7095, a decision block.
Decision block 7095 ascertains if a memory word, which for the purpose of clarity will be referred to as "SWG", has a value of "0". If the answer to this decision is "yes", the program continues to block 7096. Block 7096 gets the right hand cylinder position word stored in memory at block 7011 previously described and adds to it a swing cylinder extension distance of 5° in millimeters. This new value is then stored in memory as word "SWG". The program then continues to block 7097, a decision block to be described below.
Returning to decision block 7095, if the answer to this question is "no", the program continues directly to block 7097, a decision block. Block 7097 ascertains if the value in the word "SWG" is less than or equal to the right hand swing cylinder extension. If the answer to this decision is "no", the program continues to block 7098, a decision block to be described below. If, on the other hand, the answer is "yes", the program continues to block 7100. Block 7100 takes the value in the word "SWG" and adds to it a swing cylinder extension of 5° in millimeters. This new value is then saved to the register "SWG". The program then continues to block 7106, a decision block. Decision block 7106 determines if the "first pass" is set to "1". If the answer to this question is "yes", the program proceeds to label 2-10, which is block 7107. From block 7107, the program proceeds to block 7108. Block 7108 sends to the optimization module 87 for use in the optimization program 8000 the machine status word which also contains the information on which cylinder is extending, the actual extension value of the extending swing cylinder, the swing cylinder force described in block 7067 above, the beam propel thrust force described in block 7068 above, the accumulated average of the motor current amps, and the accumulated time from the start of the swing established from turning on the timer indicated in block 7083.
The program then continues to block 7109, a decision block. The decision block 7109 ascertains if the swing is traveling from the left to the right. If the answer to this decision is "yes", the program proceeds to decision block 7105. The decision block 7105 determines if the ramp down point determined in block 7080 above is less than or equal to the left hand swing cylinder extension. If the answer to this decision is "no", the program proceeds to label 2-8, which is block 7072 previously described. If, on the other hand, the answer to this decision is "yes", the program proceeds to label 1-11, which is block 7099. The program proceeds from block 7099 to block 7111, which will be described below.
Returning to decision block 7109, if the decision from this block is "no", the program continues to decision block 7098. Decision block 7098 determines if the ramp down point determined in block 7080 is less than or equal to the right hand swing cylinder extension. If the decision from this block is "no", the program proceeds to block 7072, which is labeled 2-8, described above. If, on the other hand, the decision reached at block 7098 is "yes", the program proceeds to label 1-11, which is block 7099. The program continues from label 1-11 or block 7099 to block 7111, which will be described below.
Returning to the decision block 7106, if the answer to this block is "no", the program then continues to label 1-15, which is block 7110. Continuing from block 7110, the program goes to block 7151, a decision block. This block determines if the "optimization mode" is equal to "1". If the answer to this questions is "yes", the program proceeds to label 2-10, which is block 7107 previously described. If, on the other hand, the answer to this decision is "no", the program continues to block 7152, a decision block. This decision block determines if the "optimization mode" is equal to "2". If the answer is in the affirmative, the program proceeds to block 7153. Block 7153 moves the first value in the swing rate matrix, which is loaded into memory elsewhere in this program, to the swing rate memory word which is established in block 7025 described above. Block 7154 then shifts the swing rate matrix stack up one position to expel the first value which was used in block 7153 above. The program then continues to label 2-10, which is block 7107 described previously.
Returning to decision block 7152, if the answer to the question posed in this block is "no", it indicates that the "optimization mode" chosen is "mode 3". This causes the program to continue at block 7155. Block 7155 reads the machine status word and the swing rate correction word from the optimization module 87 derived by optimization program 8000 and loads these to a memory buffer. The program then continues at label 1-16 which is block 7156. From block 7156, the program continues to block 7157.
At block 7157, the existing swing rate is multiplied by a swing rate correction factor that has been loaded in the buffer and this new value is then loaded to the swing rate word in memory. Block 7158 resets the buffer to 0. The program continues at label 2-10, which is block 7107 described previously. Block 7111, which was mentioned previously but not described, sets the reached ramp down bit to "1".
The program then continues at block 7112, which loads the "reached ramp down" bit to the "status" word. Block 7113 then sends the "status" word to the optimization module 87 for use in the optimization program 8000. Block 7114 causes the program to read optimization values derived in the optimization program 8000 and sent from the optimization module 87. The information read includes the machine status and mode data, the new plunge depth, the new plunge rate, the new swing rate, the new end-of-swing position, the new ramp down position, and which cylinder is going to extend. This information is then loaded to a memory buffer.
The program then continues to label 2-11 which is block 7086 described above and is in the path from decision block 7085, also described above. The program goes from block 7086 to block 7115. Block 7115 sends a reduced voltage level to the analog output module controlling the swing rate pump proportional control valve, which in turn causes the pump to produce a reduced oil flow for a reduced swing rate. The program then continues to label 1-12, which is block 7116. From block 7116, the program continues to block 7117, which is a decision block.
The decision block 7117 determines if the swing is traveling from left to right. If the answer to this decision is "yes", the program proceeds to block 7120. Block 7120 causes the left hand swing cylinder solenoid to remain energized. The program then continues to decision block 7121. Block 7121 ascertains if the left hand swing cylinder extension distance is greater than or equal the end-of-swing value previously loaded into memory. The end-of-swing value determines the turnaround point of the swing cycle. If the answer to this decision is "no", the program proceeds to label 1-9, which is block 7084 described previously. If, on the other hand, the answer to this decision is "yes", the program continues to block 7122, which will be described below.
Returning to decision block 7117, if the answer to this question is "no", the program continues to block 7118. Block 7118 keeps the right hand swing cylinder solenoid valve energized. The program then continues to decision block 7119. This block ascertains if the right hand swing cylinder extension is greater than or equal to the end-of-swing value previously loaded in memory. If the answer to this decision is "no", the program proceeds to label 1-9, which is box 7084 described previously. If, on the other hand, the answer to this decision is "yes", the program continues to block 7122. Block 7122 writes a voltage level of "0" to the analog output module supplying power to the proportional control valve controlling the swing rate pump thereby bringing the pump to 0 stroke and stopping the flow of oil. The program then continues to decision block 7123.
Decision block 7123 again determines if the swing is from left to right. If the answer to this question is "yes", the program proceeds to block 7125. Block 7125 then causes the left hand swing cylinder solenoid valve to de-energize, thereby stopping the flow of oil to the swing rate pump. The program then continues to block 7126 to be described below.
If the choice at block 7123 was "no", the program continues to block 7124. Block 7124 de-energizes the right hand swing cylinder solenoid valve, thereby stopping the flow of oil to the right hand swing cylinder. The program then continues to block 7126. Block 7126 resets the first pass bit to "0". Block 7127 sets the auto-enable bit to "1". Block 7128 resets the plunge timer accumulated value to "0". Block 7129 resets the plunge write bit to "0". The program then continues at label 1-13, which is block 7130. The program continues from block 7130 to block 7131. Block 7131 resets the swing timer accumulated value to "0". Block 7132 clears the word "SWG" and sets it to "0". Block 7133 resets the ramp down bit to "0". Block 7134 obtains the new status word, which was loaded in the buffer memory earlier in the program, and makes it available for the decision blocks to follow. The program then continues to decision block 7135.
Decision block 7135 ascertains if the optimization mode in the new status word is equal to "0". If the answer to this decision is "yes", the program proceeds to block 7136. Block 7136 resets the auto-enable bit to "0". The program then continues to the end of program designation as previously described above.
If the answer to the decision on block 7135 is "no", the program proceeds to block 7138, a decision block. Block 7138 ascertains if the optimization mode from the new status word loaded above equals "1". If the answer to this decision is "yes", the program proceeds to label 3-14, which is block 7139. Continuing from block 7139, the program goes to block 7145, to be described below.
If, on the other hand, the decision reached at block 7138 is "no", the program continues to block 7140, a decision block. Block 7140 ascertains if the "optimization mode" from the new status word loaded above is equal to "2". If the decision reached is "yes", the program continues to label 2-14, which is block 7141. Continuing from block 7141, the program goes to block 7147 to be described below. If, on the other hand, the decision reached at block 7140 is "no", the program continues to label 1-14, which is block 7142. The program continues from block 7142 to block 7143, which is a decision block.
Decision block 7143 ascertains if the "optimization mode" from the new status word loaded above is equal to "3". If the answer in this case should be "no", the program goes to block 7144. Block 7144 prompts the operator with the message "invalid data". The program then continues to label 2-13, which is block 7137. From block 7137, the program continues to block 7136, which was previously described. If, on the other hand, the decision reached at block 7143 is "yes", the program goes to block 7145. Block 7145 moves the new data that was stored in the buffer to the appropriate memory words, i.e., machine status, end-of-swing, swing rate, plunge rate, and plunge depth. The program then continues to block 7146. Block 7146 resets the buffer used to "0". The program continues from here to the end of program designation as previously described above.
Label 2-14, which is block 7141, previously described, sends the program to block 7147 mentioned earlier but not described. Block 7147 moves the new swing rate matrix that was loaded in the buffer to a location in memory. Block 7148 moves the new optimization data, which came from optimization program 8000 earlier and was stored in the buffer to the appropriate storage words, i.e., machine status, end-of-swing, plunge rate, and plunge depth. Block 7149 moves the first value in the swing rate matrix to the swing rate word in memory. Block 7150 shifts the swing rate matrix stack in memory to expel the first value which was used in block 7149 above. The program then continues from block 7150 to block 7146 described earlier.
Referring to the optimizing program 8000 of FIGS. 8A-8B, the program is a driver program that calls subroutines as required. The subroutines are detailed in FIGS. 9-16, below. Referring to block 8002 of FIG. 8 entitled "dimension matrices for data storage", five matrices are dimensioned. These matrices are for: storing values of cutterhead power, slewing velocity, cutter normal load, cutter edge load, and calculated slew velocities for the next swing. In the initial program values will be entered into the performance matrices every 5° of swing. Block 8004 is entitled "declare variables". The variables that will be used in the program are all declared at the beginning of the program for smoother operation. The variables declared are the following.
True plunge--actual machine plunge at the beginning of a slew
Cutter tip ratio--describes cutter dullness
Machine status--is the machine slewing, stopped
Extension cylinder status--cylinder for extension data
Swing cylinder extension
Calculated swing velocity
Average cutterhead motor amperage--from Processor 85
Time between transmissions of data from Processor 85
Program status--status of optimization program
Calculated swing angle
Average cutter edge load during swing
Average cutterhead power during swing
Average swing velocity during swing
Average cutter normal load during swing
Operation mode (Mode 1, 2, or 3)
Sum for cutterhead power--for 5 degree averages
Sum for normal load--for 5 degree averages
Sum for edge load--for 5 degree averages
Sum for swing rate--for 5 degree averages
Calculated cutterhead power
Calculated cutterhead torque
Calculated cutter tangential force
Max. cutter penetration at springline
Calculated cutter edge load
Calculated cutter normal load
Max. swing angle at the wall
Correction status--tells processor 85 that a swing rate correction will be made
Percent swing rate correction.
The first variable is the true plunge, which is the actual plunge that the machine has taken at the beginning of each swing.
Referring now to block 8006, "declare constants and limits", at this block constants are declared. These include: Pi (3.14159), the conversion between degrees and radians, the cutterhead RPM (this value can also be inputted into the program as a variable), the cutterhead diameter, the cutter normal load limit, the cutter diameter, the cutter edge load limit (the maximum line load that can be tolerated on the cutter flanges or cutter wing tips), the cutterhead power limit, the maximum slew rate per 4° slew (in degrees per second), the minimum time required per 5° swing, and Kerf spacing at 4° slew. The 4° slew limit is exemplary only.
Referring now to block 8008, "declare words for BTR and BTW", at this block BTR means "block transfer read" and denotes the words that will be passed to the optimization program 8000 from the PLC program 7000 and processor 85. BTW, which is "block transfer write", are the words to be transferred from the optimization program 8000 to the PLC program 7000 and processor 85.
Referring to block 8010, "mode of operation", at this block the operator is allowed to input into the program which operating mode he wishes to work under--mode 1, mode 2, or mode 3. This is also an optional feature. If initially it is decided to only operate in one of these modes, the mode can be set as a constant.
Block 8012, "operator input", optionally allows the operator to input mode selection.
Referring next to block 8014, "send first word" tells the optimization program 8000 to send a word to the PLC program 7000 and processor 85. That word will tell the PLC program 7000 and processor 85 which operating mode is in operation. If mode 3 is in operation, then the PLC program 7000 and processor 85 must read words from the optimization program on a continuous basis throughout the swing. If either mode 1 or mode 2 are employed, the PLC program 7000 and processor 85 will read words from the optimization program only at the end of each swing.
Referring to block 8016, "set sums", this block sets to zero the values which are eventually to become the sums for cutterhead power, cutter normal load, cutter edge load, and swing velocity. This function is always performed at the beginning of each swing. Also set to zero is the initial status of the optimization module 87 and the initial matrix increment (count) value.
Next referring to block 8018, "call startsweep", this block is the initiation of the actual sweep optimization routine. All of the prior blocks pertained to defining constants, declaring variables, setting matrix sizes and setting sums to zero. At block 8018, the optimization program 8000 goes to the startsweep subroutine 9000, to be described in detail later. The startsweep subroutine acquires the initial data from the PLC program 7000 and processor 85. The initial data includes the status of the machine (e.g., if it is operating or not and if it is starting to slew), the initial plunge data (which gives true plunge), the tip ratio (which defines the dullness of the cutters), the swing cylinder extension at the walls, and the swing cylinder that the data is coming from (thus informing the optimization program 8000 if the swing is from left to right or vice versa).
Referring next to block 8020, "initialize counter", at this block two counters are initialized. These include a limit counter for mode 3 and a counter for use in averaging the input data at each 5° interval.
Referring now to block 8022, "call machinedat", at this block, the machinedat subroutine is addressed. This subroutine obtains information from the PLC program 7000 and processor 85 while the cutterhead is slewing across the face. The machinedat subroutine reads words which are passed from the PLC program 7000 and processor 85. These words include the machine status (e.g., if the cutterhead is slewing or if it is starting to ramp down), the swing cylinder extension and the swing cylinder from which data is being obtained, how much time has elapsed between each data transfer (used to calculate the sweep rate), and the cutterhead motor amperage. In addition, if data is to be collected directly from the cutters, the machinedat subroutine will include words which pass the actual monitored cutter normal loads. Machinedat subroutine 11000 itself will be described in further detail below.
Connected to machinedat subroutine 11000 is ramp subroutine 10000. Ramp subroutine 10000 is used to calculate the new plunge and new slew rate to be used during the next slew. The ramp subroutine 10000 is implemented when the PLC program 7000 and processor 85 tells the optimization program 8000 that the machine is at the end of the swing and will be ramping down. At this time, new data is needed for the next swing. The ramp subroutine 10000 is the subroutine which calculates this new data.
Referring now to block 8024, "calculate swing velocity", at this block, while the machine is slewing, the data which is being brought in through the subroutine machinedat 11000 is processed and converted into a number of different values to be used in the final calculations. The values calculated at this time include: The ongoing swing velocity, the swing angle, the maximum penetration of the cutters at spring line, the ongoing cutterhead torque, the average cutter rolling force, the average cutter edge load, and the average cutter normal load.
Referring now to block 8026, at this block the values which have been calculated in the previous block 8024 are then summed for calculations of averages for every 5° interval of swing. For example, as the cutterhead power values come in, a summation is created for the cutterhead power until a 5° slew has occurred. An average power value will then be calculated for this sum. Thus, block 8026 performs summations for the cutterhead power, the cutter normal load, the cutter edge load, and the swing velocity. There is also a counter which counts the number of times a value is added to the summation. When the 5° averages are calculated, the summation are divided by that count value.
At block 8027, it is ascertained whether a 5° slew has occurred.
At block 8028, the matrix subroutine is called. The matrix subroutine is called only at the end of each 5° slew. In the matrix subroutine, the average values for the cutterhead power, cutter normal load, cutter edge load, and slew velocity for each 5° slew are calculated and stored in the performance matrix for each of these values.
After block 8028, the program proceeds to block 8029. Block 8029 ascertains whether the program is operating in mode 3. If the program is not in mode 3, block 8029 goes to block 8030, which returns the program to the machinedat subroutine 8022. If in mode 3, this block 8029 checks the values for the ongoing cutterhead power, cutter edge load, and cutter normal load to see if either they exceed the limits or if they are significantly below these limits. If they exceed the limits then at blocks 8031 and 8032 a reduction in the slewing rate will be made. If they are significantly below the limits, an increase in the slewing rate will be made at blocks 8033 and 8034. Note that mode 3 is essentially a real time mode that adjusts the slewing rate during a slew. This is not true for either mode 1 or mode 2. Slew rate increases for mode 3 are made by then going to subroutine mode 3 increase 10000 described in detail below. Slew rate decreases are made going to subroutine mode 3 reduce 15000 described in detail below. If the cutterhead power, cutter edge load or cutter normal load are not significantly below the limits at block 8033, the program goes to block 8030 described above.
Next, referring to FIG. 9, subroutine startsweep is described in detail. The startsweep subroutine 9000 provides the initial values from the PLC program 7000 and processor 85. These values include the machine status, the actual plunge which has been taken at the beginning of the sweep, the tip ratio (a value that defines the cutter dullness), the status of the swing cylinder (i.e., from which swing cylinder data is received at the beginning of the sweep, thus allowing assessment of the direction in which the cutterhead is being swept), and the extension on that swing cylinder at the beginning of the sweep (which provides the angle of sweep).
Now referring to block 9002, "machine status 0", this block looks for a machine status word which tells the program to continue. The program will keep looping until that word is updated, and once it is updated, the program will proceed. In other words, if machine status equals 0, the program will loop back to block 9002. If machine status does not equal 0, the program will continue to block 9004.
Block 9004, "read words 2 through 5", reads words that include the actual plunge at the beginning of the swing, the tip ratio for the cutters (defines the dullness of the cutters), which extension cylinder the data is coming from (defines in which direction the cutterhead is going to swing), and what the extension of that particular cylinder was (defines the position of the cutterhead at the beginning of the swing).
Next referring to block 9006, "calculate swing", at this block the actual position of the cutterhead in terms of its angle with respect to the tunnel axis is calculated from the swing cylinder extension which was inputted in the previous block 9004. Two equations are included, one for the left cylinder and one for the right cylinder: ##EQU1##
Referring next to block 9008, "clear words", all BTR words are reset to 0. The words are now ready for new transmission from the PLC program 7000 and processor 85. Words 1 through 7 are defined as follows: word 1 is the status of the machine--e.g., inactive, slewing, ramping down; word 2 describes the true plunge of the machine at the beginning of each swing; word 3 defines the cutter tip ratio; word 4 describes which swing extension cylinder the swing data is coming from; word 5 is the actual extension of that particular swing cylinder in millimeters; word 6 is the time between transmissions which is used to calculate the swing rate; word 7 is the cutterhead motor amperage. Additionally, a word 8, defining the actual normal loads on the cutters, may be employed.
Referring next to block 9010, "return to main program", at this block the startsweep subroutine 9000 is completed and the program is returned to main program 8000.
Next referring to subroutine matrix 10000 as shown in FIG. 10, subroutine 10000 performs as follows. As the cutterhead is slewing, matrix subroutine 10000 puts into a matrix the average cutterhead power, cutter normal load, cutter edge load and slew velocity for every 5° of swing. The 5° interval is not fixed, and can be changed.
First referring to block 10002, "calculate averages", at this block the average values for cutterhead power, cutter normal load, cutter edge load, the slew velocity that occurred within each 5° swing interval are calculated. In addition to calculating the average value, summations of the average values are made. These summations will eventually be used to calculate the average cutterhead power, cutter normal load, cutter edge load, and slew velocity for the entire swing.
At block 10004, "reset averages", the sums and count for the 5° averages are reset to 0 so that the next set of data can be entered.
Block 10006, "return to main program", ends subroutine matrix 10000 and returns the program to optimization program 8000, as described above.
Referring now to subroutine machinedat 11000 of FIG. 11, this subroutine reads words (i.e., data) sent to the optimization module 87 by the processor 85 and PLC program 7000 while the machine slewing. These words include the machine status, which swing extension cylinder is being operated, the actual cylinder extension, how much time has elapsed between transmissions and the cutter motor amperage. If data is also being collected from instrument cutters and true cutter normal loads are being monitored, this data can also be passed as word 8.
Referring first to block 11002, "machine status 0", if the machine status word is 0 (i.e., machine is not operating or no data is available), the program keeps looping until the status word is changed to 1 or some other value. Referring now to block 11004, "read words 4 through 7", at this block the program reads the following words: word 4, which defines the swing extension cylinder that extension data is coming from: word 5, which gives the actual extension of the cylinder; word 6, which gives the time that has elapsed between transmission of data; and word 7, which gives the cutterhead motor amperage. Again, a word 8 will be added if true cutter normal load data is collected. Additional words for other input data can also be added.
Referring next to block 11006, "calculate swing angle", at this block the cylinder extension data is converted to the swing angle (i.e., the position of the cutterhead at the face). The equations for this calculation are the same as those employed in calculating the position of the angle of the cutterhead when it is at the wall. In other words, the equations are the same as the equations for the left and right cylinder positions referred to in block 9006 of the startsweep subroutine 9000.
Next referring to block 11008, "calculate cutterhead power", at this block the actual operating cutterhead power is calculated from amperage data. This is done using an equation based on the motor power curve. The equation can be derived using curve fitting techniques.
Referring next to block 11010, "clear words" at block 11010, all BTR words are reset to 0 after the data has been collected.
At block 11012, "return to main program", the program exits subroutine machinedat 11000 and returns to optimization program 8000.
Referring next to subroutine ramp 12000 of FIGS. 12A-12B, subroutine ramp 12000 is positioned on a subroutine machinedat 11000 and is called if the mobile mining machine is ramping down. Subroutine ramp 12000 is used to calculate the average cutterhead power, cutter edge load, cutter normal load, and swing load for the previous swing. Subroutine ramp 12000 then evaluates these values and determines their relationship to the limits which have been set for them. If any of the limits are exceeded, downward adjustments are made to the previous plunge and slew velocity. Similarly, if any of the limits are not reached, upward adjustments are made to the previous plunge and the slew velocity.
Referring to block 12002, "calculate averages", at this block the average values for cutter edge load, cutterhead power, cutter normal force, and slew velocity are calculated from the average 5° values stored in the matrices.
Referring next to block 12004, "calculate average time", the average time that was required for a 5° swing is calculated.
Referring next to block 12006, this block is a decision block in which the average cutterhead power, cutter edge load, cutter normal load and slew velocity are first calculated. These are the average values for the entire swing and are calculated from the numbers that were stored in the 5° matrix. In block 12000, the values for cutterhead power and cutter normal load are checked against their limits, and a new plunge value is calculated for the next swing if the average values are above or below the limits. For example, if the limits for average normal force and average cutterhead power are both exceeded, the program proceeds to block 12008 in which a new plunge value is calculated based on ratios between the average normal force and the limiting force, and the average cutterhead power and the limiting power. The corrections to plunge values used are based on the relationships between cutter penetration and cutter normal force, and between cutter rolling force (proportional to power), and cutter penetration as derived from the published predictor equations contained in the Annual Report: Mechanical Tunnel Boring Predictions and Machine Design, L. Ozdemir, et. al., Colorado School of Mines (1973). The corrections used are: ##EQU2## The above equations, as well as Equations 3-8 below, can be employed by those skilled in the art. In addition, field performance test data can be used to derive precise relationships (which may vary with rock conditions). The calculated plunge value, which is the lesser of Eq. 1 and Eq. 2 will be chosen for the next sweep. The program proceeds from block 12008 to block 12024 described in further detail below.
Referring back to decision block 12006, if the decision is "no", the program proceeds from block 12006 to block 12010 where it is determined if the average cutter normal force has exceeded its limit. If the decision is "yes", then the average cutter normal force is higher than its limit, but the average cutterhead power is not.
At that point, the program proceeds to block 12012 in which a new plunge value is calculated based on the average cutter normal force and the normal force limit (Eq. 1). From block 12012, the program will then proceed to block 12024 to be described in further detail below. Referring back to decision block 12012, if the decision is "no", in other words, if the limiting cutter normal force is not exceeded, the program proceeds to block 12014 in which a check is made to see if the average cutterhead power has exceeded its limit. If the average power has exceeded its limit but average normal force has not, the program proceeds to block 12016.
In block 12016, a new plunge is calculated from the average cutterhead power and power limit (Eq. 1). Next, from block 12016, the program proceeds to block 12024 to be described in further detail below.
Referring back to block 12014, if neither the power limit nor the cutter normal force limit is exceeded, the program checks at block 12018 to see if the average power and average cutter normal force are below a certain percent of their limits. The actual percentages employed are to be based on field performance data.
If both the average cutter normal force and cutterhead power are below the limits, an adjustment is made to the plunge, i.e., the plunge must be increased in order to bring either the normal force or cutterhead power up to its desired limit. This is done in block 12020. In block 12020, both a new plunge based on the average cutter normal force and a new plunge based on the average cutterhead power are calculated. The lesser of these two values is then chosen.
From block 12020, the program proceeds to block 12024 to be explained in further detail below. Referring again to block 12018, if the average cutterhead power and the average cutter normal force do not exceed the limits or are not significantly below the limits, then, at block 12022, the plunge for the next swing is set to the plunge which was used in the previous swing.
Next referring to block 12024, in block 12024 the summation values used for calculation of averages are reset to 0.
Referring now to block 12026, the "check mode" block, if mode 1 has been selected, the program then proceeds, at block 12028, to mode 1 subroutine 13000. Similarly, if mode 2 has been selected, the program, at block 12030, goes to mode 2 subroutine 14000. However, if mode 3 has been selected, then the program at blocks 12032 and 12034 sends to the PLC program 7000 and processor 85 the new calculated plunge and the average slew rate from the previous swing. The program then returns to the optimization program 8000 at block 8016.
Referring to mode 1 subroutine of FIG. 13, the mode 1 subroutine 13000 calculates the new average slew rate for the next swing and sends it to the PLC program 7000 and processor 85.
Referring first to block 13002, the average cutter edge load for the previous swing is compared with the limit value for the cutter edge load. It is then determined if the average cutter edge load is either greater than or less than the limiting value. It is to be noted that block 13002 is a decision block, and if the answer is "yes", the program proceeds to block 13004. At block 13004, a new slew velocity load is calculated based on the average cutter edge load and the cutter edge load limit. This calculation is based on the relationship between cutter normal force and cutter spacing as found in the above referenced Colorado School of Mines (CSM) publication (note, cutter edge load is proportional to normal load at constant penetration): ##EQU3## From block 13004 the program proceeds to block 13008 to be described in detail below. Referring again to block 13002, a decision block, if the answer is "no" the program proceeds to block 13006. In block 13006, the new slew rate is set to the slew rate which was used in the previous swing. From block 13006, the program proceeds to block 13008, a decision block at which the calculation of the new power requirements based on the new plunge and the new slew rate is made. This calculation is based on the relationships between cutter rolling force, cutter penetration and cutter spacing as found in the above referenced Colorado School of Mines publication: ##EQU4## The new power is then compared with the power limit and it is determined if the new power exceeds that limit. If the answer is "yes", the program proceeds to block 13010. At block 13010 it is then determined if the new spacing between cutter paths (as calculated from the slew velocity) divided by the new plunge is greater than some limiting value. Initially this value will be 20 but can be changed based on field test data. It is to be noted that block 13010 is a decision block, and if the answer is "no", the program proceeds to block 13012. In block 13012, an adjustment is made to the new plunge. This adjustment is based on the relationship between cutter rolling force (directly proportional to power) and penetration as found in the above referenced Colorado School of Mines publication: ##EQU5## This adjustment is made whenever the spacing to penetration ratio is less than the limiting value, for example, 20. From block 13012, the program then proceeds to block 13016 to be described in further detail below. Referring back to block 13010, a decision block, if the answer is "yes" the program proceeds to block 13014. In block 13014, an adjustment is made to the slew rate. This occurs whenever the spacing to penetration ratio is greater than 20. This adjustment is based on the relationship between cutter rolling force (proportional to power) and cutter spacing as found in the above referenced Colorado School of Mines publication: ##EQU6## After block 13014, the program proceeds to block 13016 to be described in detail below. Referring back to decision block 13018, if the answer is "no", the program proceeds to block 13016. At block 13016, a calculation is made to determine at what swing cylinder extension the machine should ramp down during the next swing. Next, the program proceeds to block 13018. At block 13018, a plunge rate is calculated and the new plunge, new slew rate, cylinder extension at ramp down, and plunge rate are sent to the PLC program 7000 and processor 85 in block 13018. The program next proceeds to block 13020. At block 13020, the variables which represent the summations used in calculating the averages are reset to 0. Finally, at block 13022, mode 1 subroutine 13000 returns the program to the optimization program 8000 at block 8016.
Next referring to mode 2 subroutine 14000 of FIG. 14, a slew rate matrix rather than an average slew rate is calculated for the next swing. The slew rate matrix will be divided into partitions such as 5° or 10° of slew. The actual partition size is a value to be determined based on actual operating conditions. First, referring to block 14002, this block is the beginning of a "do-loop" that checks the average performance values contained in the performance data matrices.
Referring next to block 14004, block 14004 is a decision block at which the value of the average cutter edge load at each swing position is compared with the cutter edge load limit. It is determined if average cutter edge load exceeds the limit or is below the limit. If the answer at block 14004 is "yes", the program proceeds to block 14006, at which a new slew rate is determined based on the cutter edge load limit and the actual cutter edge load in that position of swing. This adjustment is based on the relationship between the cutter normal force and cutter spacing as found in Eq. 3 above. From block 14006 the program proceeds to block 14010 to be described in detail below.
Again referring to block 14004, a decision block, if the answer is "no", the program proceeds to block 14008. At block 14008, the new slew rate is set to the previous slew rate for the same swing angle position.
From block 14008, the program then proceeds to block 14010. In block 14010, a check of the power requirements based on the new slew rate and the new plunge will be made using Eq. 4 above. It will be determined if the new power is above the power limit. It will be noted that block 14010 is a decision block; if the answer is "yes", the program proceeds to block 14012.
In block 14012, because an overload cutterhead power has been determined, the slew rate must be reduced to bring the cutterhead power below its limit using Eq. 6 above. From block 14012, the program proceeds to block 14014 to be described in further detail below.
Again referring to decision block 14010, if the answer is "no", the program then proceeds to block 14014. Block 14014 is the end of the "do-loop" and the program then checks the performance data in the matrices at the next swing position. In other words, the program then loops back to block 14002. It should be noted that this do-loop is terminated when the matrix size (52) is reached in block 14002. When 52 is reached, the program then proceeds to block 14014. At block 14014, the calculated slew velocity is entered into the swing velocity matrix.
In block 14016, a calculation of the position of the cylinder extension for the next ramp down is made, and at 14017, a new plunge rate is calculated.
Next, the program goes to block 14018. At 14018, the new values of the plunge, plunge rate, slew rate, and new ramp down position are transferred to the PLC program 7000 and processor 85. At block 14020, the main variables which represent the summations for cutterhead power, cutter edge load, cutter normal force, and slew rate are reset to 0. Finally, at block 14022, the subroutine sends the program back to optimization program 8000, specifically to block 8016.
Referring next to mode 3 reduce subroutine 15000 of FIG. 15, this subroutine reduces the slew rate if an overload occurs in either the cutterhead power, the cutter edge load or the cutter normal load during a swing.
Block 15002 increments a counter that is used to determines how long the overload has occurred. Block 15004 is a decision block in which it is determined whether an overload has occurred for the average cutter edge load for a specified count. Criteria will be set for both the amount of overload and count to be tolerated based on field test data. If the answer to decision block 15004 is "yes", the program proceeds to block 15006.
In block 15006, a reduction in the slew rate is determined based on the ratio between cutter edge load limit and the observed cutter edge load value (see Eq. 3). From block 15006, the program then proceeds to block 15018 to be described in detail below.
Again referring to block 15004, if the answer to the decision is "no", the program proceeds to block 15008. Block 15008 is a decision block in which it is determined if the cutter normal load limit has been exceeded for a specified count. Again, criteria for both the overload and count will be based on field test data.
If the answer to the decision in block 15008 is "yes". the program proceeds to block 15010 at which a reduction in swing rate is calculated using the ratio between the cutter normal load limit and the cutter normal load. This ratio is based on the relationship between cutter spacing and cutter normal load as found in the above referenced Colorado School of Mines publication: ##EQU7## From block 15010, the program proceeds to block 15018, again to be described in further detail below.
Referring again to block 15008, if the answer to the decision is "no", the program proceeds to block 15012, another decision block. In block 15012, the cutterhead power is examined and it is determined if the cutterhead power has exceeded its limit for a specified count. If the answer at block 15012 is "yes", the program proceeds to block 15014.
At block 15014, an adjustment is made to the slew rate based on the ratio between the observed cutterhead power and the limiting power. This ratio is based on the relationship between the cutter normal load (proportional to edge load and power at a fixed penetration) and cutter spacing as found in the above referenced Colorado School of Mines publication. ##EQU8## From block 15014, the program then proceeds to block 15018 to be described in detail below.
Referring back to decision block 15012, if the answer is "no", the program then proceeds to block 15016. In block 15016, the status of the optimization module is set to 0 and the correction factor for the slew rate is set to 1 (i.e., no slew rate correction made).
From block 15016, the program then goes to block 15018 in which the status and the new slew rate correction is then sent to the PLC program 7000 and processor 85. From block 15018, the program proceeds, at block 15020, to block 8016 of optimization program 8000.
Next referring to mode 3 increase subroutine 16000 of FIG. 16, this subroutine is used if it is determined that the cutterhead power, the cutter normal load and the cutter edge load are all below their limits. At that point, an increase in the swing rate can take place.
First referring to block 16002, calculations of the ratios that are used to increase the swing rate are made. These ratios are a function of the observed power versus the power limit, the observed cutter edge load versus the cutter edge load limit, and the observed cutter normal load versus the normal load limit (see Eq. 3, 6 and 8).
Next referring to block 16004, it is determined which of the three ratios calculated in block 16002 is the minimal ratio. That minimal ratio is the one which will be used to modify the slew rate.
At block 16006, the slewing rate is modified by the minimal ratio.
Block 16008 is a decision block in which it is determined if the new modified slew rate exceeds the limiting slew rate. If the answer to this decision is "yes", the program proceeds to block 16010 where the slew rate is set back to the limiting value. From block 16010, the program proceeds to block 16012 to be described in detail below.
Referring back to block 16008, a decision block, if the answer is "no", the program then proceeds to block 16012. In block 16012, the new slew rate value or the correction which will be used to increase or reduce the slew rate, is then sent to the PLC program 7000 and processor 85. Finally, the program goes to block 16014 where the program is returned to optimization program 8000 at block 8016.
It will, of course, be realized that while the above has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth.
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Mining apparatus is disclosed in which a cutting wheel supporting a plurality of roller-cutters rotates about a horizontal axis and is supported on a slewing boom for cutting a tunnel with a flat floor and roof and elliptical walls as it slews across a mining face. The slewing boom is supported on a main beam assembly, the front end of which rests on powered crawler tracks and the rear end of which passes through a gripper assembly which may be clamped between the floor and roof of the tunnel, and against which the main beam assembly may be urged forward for engaging the roller-cutters with the mining face. A preload crawler is urged against the roof of the tunnel above the powered crawler tracks to locate the main beam assembly rigidly relative to the tunnel such that the roller-cutters may cut the rock in the mining face with minimal loss of cutting force due to vibration. Apparatus for automatically controlling one or more of cutter penetration depth, cutter penetration rate and cutter slew rate, which includes a sensor for sensing a given mining machine parameter, a processor for processing the given mining machine parameter to provide one or more of an optimum cutter penetration depth, cutter penetration rate or cutter slew rate value, and a controller for controlling one or more of cutter penetration depth, cutter penetration rate and cutter slew rate based on the derived optimum value.
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BACKGROUND OF THE INVENTION
This invention relates to an endless belt for transmission employed in a belt-type stepless transmission used in automotive vehicles and the like, in which an endless belt is stretched between an input pulley and an output pulley and stepless shifting is performed by varying the radius of the position of frictional engagement between the endless belt and the input and output pulleys.
Stepless transmissions have been developed in order to facilitate driving and obtain a comfortable driving feeling in automotive vehicles.
One example of such a stepless transmission that has been conceived is a belt-type stepless transmission which relies upon an endless belt. The belt-type stepless transmission is so adapted that an input pulley disposed on the output-shaft side of a starting device and an output pulley disposed on the output-shaft side of a transmission are connected by an endless belt. The position of frictional engagement between each pulley and the endless belt is suitably controlled to continuously vary the transmission (gear) ratio, thereby accomplishing shifting in stepless fashion.
One example of an endless belt employed in such a belt-type stepless transmission is as disclosed in the specification of Japanese Patent Application Laid-Open (KOKAI) No. 63-115939. The disclosed stepless belt includes a number of flat plate-shaped blocks which frictionally engage input and output pulleys, a number of link pieces which pass through holes in the blocks and are endlessly connected by pins, and a member which prevents the pins from slipping out of the link pieces.
The endless belt comprising the number of blocks is such that at the time of power transmission, power is transmitted from the input pulley to the block pieces which frictionally engage the input pulley. The power transmitted to the block pieces is transmitted to the output pulley via the link pieces and the blocks frictionally engaged with the output pulley. In this case, a stepless shifting operation is performed by so executing control as to continuously vary the rotational radius of the position of engagement between the input pulley and the blocks and the rotational radius of the position of engagement between the output pulley and the blocks.
When the blocks frictionally engage the input and output pulleys at power transmission in this disclosed endless belt, or when the blocks or disengaged from the input and output pulleys, the load applied to the blocks changes, causing neighboring blocks to collide with each other. Such collision produces vibration and noise. In particular, since the blocks generally are made of metal and the endless belt is rotated at comparatively high speed, the sound of neighboring blocks colliding is very loud and unpleasant.
In addition, the blocks themselves vibrate at engagement and disengagement of the blocks and input and output pulleys, and this vibration is also a source of noise.
SUMMARY OF THE INVENTION
An object of the present invention is to reliably prevent collision between neighboring blocks in an endless belt for transmission.
Another object of the present invention is to absorb vibration of the blocks themselves.
In order to attain the foregoing objects, the present invention provides an endless belt for transmission characterized in that the endless belt is equipped with a number of blocks which frictionally engage input and output pulleys, with a vibration-absorbing member being interposed between mutually adjacent ones of the blocks.
The present invention is further characterized in that each vibration-absorbing member interposed between mutually adjacent blocks comprises a first retainer which clamps one of the mutually adjacent blocks and a second retainer which clamps the other of the mutually adjacent blocks.
The present invention is further characterized in that at least one of the first and second retainers is formed to have a portion for preventing slip out of pins which connect a number of link pieces of the endless belt.
The present invention is further characterized in that at least one of the first and second retainers is formed to have a curved portion for coming into abutting contact with the blocks.
In accordance with the endless belt of the present invention thus constructed, a vibration-absorbing member is interposed between mutually adjacent ones of the blocks, as a result of which direction collision between neighboring blocks is reliably prevented. Accordingly, noise produced by block collision can be effectively reduced.
Further, in accordance with the present invention, not only is collision between neighboring blocks prevented, but vibration produced by one of the mutually adjacent blocks itself is absorbed by the first retainer constituting the vibration-absorbing member. At the same time, vibration produced by the other of the mutually adjacent blocks itself is absorbed by the second retainer. As a result, noise produced by the blocks themselves can also be reliably reduced.
Further, in accordance with the present invention, at least one of the first and second retainers is formed to have a portion for preventing slip-out of pins which connect the link pieces of the endless belt. This makes it unnecessary to separately provide pin retaining members. Accordingly, not only can the number of component parts be reduced, but it is also possible to reduce the labor involved in assembly.
Further, in accordance with the present invention, the retainer is formed to have a curved portion. Therefore, even if the retainer should happen to have a slight dimensional error due to manufacture, the retainer will come into abutting contact with the blocks reliably by virtue of the curved portion. This means that the dimensional precision of the retainer need not be maintained so strictly. As a result, the retainer can be manufactured in a simple manner and can be assembled simply as well.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.
The invention accordingly comprises the features of construction, combinations of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view partially illustrating an endless belt for transmission according to the present invention;
FIG. 2 is an enlarged view of a portion A shown in FIG. 1;
FIG. 3 is a sectional view taken along line III--III of FIG. 1;
FIG. 4 is a sectional view taken along line IV--IV of a FIG. 1;
FIG. 5 a front view of a link piece;
FIG. 6A -6-C illustrates a first retainer, in which FIG. 6A is a front view, FIG. 6B a plan view and FIG. 6C is a side view; and
FIG. 7A-7C illustrates a second retainer, in which FIG. 7A is a front view, FIG. 7B a plan view and FIG. 7C a sectional view taken along line VIIC--VIIC in FIG. 7(A).
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will now be described with reference to the drawings.
As shown in FIG. 1, and endless belt 1 in accordance with the present invention includes a number of alternately arranged flat, plate-shaped first and second blocks 2, 2, . . . ; 3, 3, . . . . Each first block 2 is formed to have a recess 2a approximately at the center of one side face, and a projection 2b approximately at the center of its other side face. As apparent from FIG. 2, the projection 2b has an edge 2cdefining a slightly curved surface. In this case, the curved surface 2c has a smoothly continuous shape. As evident from FIG. 3, each first block 2 comprises an outer portion 2d extending transversely of the endless belt 1, an inner portion 2e extending transversely of the endless belt 1, and a pair of connecting portions 2f, 2f connecting the outer and inner portions 2d, 2e. Left and right edges 2e 1 2e 2 of the inner portion 2e and left and right edges 2d 1 , 2d 2 of the outer portion 2d each are designed to form a straight line. Moreover, these left and right edges are formed so as to describe a V-shaped configuration, i.e., in such a manner that the block 2 narrows toward its inner side (the lower side in FIG. 3).
As clearly shown in FIGS. 1, 2 and 4, the second block 3 is formed to have substantially the same shape as that of the first block 2. That is, the only difference between the first and second blocks is that whereas the edge 2c of the projection 2b on the first block 2 defines a curved surface, an edge 3c of a projection 3b on the second block 3 defines a simple flat surface. A recess 3a, outer portion 3d, inner portion 3e, a pair of connecting portions 3f, 3f, left and right edges 3d 1 , 3d 2 of the outer portion 3d, and left and right edges 3e 1 , 3e 2 of the inner portion 3e are formed to be exactly the same as their counterparts in the first block 2.
The first and second blocks 2, 3 are so disposed that their respective projections 2b, 3b come into abutting contact with each other. Accordingly, the first block 2 and second block 3 are adapted to turn relative to each other owing to the curved surface 2c of the first block 2.
As illustrated in FIGS. 1, 3 and 4, the inner and outer portions 2e, 2d and connecting portions 2f, 2f of the first block 2 define an interior space, as do the inner and outer portions 3e, 3d and connecting portions 3f, 3f of the second block 3. A number of link pieces 4, 4, ... arranged along the length of the endless belt 1 are disposed in these interior spaces. In this case, the link pieces are so arranged that a front end of a link piece 4a and a rear end of a neighboring link piece 4b overlap each other. As shown in FIG. 5, each link piece 4 is formed of a generally elliptical, ring-shaped flat plate. Outermost link pieces 4a 1 , 4a 1 are thinner than the other link pieces 4a, 4b. More specifically, the number of link pieces constituting the link pieces 4b is one less than the number of link pieces constituting the link pieces 4a. However, since the dimensions of each of the link pieces 4a, 4b are set in such a manner that the total strength of the link pieces 4b is capable of withstanding the force applied to the link pieces, the strength of the link pieces 4a is enlarged by an amount corresponding to one link piece. Therefore, in order to make the total strength of the link pieces 4a approximately equal to the total strength of the link pieces 4b, the thicknesses of the two link pieces 4a 1 , 4a 2 are reduced. These thin link pieces 4a1, 4a2 need not necessarily be disposed at the outermost ends but can be provided at any positions between the outer ends. In addition, the thin link pieces are not limited to two in number, for it is permissible to use one or a plurality thereof.
Holes are formed in the portions where the front ends of the set of link pieces 4a and the rear ends of the set of link pieces 4b overlap each other, and a pair of pins 5, 5 are provided so as to pass through these holes. Both ends of the pair of pins 5, 5 pass through spaces formed by the recesses 2a, 3a of the first and second blocks 2, 3, respectively. Each pin 5 has one side face thereof formed into a planar surface, while the other side face thereof defines a columnar surface. These two faces are smoothly connected by a separate plurality of columnar surfaces, and the pins 5, 5 are provided in such a manner that the columnar surfaces thereof come into abutting contact with each other. The flat surface sides of the pins 5 abut against the bottom surfaces of the recesses 2a, 3a in the first and second blocks 2, 3, respectively. Accordingly, the arrangement is such that the first and second blocks 2, 3 turn relative to each other, within a predetermined range, along the columnar surfaces of the pins 5.
As clearly shown in FIGS. 1 and 3, each first block 2 is provided with a first retainer 6. As illustrated in FIG. 6(A), the first retainer 6, which comprises an upper portion 6a as well as left-and right-side portions 6b, 6c, respectively, is formed into a generally inverted U-shaped configuration as seen from the front side. As evident from FIG. 6(C), the upper portion 6a is composed of a pair of a first upper portion 6a 1 and a second upper portion 6a 2 projecting upwardly substantially in parallel. These first and second upper portions 6a1, 6a2 are formed so as to curve somewhat in one direction (upwardly in the drawing), as clearly depicted in FIG. 6(B). The first retainer 6 is formed by injection molding a synthetic resin. Instead of a resin, however, it is permissible to employ a material which is resilient and readily absorbs vibration.
The first retainer 6 is press-fitted into the first block 2 in such a manner that the outer portion 2d of the first block 2 is situated between the first and second upper portions 6a 1 , 6a 2 . In such case, owing to the curvature of the first and second upper portions 6a 1 , 6a 2 , reliable abutting contact is made with the outer portion 2d of the first block 2 at least at three points and the outer portion 2d is resiliently clamped, as depicted in FIG. 6(B). Accordingly, the dimensional precision of the first block 2 need not be especially high.
As illustrated in FIG. 3, the left- and right-side portions 6b, 6c of the first retainer 6 are disposed so as to cover the left and right ends of the pair of pins 5, 5. Thus, the left- and right-side portions 6b, 6care capable of preventing the pins 5 from slipping out of each block and link piece. In other words, the left- and right-side portions 6b, 6c serve as portions which prevent slip-out of the pin 5.
Further, as clear from FIGS. 1 and 4, the second block 3 is provided with a second retainer 7. As illustrated in FIGS. 7(A) and (C), the second retainer 7, which comprises an upper portion 7 a as well as left- and right-side portions 7b, 7c, respectively, is formed into a generally inverted U-shaped configuration as seen from the front side and an inverted L-shaped configuration as seen from the side. As is apparent from FIG. 7(B), the upper portion 7a is formed to have left and right recesses 7d, 7d, and the side portions 7b, 7c are curved somewhat in the direction of the recesses 7d, 7d (downward in the drawing). The second retainer 7 is formed of the same material as that of the first retainer 6 and by the same method of manufacture.
As shown in FIG. 7(B), the second retainer 7 is press-fitted into the second block 3 in such a manner that the second block 3 fits into the left and right recesses 7d, 7d. The side portions 7b, 7c and left and right projections 7e, 7f of the upper portion 7aresiliently clamp the second block 3. Since the side portions 7b, 7c are curved somewhat in the direction of the recesses 7d, the side portions 7b, 7c and the projections 7e, 7f reliably abut against the second block 3. Accordingly, the dimensional precision of the second block 2 need not be especially high.
It is arranged so that the front ends of the link pieces 4b, 4b, ... are alternately overlapped by the rear ends of the next link pieces 4a, 4a, ..., and in a manner similar to that set forth above, a pair of pins 5, 5 pass through holes formed in these overlapping portions. These pins 5, 5 also pass through spaces defined by the recesses 2a, 3a of the next first and second blocks 2, 3. Thus, the two sets of link pieces 4a, 4a, ...; 4b, 4b, ... are alternately connected by the pair of pins 5, 5, and the pins 5, 5 are supported by the first and second blocks, 2, 3, whereby the first and second blocks 2, 3, link pieces 4a, 4b, pins 5, 5 and first and second retainers 6, 7 are assembled to form a belt. As shown in FIG. 1, link pieces 4c, 4c,... are attached to pins 5, 5; 5, 5, which are at both ends of the belt-shaped assembly, pin retainers 8, 8 are applied to both the left and right ends of these pins (the pin retainer situated on the opposite side is not shown), and the left and right pin retainers 8, 8 are clamped by a C-shaped clip 9, thereby forming the endless belt 1.
In the endless belt 1 thus formed, either of the first and second upper portions 6a 1 , 6a 2 of the first retainer 6 is always interposed from the central portion to the outer portion between the first block 2 and second block 3. Further, as depicted in FIG. 1, a third retainer 6' is attached to the second block 2 situated at a portion formed into the endless shape last. The third retainer 6' also is formed to include a first upper portion 6'a 1 and a second upper portion 6'a 2 , which are interposed between the first and second blocks 2, 3. Unlike the first retainer 6, the third retainer 6' is not formed to have a portion which prevents the pins 5 from falling out.
In order that the endless belt 1 can curve at a predetermined radius, no retainer is interposed between the blocks 2, 3 on the inner side of the belt 1. However, the design is such that a small gap is provided so that mutually adjacent ones of the blocks 2, 3 will not make contact when the rotational radius of the endless belt 1 is at its minimum value.
The endless belt 1 is stretched between an input pulley and an output pulley in a belt-type stepless transmission. Owing to rotation of the input pulley, the endless belt 1 rotates and the rotation thereof is transmitted to the output pulley, which rotates as a result. At this time the first and second blocks 2, 3 rotate relative to each other about the pins 5 or the abutting contact portions of the projections 2b, 3b from the moment each pulley is about to be frictionally engaged by the belt until the moment the belt disengages from the pulley. When the endless belt 1 frictionally engages each pulley or when it disengages from the pulley, the first block 2 or second block 3 attempts to contact the neighboring block 3 or 2. However, since the first upper portions 6a 1 , or 6'a 1 or second upper portions 6a 2 , 6'a 2 of the first and third retainers 6, 6' are interposed between these blocks 2, 3, the first block 2 and second block 3 never come into direct contact with each other. Accordingly, collision between neighboring blocks 2, 3 to produce vibration or noise almost never occurs. Moreover, since the first and second upper portions 6a 1 , 6a 2 are curved, the first and second upper portions 6a 1 , 6a 2 deform elastically when pressed by the blocks 2, 3. This absorbs and mitigates any impact.
In addition, since the first retainer 6 comes into abutting contact with the first block 2 and the second retainer 7 comes into abutting contact with the second block 3, vibration ascribable to the blocks 2, 3 themselves can be effective absorbed.
Thus, the first, second and third retainers 6, 7 and 6', respectively, construct a vibration-absorbing member which is a characterizing feature of the present invention.
Thus, as is evident from the foregoing description, the endless belt of the present invention is such that a vibration-absorbing member is interposed between blocks. As a result, when the endless belt is running, mutually adjacent blocks no longer come into direct contact. This makes it possible to effectively reduce vibration and noise.
Further, the vibration-absorbing member is brought into abutting contact with each block. Therefore, when each block engages or disengages with a pulley, vibration produced by the block itself can be reliably absorbed by the vibration-absorbing member.
As many apparently widely different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims.
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An endless belt 1 for transmission is provided with a number of blocks 2, 3 which frictionally engage input and output pulleys, and vibration-absorbing members 6, 7 are interposed between mutually adjacent ones of the blocks 2, 3. The vibration-absorbing members 6, 7 are constituted by a first retainer 6 which clamps one block 2 of the mutually adjacent blocks 2, 3, and a second retainer 7 which clamps the other block 3, these retainers being intervening between the mutually adjacent blocks 2, 3. Accordingly, neighboring blocks 2, 3 are reliably prevented by the vibration-absorbing members 6, 7 from directly colliding with each other, as a result of which noise can be effectively reduced. In addition, vibration produced by the block 2 itself is absorbed by the first retainer 6 constituting the vibration-absorbing member. Likewise, vibration produced by the other block 3 itself is absorbed by the second retainer 7.
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BACKGROUND OF THE INVENTION
It is generally known that textile floor coverings can be provided with a firmly adhering backing layer of polyurethane foams by applying a reactive liquid mixture of polyurethane-forming components to the back of the textile (see, e.g. German Offenlegungsschriften Nos. 2,208,995; 1,926,285 and 2,262,742). In the one prior art process, a reactive liquid foamable mixture of polyisocyanates and polyols is applied to the back of a textile floor covering to form a thin coating of a flexible polyurethane foam which, before hardening, has a second layer of a preformed flexible polyurethane foam applied to it (see, e.g. German Offenlegungsschrift No. 2,262,742).
Unfortunately, many conventional processes are attended by significant disadvantages in addition to which the products obtained therefrom are of inadequate quality. In particular, the fixing of the nap and filaments of the textile floor covering is generally inadequate when foamed coatings are applied. In addition, the product is generally not "stiff" enough for the consumer.
To offset these disadvantages, the prior art has attempted to initially preconsolidate the textile substrate with a first coat which itself has high strength and, upon completion of preconsolidation, to apply the reactive foamable layer in a second operation. The art has also attempted to join a preformed foam layer to the textile floor covering by a thick coat of adhesive which is also intended to fix the nap. Unfortunately, this is both complicated and expensive because different starting components have to be used and because additional process steps are involved. In fact, because of its foam structure, the layer of adhesive is of only limited strength, with the result that, in many cases, the anchorage of the textile filaments is as inadequate as when the foamed covering is directly produced on the back of the textile.
SUMMARY OF THE INVENTION
It has now surprisingly been found that it is readily possible, using starting components generally known for use as polyurethane backings for textile floor coverings, to obtain improved fixing of the textile filaments, increased stiffness of the carpet without adverse effect upon the flexibility of the backing by applying to a textile floor covering a first coat consisting essentially of a reacting mixture of a polyol and a large excess of polyisocyanate; thereafter applying, before the first coat has hardened, a foamable main coat of substantially equivalent quantities of polyol and polyisocyanates; and, then hardening the material in a heating zone. Accordingly, the present invention relates to a process for coating the backs of textile floor coverings with foamable (and, if desired, prefoamed) reacting mixtures of one or more polyols one or more difunctional or higher-functional organic isocyanates and, optionally fillers, blowing agents, activators, stabilizers and pigments, distinguished by the fact that, in a first step, a reacting foamable mixture of polyols and polyisocyanates is directly applied as a first coat to the back of the substrate to be coated, the NCO:OH equivalent ratio in the reacting foamable mixture being from 1.5:1 to 3.5:1 and preferably from 2.0:1 to 3.0:1 and in a second step, a second foamable (and if desired, prefoamed) reacting layer of polyols and polyisocyanates is applied as a main coat either directly or by reverse coating to the first coat preferably before the first coat has fully reacted, i.e. while the first coat still contains free NCO groups and has undergone little or no foaming. The NCO:OH ratio in the second foamable layer is maintained from 0.95:1 to 1.25:1 and preferably from 1.05:1 to 1.15:1. The composite material is then left to harden.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 schematically shows an apparatus which may be used for carrying out the process according to the invention:
1. represents a storage tank containing the polyisocyanate,
2. a storage tank for the mixture of polyol and filler;
3. is a metering equipment for the first coat, 4. a metering equipment for the main coat; 5. and 6. represent mixing heads for the main coat and the first coat, respectively; 7. is a roll coater for the first coat, 8. a doctor blade for the main coat; 9. is the carpet to be coated; 10. represents a conveyor equipment for the release substrate; 11. represents the drying chamber; 12. is the coated carpet.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process according to the invention is preferably carried out utilizing the same polyol component, which may optionally contain fillers, activators, stabilizers and pigments, and the same organic isocyanate for both the main coat and the first coat. In this way, nap fixing, stiffness, and filament anchorage are considerably improved in a very simple, economic manner, using the same starting materials and compounds without any adverse effect either upon the softness or the resilience of the first product.
The polyol components used for the first coat and main coat are known and are preferably polyethers having molecular weights of from 400 to 4000. They can be used in admixture with low molecular weight polyols and with the addition of activators and blowing agents. Mineral fillers, foam stabilizers, antiagers and similar additives of the kind normally used in polyurethane chemistry may also be added to the polyols. The polyethers suitable for use include those obtained by polymerizing tetrahydrofuran or epoxides such as ethylene oxide, propylene oxide, butylene oxide, styrene oxide or epichlorohydrin in the presence of a catalyst such as BF 3 , or by adding these epoxides in admixture or in succession, to starter components containing reactive hydrogen atoms such as water, alcohols or amines. Suitable starter components include ethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol, trimethylol propane, 4,4'-dihydroxy diphenyl propane, aniline, ammonia, ethanolamine, ethylene diamine and water. Sucrose polyethers of the type described in German Auslegeschrifts 1,176,358 and 1,064,938 may also be used in accordance with the invention. In many cases, it is preferred to use polyethers of the type generally known which contain substantial amounts of primary OH-groups (up to 90% by weight, based on all the OH-groups present in the polyether). Polyethers modified with vinyl polymers of the type formed by polymerizing styrene and acrylonitrile in the presence of polyethers (U.S. Pat. Nos. 3,383,351; 3,304,273; 3,523,093 and 3,110,695 and German Pat. No. 1,152,536) are also suitable as are polybutadienes containing OH-groups.
Polyols having a molecular weight below 400 may optionally be used in addition to the polyethers. Examples of such polyols include ethylene glycol, 1,2- and 1,3-propylene glycol, 1,4- and 2,3-butylene glycol, 1,6-hexanediol, 1,8-octane diol, neopentyl glycol, 1,4-bis-hydroxy methyl cyclohexane, 2-methyl-1,3- propane diol, glycerol, trimethylol propane, 1,2,6-hexane triol, 1,2,4-butane triol, trimethylol ethane, pentaerythritol, quinitol, mannitol, sorbitol, methyl glycoside, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycols, dipropylene glycol, polypropylene glycols, dibutylene glycol, polybutylene glycols and the like.
Instead of using polyethers, it is also possible as is recognized in the polyurethane art to utilize polyesters, polythioethers, polyacetals, polycarbonates, polyester amides, or mixtures thereof, having molecular weights in the range from 400 to 10,000 and preferably from 1000 to 6000.
The polyesters containing hydroxyl groups suitable for use include the reaction products of polyhydric (preferably dihydric and optionally trihydric) alcohols with polyvalent (preferably divalent) carboxylic acids. Instead of using the free polycarboxylic acids, it is also possible to use the corresponding polycarboxylic acid anhydrides or corresponding polycarboxylic acid esters of lower alcohols or mixtures thereof for producing the polyesters. The polycarboxylic acids may be aliphatic, cycloaliphatic, aromatic and/or heterocyclic and may be substituted (e.g. with halogen atoms) and/or unsaturated. Examples of carboxylic acids of this kind include succinic acid; adipic acid; suberic acid; azelaic acid; sebacic acid; phthalic acid, isophthalic acid; trimellitic acid; phthalic acid anhydride; tetrahydrophthalic acid anhydride; hexahydrophthalic acid anhydride; tetrachlorophthalic acid anhydride; endomethylene tetrahydrophthalic acid anhydride; glutaric acid anhydride; maleic acid; maleic acid anhydride; fumaric acid; dimeric and trimeric fatty acids; such as oleic acid, which may be in admixture with monomeric fatty acids, terephthalic acid dimethyl ester; terephthalic acid bis-glycol ester and the like. Examples of suitable polyhydric alcohols include ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol; 1,4- and 2,3-butylene glycol; 1,6-hexane diol; 1,8-octane diol; neopentyl glycol; cyclohexane dimethanol (1,4-bis-hydroxy methyl cyclohexane) 2-methyl-1,3-propane diol; glycerol; trimethylol propane; 1,2,6-hexane triol; 1,2,4-butane triol; trimethylol ethane; pentaerythritol; quinitol; mannitol; sorbitol; methyl glycoside; diethylene glycol; triethylene glycol; tetraethylene glycol; polyethylene glycol; dipropylene glycol; polypropylene glycols; dibutylene glycol; polybutylene glycols and the like. The polyesters may contain some terminal carboxyl groups. It is also possible to use polyester of lactones such as ε-caprolactone, or hydroxy carboxylic acids such as ω-hydroxy caproic acid.
The polythioethers usable include the condensation products of thiodiglycol alone or thiodiglycol with other glycols, dicarboxylic acids, formaldehyde, amino carboxylic acids or amino alcohols. The products can be characterized as polythio mixed ethers, polythioether esters or polythioether ester amides, depending upon the co-components used.
Examples of suitable polyacetals include the compounds obtained from glycols, such as diethylene glycol, triethylene glycol, 4,4'-dioxethoxydiphenyl dimethyl methane, and hexane diol, and formaldehyde. Polyacetals suitable for use in accordance with the invention can also be obtained by polymerizing cyclic acetals.
Suitable polycarbonates containing hydroxyl groups are those of the type which are generally known and which may be obtained by reacting diols, such as 1,3- propane diol, 1,4-butane diol and/or 1,6-hexane diol, diethylene glycol, triethylene glycol or tetraethylene glycol, with diaryl carbonates (for example diphenyl carbonate) or phosgene.
The polyester amides and polyamides suitable for use herein include the predominantly linear condensates obtained from polyvalent saturated and unsaturated carboxylic acids or their anhydrides and polyvalent saturated and unsaturated amino alcohols, diamines, polyamines and mixtures thereof.
Polyhydroxyl compounds already containing urethane or urea groups and modified natural polyols, such as castor oil, carbohydrates or starch, may also be used. Addition products of alkylene oxides with phenol-formaldehyde resins or even with urea-formaldehyde resins may also be used in accordance with the invention.
Examples of the many and varied types of compounds suitable for use in accordance with the invention are described, for example, in High Polymers, Vol. XVI, "Polyurethanes, Chemistry and Technology", by Saunders-Frisch, Interscience Publishers, New York, London, Vol. I, 1962, pages 32 to 42 and pages 44 to 54, and Vol. II, 1964, pages 5 to 6 and 198 to 199, and also in Kunststoff-Handbuch, Vol. VII, Vieweg-Hochtlen, Carl-Hanser-Verlag, Munich, 1966, pages 45 to 71.
Essentially any organic polyisocyanate may be used herein. Thus, it is possible in accordance with the invention to utilize araliphatic, aromatic and heterocyclic polyisocyanates. Specific examples of useful isocyanates include, 1,3- and 1,4-phenylene diisocyanate; 2,4- and 2,6-tolylene diisocyanate and mixtures of these isomers, diphenyl methane-2,4'-and/or 4,4'-diisocyanate; naphthylene-1,5-diisocyanate; triphenyl methane-4,4',4"-triisocyanate; polyphenyl polymethylene polyisocyanates which may be obtained by condensing aniline with formaldehyde, followed by phosgenation and which are of the type described for example in British Pat. No. 874,430 and 848,671, perchlorinated aryl polyisocyanates of the type described in German Auslegeschrift 1,157,601; polyisocyanates containing carbodiimide groups, of the type described in German Pat. No. 1,092,007; the diisocyanates described in U.S. Pat. No. 3,492,330; polyisocyanates containing allophanate groups of the type described for example in British Pat. No. 994,890 Belgian Pat. No. 761,626 and published Dutch Pat. Application No. 7,102,524; polyisocyanates containing isocyanate groups of the type described, for example, in German Pat. Nos. 1,022,789; 1,222,067 and 1,027,394 and in German Offenlegungsschrifts Nos. 1,929,034 and 2,004,048; polyisocyanates containing urethane groups as described in U.S. Pat. No. 3,394,164; the polyisocyanates containing acylated urea groups described in German Pat. No. 1,230,778; polyisocyanates containing biuret groups of the type described, for example, in German Pat. No. 1,101,394, in British Pat. No. 889,050 and in French Pat. No. 7,017,514; polyisocyanates obtained by telomerization reactions as described in Belgian Pat. No. 723,640; polyisocyanates containing ester groups of the type described, for example, in British Pat. Nos. 956,474 and 1,072,956, in U.S. Pat. No. 3,567,763 and in German Pat. No. 1,232,688; and reaction products of the above-mentioned isocyanates with acetals as described in German Pat. No. 1,072,385.
It is also possible to use the distillation residues containing isocyanate groups which accumulate in the industrial-scale production of isocyanates, optionally in solution in one or more of the above-mentioned polyisocyanates. It is also possible to use mixtures of the aforementioned polyisocyanates.
In general, it is particularly preferred to use readily available polyisocyanates, such as 2,4- and 2,6-tolylene diisocyanate and mixtures of these isomers (TDI), polyphenyl-polymethylene polyisocyanates; of the type obtained by condensing aniline with formaldehyde, followed by phosgenation (crude MDI); and polyisocyanates containing carbodiimide groups, urethane groups, allophanate groups, isocyanurate groups, urea groups or biuret groups (so-called modified polyisocyanates).
Blowing agents suitable for use in accordance with the instant invention include water and/or readily volatile organic substances. Examples of organic blowing agents include acetone; ethyl acetate; methanol; ethanol; halogen-substituted alkanes such as methylene chloride, chloroform; ethylene chloride; vinylidene chloride; monofluorotrichloromethane; chlorodifluoromethane and dichlorodifluoromethane; butane; hexane; heptane; diethyl ethers and the like. A blowing effect can also be obtained by adding compounds of the type which decompose at temperatures above room temperature to give off gases (for example nitrogen). Examples of these compounds are the known azo compounds, such as azoisobutyronitrile. Further examples of blowing agents and information at to their use may be found in Kunststoff-Handbuch, Vol. VII, Vieweg and Hochtlen, Carl-Hanser-Verlag, Munich 1966, pages 108 and 109, 453 to 455 and 507 to 510.
Additionally, catalysts are often used in the process of the instant invention. Suitable catalysts include those of the type generally known. Examples include tertiary amines such as triethyl amine, tributyl amine, N-methyl morpholine, N-ethyl morpholine, N-cocomorpholine, N,N,N', N'-tetramethyl ethylene diamine, 1,4-diazabicyclo-(2,2,2)-octane, N-methyl-N'-dimethyl aminoethyl piperazine, N,N-dimethyl benzyl amine, bis-(N,N-diethyl aminoethyl)-adipate, N,N-diethyl benzyl amine, pentamethyl diethylene triamine, N,N-dimethyl cyclohexyl amine, N,N,N',N'-tetramethyl-1,3-butane diamine, N,N-dimethyl-β-phenyl ethyl amine, 1,2-dimethyl imidazole and 2-methyl imidazole.
Other suitable catalysts include metal chelates, bicyclic amidines and monocyclic amidines, either alone or especially in combination with monocarboxylic or dicarboxylic acids.
Suitable bicyclic amidines include compounds corresponding to the general formula ##STR1## in which m = 2 or 3 and n = 3, 4 or 5.
Examples of monocyclic amidines include compounds corresponding to the general formula ##STR2## in which R is an optionally branched and/or hetero-atom-containing aliphatic, cycloaliphatic, araliphatic or aromatic radical having 1 to 15 carbon atoms. R may thus be, for example, methyl, cyclohexyl, 2-ethyl hexyl, benzyl, cyclohexyl methyl, ethoxyl or a radical corresponding to the formula ##STR3##
In addition, other catalysts may also be used in the process according to the invention. Examples of these catalysts and information about the manner in which they perform may be found in Kunststoff-Handbuch, Vol. VII, Vieweg and Hochtlen, Carl-Hanser-Verlag, Munich 1966, pages 96-102.
It is advantageous although not absolutely essential, to use surface-active additives, such as emulsifiers and foam stabilizers, of the type commonly used in the production of foamed polyurethanes, in the process according to the invention. Silicone-containing stabilizers are particularly desirable in cases where the reactive mixture is prefoamed by "whipping in" air and "whip-foaming" before or during the chemical reaction. One example of a silicone stabilizer of this kind suitable for mechanically prefoamed compounds in Union Carbide's Silicon Surfactant L 5612 (see Example 1 of DOS 2 210 934 corresponding to U.S. Ser. No. 122 164).
Polyols containing fillers may also be used for the process according to the invention. Examples of suitable fillers include, naturally occurring minerals such as chalk, kaolin or baryta in finely divided form, aluminum oxide hydrates, mixtures thereof and mixtures with other fillers and/or flameproofing additives.
The reaction components may be generally reacted in known manner by the one-stage process, by the prepolymer process or even by the semi-prepolymer process, advantageously using machinery of the kind described, for example, in Kunststoff-Handbuch, Vol. 7, Vieweg-Hochtlen, Carl-Hanser-Verlag, Munich 1966 on pages 121 to 205. The reactive mixtures which are prepared in separate mixers for the first coat and for the main coat may be successively applied in known manner to the textile floor covering to be coated either by spray-coating or by spread-coating (doctor-coating). In order to obtain a coating with a particularly smooth surface, it is generally preferable to directly coat only the first coat onto the substrate in quantities of from 50 to 500 g/m 2 and preferably in quantities of from 150 to 250 g/m 2 , while the liquid, foamable or prefoamed mixture of the main coat is applied to a substrate provided with parting release means and this layer combined in as fresh a condition as possible with the precoated floor covering on the "wet-in-wet" principle (cf. drawing). The NCO:OH ratio in the reaction mixture for the main coat must be considerably lower than the NCO:OH ratio in the reaction mixture for the first coat, because, with too large an excess of NCO in the main coat, the coating as a whole would be too hard, would lack flexibility and hence would be susceptible to cracking. At least one of the two reactive layers should not be permitted to react to completion before it is combined with the other layer, since the bond between the two layers would otherwise lose strength. The wet-in-wet combined reactive layers are reacted, generally by heating, and on completion of the reaction the main coat is optionally separated from the parting substrate.
The hardening times of the reaction mixtures for the first coat and main coat may be varied by the type and quantity of catalyst used and by the heating temperature. The heating temperature is generally 100° C and the quantity of catalyst selected in such a way that the main coat takes from 1 to 5 minutes to harden. Atmospheric moisture is required to completely harden the first coat at room temperature because of the large excess of NCO, which naturally gives rise to a longer reaction time. However, this does not generally affect the mold-release time of the coated floor covering.
Instead of using release substrates, it is also possible to use so-called "second backings". Second backings of this kind remain joined to the finished carpet on completion of the reaction and thus increase its strength. In practice, inexpensive woven fabrics or non-wovens of natural or synthetic fibers are used as second backings.
The process according to the invention for coating floor coverings is particularly suitable for finishing tufted, woven and knitted floor coverings, and felted textile floor coverings, although it is by no means limited to floor coverings of this kind. Thus, the process of the invention may also be used for coating mats of vegetable starting materials and other sheet-form materials.
The figures quoted in the examples represent parts by weight and percent by weight unless otherwise stated.
EXAMPLE 1
An activated polyol mixture was prepared by mixing the following components:
90 parts of a trifunctional polypropylene glycol ether started on trimethylol propane with terminal hydroxy ethyl groups (OH-number 32; 85 % of propylene oxide units and 15 % of ethylene oxide units) 10 parts of pure commercial-grade dipropylene glycol (OH-number 750)
2 parts of pure commercial-grade oleic acid
0.5 parts of 1,5-diazabicyclo-(4,3,o)-non-5-ene
0.3 parts of water
Taking its acid number and water content into account, this polyol mixture has a calculated OH-number of 123. 100 parts of dry, powdered chalk were stirred into 100 parts of this polyol mixture, resulting in the formation of "compound A" having an OH-number of 61.5.
1A. Conventional Process (comparison test)
16.9 parts (115% of the equivalent quantity) of a crude 4,4'-diisocyanato diphenyl methane (NCO-content 31.5%; viscosity at 25° C, 80 cP) were added to 100 parts of compound A. This reactive mixture was coated in a quantity of 1200 g/m 2 onto a plate pretreated with a release agent ("parting substrate"). The release agent was the bis-stearylamide of ethylene diamine, dissolved in a mixture of petrol ether and perchloro ethylene. The back of a 1 square meter tufted carpet ("loop fabric") was quickly introduced into the fresh mixture, after which the material was hardened for 5 minutes in a heating cabinet at 100° C. After it had been lifted off the parting substrate, the carpet was found to be coated with a uniform foam having a gross density of 0.37 g/cc. The properties were tested after storage for 24 hours at room temperature (Table 1/column 1A).
1B. Process according to the invention
150 g of "compound A" were mixed with 51 g (230% of the equivalent quantity) of the crude 4,4'-diisocyanato diphenyl methane from 1A, and the resulting mixture uniformly roll-coated onto a 1 square meter of the back of a tufted carpet. The carpet thus pretreated was introduced "wet-in-wet" into a fresh coating mixture corresponding to 1A, except that on this occasion only 1000 g/m 2 were used in order to qualize the weight per unit area of the first coat. The material was hardened for 5 minutes at 110° C. The properties were tested, after storage for 24 hours at room temperature. The test results are set out in Table 1, column 1B.
1C. Comparison test
A part (200 g/m 2 ) of the reactive mixture from Example 1A was applied to the carpet. The carpet was then introduced wet-in-wet into the remainder (main coat about 1000 g/m 2 ) of the coating mixture. After hardening for 5 minutes at 110° C, the material was allowed to stand at room temperature for 24 hours. The material was then tested with the results set out in Table 1, column 1C.
1D. Process according to the invention
The procedure was as in 1B using the same amounts of each layer, except that the first coat was first "prereacted" on the carpet for 1 hour at room temperature, after which the first coat was much more viscous and very tacky (filament-pulling). After the first coat had been joined to the main coat, the material was left to harden for 5 minutes at 110° C and tested after 24 hours. The test results are set out in Table 1, column 1D.
1E. Process according to the invention
The procedure was as in 1D except that pre-reaction was conducted with brief heating (50 seconds at 110° C) from a heat source. The test results are set out in Table 1, column 1E.
1F. Process according to the invention
300 g/m 2 of "first coat" of 100 parts of compound A and 26.5 parts (approximately 180% of the equivalent quantity) of the crude 4,4-diphenyl methane diisocyanate from 1A, were applied to the back of the tufted carpet. The carpet thus pretreated was introduced wet-in-wet into the mixture for the main coat (900 g/m 2 ) and hardened by exposure to heat. The test results are set out in Table 1, column 1F.
1G. Process according to the invention
200 g of a reactive mixture of 100 parts of compound A and 34.0 parts (200% of the equivalent quantity) of crude diisocyanato diphenyl methane, were applied to a 1 square meter of the tufted, untreated carpet, followed by storage for several hours at 100° C in a heating cabinet. After the first-coat mixture had completely hardened, 1000 g/m 2 of the main coat (as in 1A) were applied, followed by tempering for 5 minutes at 110° C. Nap fixing and filament anchorage were not as good as in the wet-in-wet method. Additionally, the bond between the first coat and main coat was not entirely optimal in places, although there was still a distinct improvement compared with the conventional process.
TABLE 1__________________________________________________________________________ 1 A 1 B 1 C 1 D 1 E 1 F 1 G__________________________________________________________________________Nap strength inkp (average from10 measurements) 2.7 7.5 3.8 7.6 7.4 7.7 5.8filamentanchorage adequate very good adequate very good very good very good goodstiffness inadequate very good inadequate very good very good very good very goodroll stand test(DIN draft 54 324) 10,000 25,000 12,000 25,000 25,000 28,000 27,000gross densityg/cc 0.37 0.38 0.38 0.38 0.38 0.38 0.37__________________________________________________________________________
Discussion of the test results
a. Nap strength, which is measured in a tensile tester of the type normally used for testing in accordance with DIN 53 504, is defined as the force required to rip out a nap from the backing fabric moving at a speed of 150 mm/minute. Nap strength is increased several times by the pretreatment according to the instant invention and reaches values in excess of 5 kp.
b. Filament anchorage was assessed optically from exposed and cut naps and was evaluated subjectively from the signs of wear of the textile by the "roll stand test".
c. Stiffness: a 10 cm wide strip of carpet was arranged horizontally between grips in such a way that a 10 × 10 cm piece projected freely. The stiffness S is defined as the quotient of weight per unit area of the sample G (p/m 2 ) and the dip or sag f (mm): S=G/f. Values above 125 were regarded as very good, values between 100 and 110 as satisfactory and values below 70 as inadequate.
d. The roll stand test was carried out in accordance with DIN draft 54 324. Roll stand-compatible carpets should be able to withstand 25,000 revolutions without suffering any appreciable damage. Although the untreated tufted carpet used was not designed for heavy stressing and, for this reason, was destroyed in every test, a considerable improvement is nevertheless obtained by the pretreatment according to the invention.
EXAMPLE 2
A polyol compound B was prepared by mixing
70 parts of the trifunctional polypropylene-ethylene glycol (OH-number 32) of Example 1
20 parts of trifunctional polypropylene glycol started on trimethylol propane (OH-number 370)
10 parts of pure commercial-grade dipropylene glycol
1.7 parts of nickel acetonyl acetonate
0.05 parts of tetramethyl butylene diamine
0.4 parts of water
150 parts of chalk powder.
The compound has a calculated OH-number of 78.5. Accordingly, 100 parts by weight of compound B are theoretically equivalent to a quantity of 18.7 parts by weight of crude 4,4'-diisocyanato diphenyl methane (31.5% by weight NCO, viscosity at 25° C = 80 cP).
2A. Process according to the invention
A mixture of 100 parts of compound B and 37 parts (200 % of the equivalent quantity) of crude 4,4'-diisocyanato diphenyl methane, was applied in a quantity of 400 g/m 2 to the back of an untreated tufted carpet. Immediately afterwards 1000 g/m 2 of a mixture of 100 parts of compound B and 20.5 parts (110% of the equivalent quantity) of crude 4,4'-diisocyanato diphenyl methane were applied as the main coat, and the coated carpet heated for 15 minutes to 120° C.
The product had a nap strength of 8.5 kp. In the roll stand test, the coating underwent 24,000 cycles before destruction. Filament anchorage is extremely good. The foam layer has a gross density of 0.34 g/cc.
2B. Comparison test
The untreated carpet was directly coated with 1500 g/m 2 of a mixture of 100 parts of compound B and 20.5 parts of 4,4'-diphenyl methane diisocyanate, followed by hardening for 15 minutes at 120° C. The roll stand test had to be terminated after 9000 revolutions as a result of destruction of the material. Filament anchorage was inadequate, nap strength only amounted to 2.67 kp and stiffness S to 85-90. The foam layer has a gross density of 0.35 g/cc.
2C. Process according to the invention
70 parts of chalk were additionally stirred into 250 parts of compound B. The "first-coat compound" thus obtained has a calculated OH-number of approximately 61.5, disregarding the moisture content of the additional quantity of chalk. Accordingly, 44 parts (approximately 300% of the equivalent quantity) of crude 4,4'-diisocyanato diphenyl methane were added to 100 parts of the first-coat compound. 1000 g/m 2 of the main coat were applied to 600 g/m 2 of the first coat and hardened by heating. The coated carpet thus produced has a high degree of stiffness (S = 130), withstands more than 25,000 revolutions in the roll stand test and shows extremely good fiber anchorage.
EXAMPLE 3
Polyol compound C consists of a mixture of
70 parts of a linear polypropylene glycol ether modified with ethylene oxide (OH-number 28), prepared by polyaddition of 80% of propylene oxide and 20% of ethylene oxide, started on propylene glycol
8 parts of pure commercial-grade dipropylene glycol (OH-number 750)
30 parts of a trifunctional polypropylene glycol ether (OH-number 345), started on glycerol
2 parts of ricinoleic acid (calculated OH-number 376)
0.4 parts of 2,3-dimethyl-3,4,5,6-tetrahydropyrimidine
150 parts of chalk powder.
Compound C has an OH-number of 73, taking into account the moisture content of the filler (approximately 0.1%).
3A. Comparison test (without precoating)
Coating is carried out by means of an installation of the type shown in FIG. 1 (coating rate = 3 m/minute, working width 2 m, output 6 m 2 /minute). A high-shear mixer was fed by a metering unit with 6,000 g per minute of compound C and 120 g per minute of a crude polyphenyl polymethylene polyisocyanate (crude MDI) having an NCO content of 30.6, 150 g per minute of a silicone stabilizer (silicone surfactant L 5612 by union carbide) and compressed air (under about 6 atms) being introduced at the same time through another, small metering pump (not shown in the drawing). The mixer hose discharged a mechanically prefoamed reactive mass which was uniformly distributed over the parting substrate (fabric coated with silicone rubber) by means of a doctor coater and subsequently combined with the untreated, tufted carpet. The mixer was hardened in a heating oven (residence time: 3 minutes at 100° C).
The coating has a gross density of 0.30 g/cc. Nap strength amounts to 1.7 - 2.2 kp. The roll stand test was terminated after 6000 revolutions because some of the tufting loops had been pulled out of the backing material and some of the filaments were torn out.
3B. Process according to the invention
While as in 3A, 5 kg per minute of the mechanically prefoamed main-coat mixture were being prepared and coated onto the parting substrate, a pre-coat mixture of 1000 g/minute of polyol compound C and 400 g/minute of polyisocyanate was prepared in a small adjacent metering/mixing unit without prefoaming by stirring in air and without the addition of silicon. The pre-coat mixture was roll-coated onto the back of the untreated tufted carpet in a quantity of approximately 230 g/m 2 . Thereafter the first coat and main coat were combined and hardened in the heating zone.
The carpet so produced withstood more than 35,000 revolutions in the roll stand test. Nap strength amounts to 7.1 kp and stiffness S to 120. Filament anchorage is excellent.
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The instant invention relates to a process for coating the back of textile floor coverings, e.g. carpets, with polyurethane foams wherein it is possible to obtain particularly firm fixing of the nap and improved anchorage of the textile filaments. The process broadly comprises:
A. applying to the back of a textile floor covering a first coat consisting essentially of a reacting foamable mixture of a polyol and a large excess of polyisocyanate,
B. before said first coat has been hardened, applying thereto reacting foamable mixture of substantially equivalent quantities of polyol and polyisocyanate, and
C. thereafter hardening the resultant product.
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TECHNICAL FIELD
The present invention relates to a lever-type connector to be attached to a panel.
BACKGROUND ART
A conventional lever-type connector to be attached to a panel includes: a first connector; a second connector fittable to the first connector; and a lever provided on the first connector and configured to be turned to fit the first connector and the second connector to each other. Here, the first connector and the second connector in a fitted state are attached to an attachment hole in a panel (Japanese Patent Application Laid-open Publication No. 2002-359037).
In this lever-type connector, the lever is provided with an interference portion in order to prevent the connectors in an incompletely fitted state from being attached to the panel. The interference portion does not interfere with a hole edge of the attachment hole in the panel when the connectors are in a completely fitted state. The interference portion interferes with the hole edge of the attachment hole when the connectors are in the incompletely fitted state.
Accordingly, in the process of attaching the connectors to the attachment hole in the panel, it is possible to detect a fitted state of the connectors based on whether or not the interference portion interferes with the hole edge of the attachment hole.
When the connectors are fitted into the attachment hole in the state where the interference portion does not interfere with the hole edge of the attachment hole (the state where the connectors are properly fitted to each other), an elastic retaining piece formed on the interference portion is inserted through the attachment hole and locks the hole edge of the attachment hole from the back side. Thus, the connectors are attached to the panel.
CITATION LIST
Patent Literature
[PTL 1] Japanese Patent Application Laid-open Publication No. 2002-359037
SUMMARY OF INVENTION
Technical Problem
In the above-described lever-type connector, the connectors transition from the incompletely fitted state to the completely fitted state depending on the turning angle of the lever. For this reason, when the tuning angle of the lever is close to the angle corresponding to the completely fitted state, the interference by the interference portion with the hole edge of the attachment hole is so small that the connectors may be fitted into the attachment hole in spite of the incompletely fitted state. In such a case, it is difficult to detect that the connectors are in the incompletely fitted state.
Meanwhile, the elastic retaining piece is designed to be elastically deformed by the hole edge of the attachment hole when the lever-type connector is fitted into the attachment hole. For this reason, if the elastic retaining piece is elastically deformed by an external force after the connectors are attached to the attachment hole in the panel, the connectors may come off the attachment hole.
In view of the above, it is an object of the present invention to provide a lever-type connector capable of solving the existing challenge to prevent the connectors in an incompletely fitted state from being attached to a panel, and also preventing the connectors from coming off the panel.
Solution to Problem
For the purpose of achieving the foregoing object, a lever-type connector according to a first aspect of the present invention includes: a first connector; a second connector fittable to the first connector; and a lever provided on any one of the first connector and the second connector, and configured to be turned to fit the first connector and the second connector to each other. The first connector and the second connector in a fitted state are attached to an attachment hole in a panel. The one connector includes a lock portion designed to be flexurally deformed toward its inner surface side and inserted through the attachment hole in the course of attaching the connectors to the attachment hole. The lever includes: an arm portion located on the inner surface side of the one connector while the lever is being turned; and a panel contact part configured to turn the lever by coming into contact with a hole edge of the attachment hole in a state where the lock portion is inserted through the attachment hole. The arm portion includes: a deformation allowing part designed to allow flexural deformation of the lock portion by being located on an inner surface side of the lock portion when the lever is situated in a turning position to bring the first connector and the second connector into an incompletely fitted state; and a deformation blocking part designed to block the flexural deformation of the lock portion by being located on the inner surface side of the lock portion when the lever is situated in a turning position to bring the first connector and the second connector into a completely fitted state. The lever is turned to the turning position to bring the first connector and the second connector into the completely fitted state by pressing the panel contact part against the hole edge while keeping the panel contact part in contact with the hole edge.
In the lever-type connector, the deformation allowing part may include a recessed groove portion provided in a surface of the arm portion, and the deformation blocking part may include the surface of the arm portion excluding the recessed groove portion.
Furthermore, in the lever-type connector, the lever further includes an operating portion configured to perform a turning operation of the lever, and the lever is turned by the turning operation of the operating portion, or by pressing the panel contact part against the hole edge while keeping the panel contact part in contact with the hole edge.
Advantageous Effects of Invention
According to the lever-type connector of the first aspect of the present invention, when the connectors are in the incompletely fitted state, the deformation allowing part is located on the inner surface side of the lock portion. Thus, the flexural deformation of the lock portion is allowed and the connectors can be attached to the attachment hole in a panel.
On the other hand, when the connectors are brought into the completely fitted state by pressing the panel contact part against the hole edge while keeping the panel contact part in contact with the hole edge, the deformation blocking part is located on the inner surface side of the lock portion. Thus, the flexural deformation of the lock portion is blocked and the completely fitted connectors can be prevented from coming off the attachment hole in the panel.
Meanwhile, the lever is turned to the turning position to bring the connectors into the completely fitted state by pressing the panel contact part against the hole edge while keeping the panel contact part in contact with the hole edge. Accordingly, it is possible to reliably prevent the connectors in the incompletely fitted state from being attached to the panel.
Thus, it is possible to provide the lever-type connector capable of preventing the connectors in the incompletely fitted state from being attached to the panel, and preventing the connectors from coming off the panel.
According to the lever-type connector, the deformation allowing part may include the recessed groove provided in the surface of the arm portion while the deformation blocking part may include the surface of the arm portion excluding the recessed groove. Thus, the flexural deformation of the lock portion can be blocked or allowed by using the simple structures.
Meanwhile, according to the lever-type connector, the connectors can be brought into the completely fitted state by: bringing the connectors into the incompletely fitted state by using the operating portion; and then pressing the panel contact part against the hole edge while keeping the panel contact part in contact with the hole edge. Thus, a fitting operation of the connectors can be easily achieved.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an exploded perspective view of a lever-type connector according to an embodiment of the present invention.
FIG. 2 is a perspective view showing a lever according to the embodiment of the present invention.
FIG. 3 depicts a perspective view and a cross-sectional view showing connectors according to the embodiment of the present invention, which are in an incompletely fitted state.
FIG. 4 is a cross-sectional view showing relations between lock portions and arm portions when the connectors according to the embodiment of the present invention are in the incompletely fitted state.
FIG. 5 is a side view showing a position of a deformation allowing part when the connectors according to the embodiment of the present invention are in the incompletely fitted state.
FIG. 6 depicts a perspective view and a cross-sectional view showing the connectors according to the embodiment of the present invention, which are in a completely fitted state.
FIG. 7 is a cross-sectional view showing relations between the lock portions and the arm portions when the connectors according to the embodiment of the present invention are in the completely fitted state.
FIG. 8 is a side view showing a position of a deformation blocking part when the connectors according to the embodiment of the present invention are in the completely fitted state.
DESCRIPTION OF EMBODIMENTS
An embodiment of the present invention will be described below with reference to the drawings. First, a configuration of a lever-type connector according to the embodiment of the present invention will be described in detail with reference to FIG. 1 and FIG. 2 . FIG. 1 is an exploded perspective view of the lever-type connector according to the embodiment of the present invention. FIG. 2 is a perspective view showing a lever according to the embodiment of the present invention.
The lever-type connector according to the embodiment of the present invention relates to an LIF (low insertion force) connector which causes male and female connectors (a first connector and a second connector to be described later), each including multiple terminal tags, to be fitted to each other with a low insertion force.
As shown in FIG. 1 , a lever-type connector 1 according to the embodiment of the present invention mainly includes: a first connector 11 ; a second connector 21 fittable to the first connector 11 ; and a lever 31 provided on the first connector 11 and configured to be turned to fit the first connector 11 and the second connector 21 to each other.
Further, with the first connector 11 and the second connector 21 incompletely fitted to each other, the lever-type connector 1 configured as described above is fitted into an attachment hole 52 formed in a panel 51 to be described later.
After the first connector 11 and the second connector 21 are fitted into the attachment hole 52 to be described later, the connectors 11 and 21 are brought into a completely fitted state by turning the lever 31 while pressing the lever-type connector 1 against the later-described panel 51 . Thus, the connectors 11 and 21 are attached to the panel 51 .
The first connector 11 (the female connector) includes: an inner housing 12 configured to house female terminal tags (not shown) provided on a cable terminal; and a frame 13 configured to enclose the inner housing 12 .
The inner housing 12 has a structure in which two housing components are vertically superposed. The multiple female terminal tags (not shown) are housed inside the inner housing 12 . The inner housing 12 is enclosed in the frame 13 .
The frame 13 includes: multiple (four in the embodiment of the present invention) lock portions 14 which are flexurally deformably provided; a flange portion 15 provided on the outer periphery of the frame 13 ; and a pair of rotating shaft holes 16 (one of which is not shown), into which rotating shaft pins 34 (see FIG. 2 ) of the lever 31 to be described later are inserted.
Each of the multiple lock portions 14 includes: a lock projecting part 17 which projects to the outside of the first connector 11 (for example, a side in an arrow X direction in FIG. 4 to be described later); and a lock contact part 18 provided on the inside of the first connector 11 (for example, a side in an arrow Y direction in FIG. 4 to be described later) and contactable with the lever 31 (see FIG. 4 to be described later).
In addition, when the multiple lock portions 14 configured as described above are attached to the attachment hole 52 in the panel 51 to be described later, each of the lock portions 14 is inserted through the attachment hole 52 to be described later while being flexurally deformed toward an inner surface side of the first connector 11 (for example, the side in the arrow Y direction in FIG. 4 to be described later).
When the first connector 11 and the second connector 21 in the incompletely fitted state are pressed toward a front face side of the panel 51 (a side in an arrow Z direction in FIG. 1 and FIG. 4 to be described later), the lock projecting parts 17 come into contact with the later-described panel 51 from its rear face side 54 (see FIG. 1 ), and thereby fix the connectors 11 and 21 to the panel 51 (see FIG. 4 to be described later).
The lock contact parts 18 come into contact with deformation blocking parts 36 (see FIG. 2 ) of the lever 31 to be described later, thereby blocking the flexural deformation of the lock portions 14 . In addition, when the lock contact parts 18 come out of contact with the lever 31 with the assistance of deformation allowing parts 37 (see FIG. 2 ) of the lever 31 to be described later, the lock contact parts 18 allow the flexural deformation of the lock portions 14 (see FIG. 5 and FIG. 8 to be described later).
When the first connector 11 and the second connector 21 in the completely fitted state are attached to the attachment hole 52 in the panel 51 , the flange portion 15 comes into contact with a hole edge 53 from the front face side (the side in the arrow Z direction in FIG. 1 and FIG. 4 to be described later) of the panel 51 to be described later (see FIG. 6( b ) to be described later).
The pair of rotating shaft pins 34 (see FIG. 2 ) provided on the lever 31 to be described later are respectively inserted into the pair of rotating shaft holes 16 from an inner wall side of the first connector 11 . As a consequence of the insertion of the rotating shaft pins 34 into the rotating shaft holes 16 , the lever 31 is rotatably attached to the first connector 11 (the frame 13 ).
The second connector 21 has a structure in which two housing components larger than the inner housing 12 are vertically superposed. The multiple male terminal tags (not shown) are housed inside the second connector 21 . When the first connector 11 and the second connector 21 are brought into the completely fitted state, the male terminal tags are connected to the female terminal tags (not shown) housed inside the inner housing 12 .
Meanwhile, cam followers 22 (one of which is not shown) to be inserted into cam grooves 35 (see FIG. 2 ) of the lever 31 to be described later are respectively provided in a projecting manner on two side surfaces of the second connector 21 . By inserting the cam followers 22 into the cam grooves 35 and then turning the lever 31 , the second connector 21 is drawn into the first connector 11 .
As shown in FIG. 2 , the lever 31 includes: a pair of arm portions 32 , each of which is located on the inner surface side (for example, the side in the arrow X direction in FIG. 4 to be described later) of the first connector 11 (see FIG. 1 ) when the lever 31 is turned; and a connecting portion 33 that connects the pair of arm portions 32 .
The pair of arm portions 32 include: the pair of rotating shaft pins 34 (one of which is not shown) to be inserted into the rotating shaft holes 16 (see FIG. 1 ) of the frame 13 ; the pair of cam grooves 35 into which the cam followers 22 (see FIG. 1 ) of the second connector 21 are inserted; the deformation blocking parts 36 which block the flexural deformation of the lock portions 14 of the frame 13 ; and the deformation allowing parts 37 which allow the flexural deformation of the lock portions 14 .
The pair of rotating shaft pins 34 are inserted into the rotating shaft holes 16 (see FIG. 1 ) from the inner wall side of the first connector 11 . Thus, the lever 31 is rotatably attached to the first connector 11 (the frame 13 ).
The cam grooves 35 are respectively formed on the pair of arm portions 32 . When the lever 31 is turned with the cam followers 22 (see FIG. 1 ) inserted in the cam grooves 35 , the distance between each cam follower 22 and the corresponding rotating shaft pin 34 is changed whereby the second connector 21 moves toward the first connector 11 (see FIG. 1 ).
The deformation blocking parts 36 are formed from the surfaces of the arm portions 32 excluding the recessed grooves (the deformation allowing parts 37 ) formed in those surfaces. Each of the deformation blocking parts 36 is located on the inner surface side of the corresponding lock portion 14 (for example, the side in the arrow Y direction in FIG. 4 to be described later) when the lever 31 is situated in a turning position to bring the first connector 11 and the second connector 21 into the completely fitted state. Thus, the deformation blocking parts 36 block the flexural deformation of the lock portions 14 (see FIG. 4 and FIG. 5 to be described later).
In other words, when each of the deformation blocking parts 36 is located on the inner surface side of the corresponding lock portion 14 (for example, the side in the arrow Y direction in FIG. 4 to be described later), the deformation blocking part 36 is in contact with the lock contact part 18 of the corresponding lock portion 14 and blocks the flexural deformation of the lock portion 14 .
Each of the deformation allowing parts 37 is formed from the recessed groove provided in the surface of the corresponding arm portion 32 . Each deformation allowing part 37 is located on the inner surface side of the corresponding lock portion 14 when the lever 31 is situated in a turning position to bring the first connector 11 and the second connector 21 into the incompletely fitted state. Thus, the deformation allowing parts 37 allow the flexural deformation of the lock portions 14 (see FIG. 7 and FIG. 8 to be described later).
In other words, when each of the deformation allowing parts 37 is located on the inner surface side of the corresponding lock portion 14 (for example, the side in the arrow Y direction in FIG. 4 to be described later), the lock contact part 18 of the lock portion 14 is out of contact with the corresponding arm portion 32 of the lever 31 . Thus, the deformation allowing parts 37 allow the flexural deformation of the lock portions 14 .
As described above, the deformation allowing parts 37 are formed from the recessed grooves provided in the surfaces of the arm portions 32 , while the deformation blocking parts 36 are formed from the surfaces of the arm portions 32 excluding the recessed grooves. As a consequence, the flexural deformation of the lock portions 14 can be blocked or allowed by using the simple structures.
When the lever 31 is situated in the turning position to bring the first connector 11 and the second connector 21 into the incompletely fitted state (for example, a position of the lever 31 shown in FIG. 3 to FIG. 5 ), each of the above-described arm portions 32 is displaced in response to the turn of the lever 31 in such a way as to locate the corresponding deformation allowing part 37 on the inner surface side of the corresponding lock portion 14 (for example, the side in the arrow Y direction in FIG. 4 to be described later).
In the meantime, when the lever 31 is situated in the turning position to bring the first connector 11 and the second connector 21 into the completely fitted state (for example, the position of the lever 31 shown in FIG. 6 to FIG. 8 ), each of the arm portions 32 is displaced in response to the turn of the lever 31 in such a way as to locate the corresponding deformation blocking part 36 on the inner surface side of the corresponding lock portion 14 (for example, the side in the arrow Y direction in FIG. 4 to be described later).
Hence, each of the arm portions 32 is provided with the deformation blocking part 36 and the deformation allowing part 37 corresponding to the turning angles of the lever 31 in such a way that either one of the deformation blocking part 36 and the deformation allowing part 37 is located on the inner surface side of the corresponding lock portion 14 (for example, the side in the arrow Y direction in FIG. 4 to be described later) depending on the turning position of the lever 31 .
The connecting portion 33 includes: an operating portion 38 which is subjected to a tuning operation when the lever 31 is turned to bring the first connector 11 and the second connector 21 into the incompletely fitted state; and a panel contact part 39 configured to turn the lever 31 by causing the lock portions 14 , which are in the state of being inserted through the attachment hole 52 in the panel 51 to be described later, to come into contact with the hole edge 53 of the attachment hole 51 to be described later.
The panel 51 is provided with: the attachment hole 52 having a vertical ellipsoidal shape and allowing the insertion of the lock portions 14 ; the hole edge 53 with which the flange portion 15 is contactable; and the rear surface side 54 with which the lock projecting parts 17 are contactable (see FIG. 1 ).
When the lever 31 is turned by operating the operating portion 38 in an arrow A direction in FIG. 2 , the connecting portion 33 is displaced along an arc around the rotating shaft pins 34 (the rotation center).
The panel contact part 39 is formed into a plate shape and provided to protrude outward from the lever 31 . When the panel contact part 39 is pressed against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 of the panel 51 , the panel contact part 39 turns the lever 31 , thereby bringing the first connector 11 and the second connector 21 , being brought into the incompletely fitted state by using the operating portion 38 , further into the completely fitted state.
Thus, it is possible to establish the completely fitted state of the connectors 11 and 21 by: bringing the connectors 11 and 21 into the incompletely fitted state by using the operating portion 38 ; and then pressing the panel contact part 39 against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 . Hence, a fitting operation of the connectors 11 and 21 can be achieved easily.
In addition, since the connectors 11 and 21 are brought into the completely fitted state by pressing the panel contact part 39 against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 , it is possible to reliably prevent the connectors 11 and 21 in the incompletely fitted state from being attached to the panel 51 .
Moreover, the above-described first connector 11 and second connector 21 in the incompletely fitted state are fitted into the attachment hole 52 in the panel 51 . Then, the lever 31 is pressed against the panel 51 and the connectors 11 and 21 in the completely fitted state are thus attached to the panel 51 (see FIG. 3 to FIG. 8 to be described later).
Next, the fitting operation of the lever-type connector according to the embodiment of the present invention will be described with reference to FIG. 3 to FIG. 8 . FIG. 3( a ) is a perspective view showing the connectors according to the embodiment of the present invention, which are in the incompletely fitted state. FIG. 3 ( b ) is a cross-sectional view corresponding to FIG. 3( a ).
Meanwhile, FIG. 4 is a cross-sectional view showing relations between the lock portions and the arm portions when the connectors according to the embodiment of the present invention are in the incompletely fitted state. FIG. 5 is a side view showing a position of a deformation allowing part when the connectors according to the embodiment of the present invention are in the incompletely fitted state.
Further, FIG. 6( a ) is a perspective view showing the connectors according to the embodiment of the present invention, which are in the completely fitted state. FIG. 6( b ) is a cross-sectional view corresponding to FIG. 6( a ). FIG. 7 is a cross-sectional view showing relations between the lock portions and the arm portions when the connectors according to the embodiment of the present invention are in the completely fitted state. FIG. 8 is a side view showing a position of a deformation blocking part when the connectors according to the embodiment of the present invention are in the completely fitted state.
When the second connector 21 is fitted to the first connector 11 , the rotating shaft pins 34 of the lever 31 are first inserted into the rotating shaft holes 16 in the frame 13 . Thus, the lever 31 is rotatably attached to the first connector 11 (the frame 13 ) (see FIG. 3 and FIG. 4 , for example).
After the lever 31 is attached to the first connector 11 , the second connector 21 is slightly fitted into the frame 13 while holding the lever 31 at an initial position (such as a position shown in FIG. 1 ). Thus, the cam followers 22 are inserted into the cam grooves 35 .
When the operating portion 38 of the lever 31 is subjected to the turning operation with the cam followers 22 inserted in the cam grooves 35 , the distance between each cam follower 22 and the corresponding rotating shaft pin 34 becomes shorter and the second connector 21 is drawn into the first connector 11 .
Then, after the lever 31 is turned to the position to bring the first connector 11 and the second connector 21 into the incompletely fitted state (the position of the lever 31 shown in FIG. 3 to FIG. 5 ), the connectors 11 and 21 are fitted into the attachment hole 52 in the panel 51 as shown in FIG. 3( a ) and FIG. 3( b ).
Here, when the lever 31 is situated in the turning position to bring the first connector 11 and the second connector 21 into the incompletely fitted state (the position of the lever 31 shown in FIG. 3 to FIG. 5 ), each of the deformation allowing parts 37 is located on the inner surface side of the corresponding lock portion 14 (for example, the side in the arrow Y direction in FIG. 4 ) as shown in FIG. 4 and FIG. 5 .
For this reason, as shown in FIG. 4 and FIG. 5 , the lock contact parts 18 of the lock portions 14 are out of contact with arm portions 32 of the lever 31 . Thus, the deformation allowing parts 37 allow the flexural deformation of the lock portions 14 .
Moreover, since the flexural deformation of the lock portions 14 is allowed, when the first connector 11 and the second connector 21 are fitted into the attachment hole 52 in the panel 51 , each of the lock portions 14 is flexurally deformed toward the inner surface side of the first connector 11 (for example, the side in the arrow Y direction in FIG. 4 ) by a force to press the connectors 11 and 21 toward the front face side of the panel 51 (the side in the arrow Z direction in FIG. 1 and FIG. 4 ), and is thereby inserted through the attachment hole 52 (see FIG. 4 ).
After the lock portions 14 are inserted through the attachment hole 52 , each of the flexurally deformed lock portions 14 restores its original form, and the lock projecting parts 17 come into contact with the panel 51 from the rear surface side 54 (see FIG. 4 ). In addition, when the lock portions 14 are inserted through the attachment hole 52 , the panel contact part 39 of the lever 31 comes into contact with the hole edge 53 as shown in FIG. 3( b ).
Then, while the panel contact part 39 is in contact with the hole edge 53 , the lever-type connector 1 is pressed toward the front face side of the panel 51 (the side in the arrow Z direction in FIG. 1 and FIG. 4( a )). Thus, the panel contact part 39 is pressed against the hole edge 53 .
When the panel contact part 39 is pressed against the hole edge 53 , the lever 31 is turned from the position to bring the first connector 11 and the second connector 21 into the incompletely fitted state (the position shown in FIG. 3 to FIG. 5 ) to the position to bring the connectors 11 and 21 into the completely fitted state (the position shown in FIG. 6 to FIG. 8 ). Thus, the first connector 11 and the second connector 21 are fitted to the attachment hole 52 in the panel 51 (see FIG. 6( a ) and FIG. 6( b )).
When the first connector 11 and the second connector 21 are brought into the completely fitted state, the female terminal tags (not shown) of the first connector 11 are connected to the male terminal tags (not shown) of the second connector 21 to achieve conduction.
Here, when the lever 31 is situated in the turning position to bring the first connector 11 and the second connector 21 into the completely fitted state (the position of the lever 31 shown in FIG. 6 to FIG. 8 ), each of the deformation blocking parts 36 is located on the inner surface side of the corresponding lock portion 14 (for example, the side in the arrow Y direction in FIG. 4 to be described later) as shown in FIG. 7 and FIG. 8 .
For this reason, as shown in FIG. 7 and FIG. 8 , the lock contact parts 18 of the lock portions 14 come into contact with the deformation blocking parts 36 . Thus, the deformation blocking parts 36 block the flexural deformation of the lock portions 14 .
As described above, when the lever 31 is situated in the turning position (the position of the lever 31 shown in FIG. 6 to FIG. 8 ) to bring the first connector 11 and the second connector 21 into the completely fitted state, the flexural deformation of the lock portions 14 is blocked by the deformation blocking parts 36 , and the lock portions 14 cannot be inserted through the attachment hole 52 .
For this reason, the lock portions 14 are not flexurally deformed even when an external force is applied to the lock portions 14 after the first connector 11 and the second connector 21 are attached to the attachment hole 52 in the panel 51 . Thus, it is possible to prevent the connectors 11 and 21 from coming off the attachment hole 52 .
When the first connector 11 and the second connector 21 are brought into the completely fitted state, the flange portion 15 comes into contact with the hole edge 53 from the front face side (the side in the arrow Z direction in FIG. 1 and FIG. 4 ) of the panel 51 . Thus, the first connector 11 and the second connector 21 are fixed to the attachment hole 52 in the panel 51 (see FIG. 6( b )).
Thus, the deformation allowing parts 37 are located on the inner surface sides of the lock portions 14 when the connectors 11 and 21 are in the completely fitted state. Accordingly, the flexural deformation of the lock portions 14 is allowed and the connectors 11 and 21 can be attached to the attachment hole 52 in the panel 51 .
In the meantime, when the connectors 11 and 21 are brought into the completely fitted state by pressing the panel contact part 39 against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 , the deformation blocking parts 36 are located on the inner surface sides of the lock portions 14 . Accordingly, the flexural deformation of the lock portions 14 is blocked and the completely fitted connectors 11 and 21 can be prevented from coming off the attachment hole 52 in the panel 51 .
Meanwhile, the lever 31 is turned to the turning position to bring the connectors 11 and 21 into the completely fitted state by pressing the panel contact part 39 against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 . Accordingly, the connectors 11 and 21 in the incompletely fitted state can be reliably prevented from being attached to the panel 51 .
As described above, the lever-type connector 1 according to the embodiment of the present invention includes: the first connector 11 ; the second connector 21 fittable to the first connector; and the lever 31 provided on any one of the first connector 11 and the second connector 21 , and configured to be turned to fit the first connector 11 and the second connector 21 to each other. The first connector 11 and the second connector 21 in the fitted state are attached to the attachment hole 52 in the panel 51 . The one connector 11 includes the lock portions 14 which are flexurally deformed toward the inner surface sides and inserted through the attachment hole 52 when the connectors are attached to the attachment hole 52 . The lever 31 includes: the arm portions 32 located on the inner surface sides of the one connector 11 when the lever 31 is turned; and the panel contact part 39 which turns the lever 31 by coming into contact with the hole edge 53 of the attachment hole 52 in the state where the lock portions 14 are inserted through the attachment hole 52 . Each arm portion 32 includes: the deformation allowing part 37 allowing the flexural deformation by being located on the inner surface side of the corresponding lock portion 14 when the lever 31 is situated in the turning position to bring the first connector 11 and the second connector 21 into the incompletely fitted state, thereby allowing the flexural deformation; and the deformation blocking part 36 blocking the flexural deformation by being located on the inner surface side of the corresponding lock portion 14 when the lever 31 is situated in the turning position to bring the first connector 11 and the second connector 21 into the completely fitted state. The lever 31 is turned to the turning position to bring the first connector 11 and the second connector 21 into the completely fitted state by pressing the panel contact part 39 against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 .
Moreover, in the lever-type connector 1 according to the embodiment of the present invention, each deformation allowing part 37 is formed from the recessed groove portion provided in the surface of the arm portion 32 , while each deformation blocking part 36 is formed from the surface of the arm portion 32 excluding the recessed groove portion.
In addition, in the lever-type connector 1 according to the embodiment of the present invention, the lever 31 further includes the operating portion 38 configured to perform the turning operation of the lever 31 . Here, the lever 31 is turned by the turning operation of the operating portion 38 or by pressing the panel contact part 39 against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 .
Furthermore, according to the lever-type connector 1 of the embodiment of the present invention, when the connectors 11 and 21 are in the incompletely fitted state, the deformation allowing part 37 is located on the inner surface side of the corresponding lock portion 14 . As a consequence, the flexural deformation of the lock portion 14 is allowed, whereby the connectors 11 and 21 can be attached to the attachment hole 52 in the panel 51 .
In the meantime, when the connectors 11 and 21 are brought into the completely fitted state by pressing the panel contact part 39 against the edge hole 53 while keeping the panel contact part 39 in contact with the hole edge 53 , the deformation blocking part 36 is located on the inner surface side of the lock portion 14 . Accordingly, the lock portion 14 is inhibited from the flexural deformation, and the completely fitted connectors 11 and 21 can be prevented from coming off the attachment hole 52 in the panel 51 .
In addition, the lever 31 is turned to the turning position to bring the connectors 11 and 21 into the completely fitted state by pressing the panel contact part 39 against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 . Accordingly, the connectors 11 and 21 in the incompletely fitted state can be reliably prevented from being attached to the panel 51 .
Thus, it is possible to provide the lever-type connector 1 capable of preventing the connectors 11 and 21 in the incompletely fitted state from being attached to the panel 51 , and preventing the connectors 11 and 21 from coming off the panel 51 .
Moreover, in the lever-type connector 1 according to the embodiment of the present invention, the deformation allowing part 37 is formed from the recessed groove provided in the surface of the arm portion 32 , while the deformation blocking part 36 is formed from the surface of the arm portion 32 excluding the recessed groove. As a consequence, the flexural deformation of the lock portion 14 can be blocked or allowed by using the simple structures.
Furthermore, in the lever-type connector 1 of the embodiment of the present invention, it is possible to establish the completely fitted state of the connectors 11 and 21 by: bringing the connectors 11 and 21 into the incompletely fitted state by using the operating portion 38 ; and then pressing the panel contact part 39 against the hole edge 53 while keeping the panel contact part 39 in contact with the hole edge 53 . Hence, the fitting operation of the connectors 11 and 21 can be achieved easily.
The lever-type connector according to the embodiment of the present invention has been described above on the basis of the illustrated embodiment. It is to be noted, however, that the present invention is not limited only to the above-described embodiment. The configurations of the components therein may be replaced with other arbitrary configurations having similar functions thereto.
For example, the foregoing descriptions have been provided for the embodiment in which the lock portions 14 are provided at the four positions on the frame 13 . However, the number of the lock portions 14 can be changed as appropriate.
In such a case, at least one of the lock portions 14 is to be disposed in such a position to locate the deformation allowing part 37 on the inner surface side of the lock portion 14 when the connectors 11 and 21 are in the incompletely fitted state and to locate the deformation blocking part 36 on the inner surface side when the connectors 11 and 21 are in the completely fitted mode. Thus, it is possible to achieve the same operation and effects as those of the lever-type connector according to the above-described embodiment of the present invention.
INDUSTRIAL APPLICABILITY
The present invention is extremely useful for preventing incompletely fitted connectors of a lever-type connector from being attached to a panel, and for preventing the connectors of the lever-type connector from coming off the panel.
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This lever-type connector ( 1 ) having: a first connector ( 11 ); a second connector ( 21 ); and a lever ( 31 ) that fits the connectors ( 11, 21 ) together by being rotated. The first connector ( 11 ) has an engagement lock part ( 14 ) that is inserted through an attachment hole ( 52 ) by being bent and deformed toward the inner surface side at the time of attaching the first connector to the attachment hole ( 52 ). The lever ( 31 ) has an arm part ( 32 ) that is located on the inner surface side of the first connector ( 11 ) during the rotation of the lever ( 31 ). The arm part ( 32 ) has: a deformation permitting part ( 37 ) that permits the bending deformation thereof when the lever ( 31 ) is at a rotation position where the connectors ( 11, 21 ) are in a half-fitted state; and a deformation preventing part ( 36 ) that prevents the bending deformation thereof.
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FIELD OF THE INVENTION
[0001] The invention relates to a process to blend a mineral derived hydrocarbon product and a Fischer-Tropsch derived hydrocarbon product.
BACKGROUND OF THE INVENTION
[0002] WO-A-2004104142 discloses the blending of a mineral derived hydrocarbon product and a Fischer-Tropsch derived hydrocarbon product and subsequent supplying of the blend to a ship.
[0003] A process to blend mineral derived gas oil and a Fischer-Tropsch derived gas oil is described in WO-A-03087273. This publication describes that a mineral derived may be blended in a refinery environment to achieve a blended product having a certain cetane number.
[0004] Although WO-A-03087273 provides a process to achieve a blend having a certain quality property it can still be improved in terms of the blending operation itself. The present process provides such a solution.
SUMMARY OF THE INVENTION
[0005] Process to blend a mineral derived hydrocarbon product and a Fischer-Tropsch derived hydrocarbon product by providing in a storage vessel of a marine vessel with a quantity of mineral derived hydrocarbon product and Fischer-Tropsch derived hydrocarbon product such that initially the mineral derived hydrocarbon product is located substantially above the Fischer-Tropsch derived hydrocarbon product, transporting the combined products in the marine vessel from one location to another location, also referred to as the destination, and obtaining a blended product at arrival of the marine vessel at its destination.
[0006] Applicants found that a fully blended product can be obtained by the process according to the invention. The process makes available a blended product suited for direct use near the costumer or at a refinery for further upgrading. The process eliminates blending operations at the destination and eliminates the use of multiple marine vessels to carry the separate blending products to the destination.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The invention is directed to a process to blend a mineral derived hydrocarbon product and a Fischer-Tropsch derived hydrocarbon product. The Fischer-Tropsch derived hydrocarbon product is suitably obtained by converting a mixture of carbon monoxide and hydrogen in the presence of a suitable Fischer-Tropsch catalyst under Fischer-Tropsch operating conditions. The catalysts used for the catalytic conversion of the mixture comprising hydrogen and carbon monoxide into the Fischer-Tropsch derived paraffinic hydrocarbon product are known in the art. Catalysts for use in this process frequently comprise, as the catalytically active component, a metal from Group VIII of the Periodic Table of Elements. Particular catalytically active metals include ruthenium, iron, cobalt and nickel. Cobalt is a preferred catalytically active metal.
[0008] Examples of suitable Fischer-Tropsch synthesis processes are for example the so-called commercial Sasol process, the Shell Middle Distillate Synthesis Process or by the AGC-21 ExxonMobil process. These and other processes are for example described in more detail in EP-A-776959, EP-A-668342, U.S. Pat. No. 4,943,672, U.S. Pat. No. 5,059,299, WO-A-9934917 and WO-A-9920720 and are incorporated by reference. The Fischer-Tropsch process may be carried out in a slurry reactor, a fixed bed reactor, especially a multitubular fixed bed reactor or in a three phase fluidised bed reactor.
[0009] Syngas, i.e. the mixture of carbon monoxide and hydrogen used in the Fischer-Tropsch process may be prepared from various hydrocarboneous sources such as for example biomass, coal, mineral crude oil fractions like residual fractions and methane containing gasses, for example natural gas or coal bed methane gas.
[0010] The Fischer-Tropsch derived hydrocarbon product is suitably liquid at 0° C. If the product is not liquid it is preferably kept in the storage vessel of the ship at conditions at which the product is liquid. The Fischer-Tropsch derived product can be the wax as such is directly prepared in the Fischer-Tropsch synthesis step. Suitably this Fischer-Tropsch synthesis product is first subjected to a mild hydroisomerisation to reduce the congealing point of the product and increase its pumpability and to more easily have the product in the liquid state in the process of the present invention. Such a product is also referred to as Syncrude.
[0011] The Fischer-Tropsch derived hydrocarbon product may also be the lower boiling liquid fractions as isolated from the waxy Fischer-Tropsch product boiling between 35 and 300° C. These products comprising substantially, i.e. more than 80 wt % of normal paraffins, may be shipped as hydrocarbon solvents, as steam cracker feedstock or as feedstock for the preparation of detergents.
[0012] Alternatively the waxy product is subjected to a hydrocracking/hydroisomerisation process wherein lower boiling fractions are obtained, such as for example paraffin products boiling in the naphtha, kerosene and gas oil boiling range. The partly isomerised liquid products so obtained may be shipped to end costumers for use as aviation fuel, diesel fuel, industrial gas oil, drilling fluids, steam cracker feedstock or solvents. The partly isomerised wax, also referred to as waxy Raffinate, as obtained in such process steps may advantageously be further processed by means of solvent or catalytic dewaxing to obtain lubricating base oils or may be shipped as such to be used as an intermediate product to base oil manufacturing locations more near to the end users. Waxy Raffinate is a distillate fraction. Residual fractions boiling in the base oil range may also be used. However it may be more difficult to keep these products in a liquid state during blending. Examples of such processes are described in more detail in U.S. Pat. No. 6,309,432, U.S. Pat. No. 6,296,757, U.S. Pat. No. 5,689,031, EP-A-668342, EP-A-583836, U.S. Pat. No. 6,420,618, WO-A-02070631, WO-A-02070629, WO-A-02070627, WO-A-02064710 and WO-A-02070630, which references are incorporated by reference. The referred to hydrocracking/hydroisomerisation and optimal dewaxing steps are thus performed at the Fischer-Tropsch manufacturing location and the resulting above described liquid products are suited as the Fischer-Tropsch hydrocarbon products to be shipped.
[0013] The volume ratio between the mineral derived hydrocarbon product and the Fischer-Tropsch derived product may range in a wide span, for example between 1:99 to 99:1 and more preferably between 10:90 and 90:10. The mineral derived hydrocarbon product preferably has a T90 vol % boiling point as measured by ASTM D86, which is greater than the T50 vol % boiling point of the Fischer-Tropsch derived hydrocarbon product. More preferably more than 50 vol % and even more preferably more than 80 vol % of the boiling ranges of the mineral and the Fischer-Tropsch derived products overlap.
[0014] The mineral hydrocarbon product may be any product which is extracted from a subterranean environment or derivatives there from. Examples of such products are crude mineral oil, gas field condensates, plant condensates, naphtha, kerosene, gas oil, vacuum distillates, deasphalted oils, residual fractions of crude oils and the like.
[0015] Examples of combinations for which the present process will find utility are the blending of mineral crude oil and syncrude, blending of Fischer-Tropsch derived naphtha and gas field condensate, blending of Fischer-Tropsch derived gas oil and mineral derived gas oil and the blending of Fischer-Tropsch derived waxy raffinate and mineral oil derived vacuum distillates and/or mineral oil derived deasphalted oil.
[0016] Preferably the Fischer-Tropsch derived hydrocarbon product is the gas oil fraction, preferably as obtained after hydroisomerisation. The gas oil product may thus be obtained by fractionation of such a Fischer-Tropsch synthesis product or obtained from a hydroconverted (hydrocracking/hydroisomerisation) Fischer-Tropsch synthesis product. Optionally the gas oil may have been subjected to a catalytic dewaxing treatment. Mixtures of the afore mentioned gas oil fractions may also be used as the Fischer-Tropsch derived hydrocarbon product. Examples of Fischer-Tropsch derived gas oils are described in EP-A-583836, WO-A-9714768, WO-A-9714769, WO-A-011116, WO-A-011117, WO-A-0183406, WO-A-0183648, WO-A-0183647, WO-A-0183641, WO-A-0020535, WO-A-0020534, EP-A-1101813, WO-A-03070857 and U.S. Pat. No. 6,204,426.
[0017] Suitably the Fischer-Tropsch derived gas oil will consist of at least 90 wt %, more preferably at least 95 wt % of iso and linear paraffins. The weight ratio of iso-paraffins to normal paraffins will suitably be greater than 0.3. This ratio may be up to 12. Suitably this ratio is between 2 and 6. The actual value for this ratio will be determined, in part, by the hydroconversion process used to prepare the Fischer-Tropsch derived gas oil from the Fischer-Tropsch synthesis product. Some cyclic-paraffins may be present. By virtue of the Fischer-Tropsch process, the Fischer-Tropsch derived gas oil has essentially zero content of sulphur and nitrogen (or amounts which are no longer detectable). These hereto-atom compounds are poisons for Fischer-Tropsch catalysts and are removed from the synthesis gas that is the feed for the Fischer-Tropsch process. Further, the process does not make aromatics, or as usually operated, virtually no aromatics are produced. The content of aromatics as determined by ASTM D 4629 will typically be below 1 wt %, preferably below 0.5 wt % and most preferably below 0.1 wt %.
[0018] The Fischer-Tropsch derived gas oil will suitably have a distillation curve which will for its majority be within the typical gas oil range: between about 150 and 400° C. The Fischer-Tropsch gas oil will suitably have a T90 wt % of between 320-400° C., a density of between about 0.76 and 0.79 g/cm 3 at 15° C., a cetane number greater than 70, suitably between about 74 and 82, and a viscosity between about 1.9 and 4.5 centistokes at 40° C.
[0019] The above Fischer-Tropsch derived gas oil is preferably blended with a mineral derived kerosene or gas oil or mixtures of said kerosene and gas oil. Preferred mineral derived gas oils or kerosenes are gas oils or kerosenes as obtained from refining and optionally (hydro)processing of a crude mineral source or the gas oil or kerosene fraction as isolated from a gas field condensate. The mineral derived gas oil may be a single gas oil stream as obtained in such a refinery process or be a blend of several gas oil fractions obtained in the refinery process via different processing routes. Examples of such different gas oil fractions as produced in a refinery are straight run gas oil, vacuum gas oil, gas oil as obtained in a thermal cracking process and light and heavy cycle oil as obtained in a fluid catalytic cracking unit and gas oil as obtained from a hydrocracker unit or the equivalent kerosene fraction.
[0020] The straight run gas oil or kerosene fraction is the fraction, which has been obtained in the atmospheric distillation of the crude mineral refinery feedstock. The above fractions suitably have an Initial Boiling Point (IBP) of between 150 and 280° C. and a Final Boiling Point (FBP) of between 290 and 380° C. The vacuum gas oil is the gas oil fraction as obtained in the vacuum distillation of the residue as obtained in the above referred to atmospheric distillation of the crude mineral refinery feedstock. The vacuum gas oil has an IBP of between 240 and 300° C. and a FBP of between 340 and 380° C. The thermal cracking process also produces a gas oil fraction, which may be used in step (a). This gas oil fraction has an IBP of between 180 and 280° C. and a FBP of between 320 and 380° C. The light cycle oil fraction as obtained in a fluid catalytic cracking process will have an IBP of between 180 and 260° C. and a FBP of between 320 and 380° C. The heavy cycle oil fraction as obtained in a fluid catalytic cracking process will have an IBP of between 240 and 280° C. and a FBP of between 340 and 380° C. These feedstocks may have a sulphur content of above 0.05 wt %. The maximum sulphur content will be about 2 wt %. Although the Fischer-Tropsch derived gas oil comprises almost no sulphur it could still be necessary to lower the sulphur level of the mineral derived gas oil in order to meet the current stringent low sulphur specifications. Typically the reduction of sulphur will be performed by processing these gas oil fractions in a hydrodesulphurisation (HDS) unit.
[0021] Gas oil as obtained in a fuels hydrocracker has suitably an IBP of between 150 and 280° C. and a FBP of between 320 and 380° C.
[0022] The cetane number of the blend of mineral derived gas oil as described above is preferably greater than 40 and less than 70. If also other properties like for example Cloud Point, CFPP (cold filter plugging point), Flash Point, Density, Di+-aromatics content, Poly Aromatics and/or distillation temperature for 95% recovery comply with the local regulations the blend may be advantageously used as a diesel fuel component.
[0023] Preferably the final blended gas oil product comprising the Fischer-Tropsch and the mineral derived gas oil will have a sulphur content of at most 2000 ppmw (parts per million by weight) sulphur, preferably no more than 500 ppmw, most preferably no more than 50 or even 10 ppmw. The density of such a blend is typically less than 0.86 g/cm 3 at 15° C., and preferably less than 0.845 g/cm 3 at 15° C. The lower density of such a blend as compared to conventional gas oil blends results from the relatively low density of the Fischer-Tropsch derived gas oils. The above fuel composition is suited as fuel in an indirect injection diesel engine or a direct injection diesel engine, for example of the rotary pump, in-line pump, unit pump, electronic unit injector or common rail type.
[0024] The final gas oil blend may be an additised (additive-containing) oil or an unadditised (additive-free) oil. If the fuel oil is an additised oil, it will contain minor amounts of one or more additives, e.g. one or more additives selected from detergent additives, for example those obtained from Infineum (e.g., F7661 and F7685) and Octel (e.g., OMA 4130D); lubricity enhancers, for example EC 832 and PARADYNE 655 (ex Infineum), HITEC E580 (ex Ethyl Corporation), VELTRON 6010 (ex Infineum) (PARADYNE, HITEC and VELTRON are trademarks) and amide-based additives such as those available from the Lubrizol Chemical Company, for instance LZ 539 C; dehazers, e.g., alkoxylated phenol formaldehyde polymers such as those commercially available as NALCO EC5462A (formerly 7D07) (ex Nalco), and TOLAD 2683 (ex Petrolite)(NALCO and TOLAD are trademarks); anti-foaming agents (e.g., the polyether-modified polysiloxanes commercially available as TEGOPREN 5851 and Q 25907 (ex Dow Corning), SAG TP-325 (ex OSi), or RHODORSIL (ex Rhone Poulenc))(TEGOPREN, SAG and RHODORSIL are trademarks); ignition improvers (cetane improvers) (e.g., 2-ethylhexyl nitrate (EHN), cyclohexyl nitrate, di-tert-butyl peroxide and those disclosed in U.S. Pat. No. 4,208,190 at column 2, line 27 to column 3, line 21); anti-rust agents (e.g., that sold commercially by Rhein Chemie, Mannheim, Germany as “RC 4801”, a propane-1, 2-diol semi-ester of tetrapropenyl succinic acid, or polyhydric alcohol esters of a succinic acid derivative, the succinic acid derivative having on at least one of its alpha-carbon atoms an unsubstituted or substituted aliphatic hydrocarbon group containing from 20 to 500 carbon atoms, e.g., the pentaerythritol diester of polyisobutylene-substituted succinic acid); corrosion inhibitors; reodorants; anti-wear additives; anti-oxidants (e.g., phenolics such as 2,6-di-tert-butyl-phenol, or phenylenediamines such as N,N′-di-sec-butyl-p-phenylenediamine); and metal deactivators.
[0025] The additive concentration of each such additional component in the additivated fuel composition is preferably up to 1% w/w, more preferably in the range from 5 to 1000 ppmw, advantageously from 75 to 300 ppmw, such as from 95 to 150 ppmw.
[0026] In addition to the above gas oil components also a relatively small portion of an oxygenate type fuel component may be present in the final blend to obtain diesel fuel as for example described in WO-A-2004035713. The oxygenate fuel may be present in a content of between 2 and 20 wt %, more preferably between 2 and 10 wt % as measured in the final fuel composition The oxygenate is an oxygen containing compound, preferably containing only carbon, hydrogen and oxygen. It may suitably be a compound containing one or more hydroxyl groups —OH, and/or one or more carbonyl groups C=O, and/or one or more ether groups —O—, and/or one or more ester groups —C(O)O—. It preferably contains from 1 to 18 carbon atoms and in certain cases from 1 to 10 carbon atoms. Ideally it is biodegradable. It is suitably derived from organic material, as in the case of currently available “biofuels” such as vegetable oils and their derivatives.
[0027] Preferred oxygenates for use are esters, for example alkyl, preferably C1 to C8 or C1 to C5, such as methyl or ethyl, esters of carboxylic acids of vegetable oils. The carboxylic acid in this case may be an optionally substituted, straight or branched chain, mono-, di- or multi-functional C1 to C6 carboxylic acid, typical substituents including hydroxy, carbonyl, ether and ester groups. Suitable examples of oxygenates (iii) include succinates and levulinates.
[0028] Ethers are also usable as the oxygenate (iii), for example dialkyl (typically C1 to C6) ethers such as dibutyl ether and dimethyl ether.
[0029] Alternatively the oxygenate may be an alcohol, which may be primary, secondary or tertiary. It may in particular be an optionally substituted (though preferably unsubstituted) straight or branched chain C1 to C6 alcohol, suitable examples being methanol, ethanol, n-propanol and iso-propanol. Typical substituents include carbonyl, ether and ester groups. Methanol and in particular ethanol may for instance be used.
[0030] The oxygenate (iii) will typically be a liquid at ambient temperature, with a boiling point preferably from 100 to 360° C., more preferably from 250 to 290° C. Its density is suitably from 0.75 to 1.2 g/cm 3 , more preferably from 0.75 to 0.9 g/cm 3 at 15° C. (ASTM D4502/IP 365), and its flash point greater than 55° C. Adding the additives and/or the oxygenates may be performed at the destination or on-board the marine vessel as part of the process of the present invention. Even more preferred is to add, or at least part of, the additives and/or the oxygenates when off-loading the blended product from the marine vessel at the destination. Addition is preferably performed by means of so-called in-line blending. This is advantageous because the blend as thus obtained can be directly used as a finished fuel for use as Automotive Gas Oil (AGO) or as an Industrial Gas Oil (IGO). Thus a separate blending operation in a blending park at the destination is avoided and a more efficient process is obtained.
[0031] The mineral derived hydrocarbon product can be loaded at the same location or at a different location from where the Fischer-Tropsch derived product is loaded to the storage vessel of the marine vessel. With substantially above is meant that at loading is meant that at least 50, preferably at least 70 and even more preferably at least 90 vol %, of the Fischer-Tropsch derived product is present in the lower half of the storage vessel. When loading the marine vessel using a bottom filling device the mineral hydrocarbon product is preferably supplied first and the Fischer-Tropsch derived product second. With a blended product at the destination is meant a mixture wherein the difference in density between a sample taken at 10% of the liquid height below the liquid surface, referred to as d10, and the density of a sample taken at 90% of the liquid height below the liquid surface, referred to as d90, is small, preferably such that the ratio of the (d10-d90)/d10 is less than 0.01, more preferably less than 0.001. Preferably the duration of the blending operation during transport to the destination is at least 10 days, more preferably at least 20 days. Preferably the marine vessel travels through the more rough water areas in order to further enhance blending. For this purpose the process is conducted for more than 90% of its duration at a distance of at least 10 nautic miles from the coast.
[0032] The invention is also directed to the blended product and to the above marine vessel comprising the blended product as it arrives at its destination. The invention is also directed to the direct use of the blended product as a fuel, more preferably as an automotive gas oil or as an industrial gas oil.
[0033] The invention will be illustrated by means of the following non-limiting examples.
EXAMPLE
[0034] A typical mineral derived gas oil (further referred to as AGO) and a typical Fischer-Tropsch gas oil (further referred to as GTL) having the properties as listed in Table 1 were used in the following experiment.
[0000]
TABLE 1
Fuel Reference
Units
AGO
GTL
Cetane Index (ASTM D613)
51.5
>74.8
Sulphur
mg/kg
7
<5
Vk @ 40° C.
cSt
2.559
3.606
Distillation
IBP
° C.
167.8
211
50%
° C.
263.5
298
90%
° C.
325.3
339
95%
° C.
341.6
349
FBP
° C.
351.2
354
HPLC Aromatics
Total
wt %
26.9
0
[0035] Two methods of fuel addition were adopted for this assessment, although the essence of both experiments remained the same. These method were the Funnel Technique and the Beaker Technique.
[0036] The objective of each technique was to minimise turbulence (and hence mixing) during addition of the second fuel so that the majority of any mixing of the two fuels was due to the length of the contact time. Both techniques involved the preparation of 2×2 liter glass beakers, one containing 800 ml of AGO, the other containing 800 ml of GTL. To the AGO, 800 ml of GTL was added slowly, using a 1 liter glass cylinder, taking approximately 2 minutes to complete (Blend A.) This technique was repeated for the addition of the AGO (800 ml) to GTL (Blend B). To evaluate blend homogeneity, densities of the fuel blends were measured after a period of time at 400 ml and 1200 ml from the bottom of the beaker to assess the density at bottom and top of each blend. The funnel technique for fuel addition involved the pouring of the added fuel over the outer surface of an upside down glass funnel that had its base (funnel mouth) in contact with the inner walls of the glass beaker. This was designed to produce fuel addition over a large surface area, minimise turbulence and hence minimise the mixing of the two fuel layers during addition of the second fuel.
[0037] The beaker technique for fuel addition involved the direct pouring of the added fuel down the inner wall of the beaker. This produced fuel addition over a smaller surface area than that of the funnel technique, more turbulence and hence more mixing of the two fuel layers during addition of the second fuel.
[0038] Density follows, volume/volume, linear blending rules and a homogeneous 50:50 blend of the AGO and GTL samples studied will have a theoretical density of 813.3 kg/m 3 . Thus density measurements of the blends can be used to calculate the amount of each component present.
[0039] Table 2 depicts the density results and calculated percentage for each component sampled at a depth represented by a volume of 400 ml (bottom), and 1200 ml (top) on the graduated beaker. It should be noted that the density result of 841.8 kg/m 3 obtained for Blend A ‘Bottom’—funnel method, is greater than 841.4 kg/m 3 —the density of neat AGO. However, this result does fall within the reproducibility of the IP365 method, and the result indicates that the ‘Bottom’ sample is 100% AGO. The time that the blends were sub sampled for density analysis were not considered to have to be identical, as the appearance of each blend did not seem to change over the 24-hour period observed.
[0000]
TABLE 2
Time at which
Density
Fischer-
the blend was
of
Tropsch
Mineral
checked
layer
derived
gas oil
Method type
Blend ref.
Blend configuration
(minutes)
(kg/m 3 )
% vol.
% vol
Funnel method
A
GTL on top
135
788.4
94
6
AGO in bottom
841.8
0
100
Beaker method
GTL on top
10
797.7
78
22
AGO in bottom
824.3
30
70
Funnel method
B
AGO on top
145
810.9
55
45
GTL in bottom
815.8
46
54
Beaker method
AGO on top
7
810.0
56
44
GTL in bottom
816.5
44
56
[0040] When considering respective sets of blends A and B for each method, it is obvious by the percentage of each component present, at both top and bottom, of each blend that to provide optimum blending without agitation then the AGO should be added on top of the GTL and not vice versa.
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Process to blend a mineral derived hydrocarbon product and a Fischer-Tropsch derived hydrocarbon product by providing in a storage vessel of a marine vessel a quantity of mineral derived hydrocarbon product and Fischer-Tropsch derived hydrocarbon product such that initially the mineral derived hydrocarbon product is located substantially above the Fischer-Tropsch derived hydrocarbon product, transporting the combined products in the marine vessel from one location to another location, also referred to as the destination, and obtaining a blended product at arrival of the marine vessel at its destination.
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FIELD OF THE INVENTION
This invention relates to ice makers and, more particularly, to an ice maker which provides for dispensing of pure water.
BACKGROUND OF THE INVENTION
In Barnard et al, in U.S. Pat. No. 4,009,595, owned by the assignee hereof, an ice cube making apparatus is disclosed wherein the ice is formed as a slab of clear ice sufficient in size to form a number of ice cubes. When a slab of the desired thickness is produced on an evaporator portion of the ice maker, the freezing operation is discontinued and the support on which the ice slab is formed is heated to disengage the slab of ice and cause it to move downwardly onto a grid of electrically heated wires which slowly melt through the ice separating the slab into individual cubes.
To form the ice on an evaporator plate, water is recirculated over the plate by means of a pump, the water flowing downwardly from the plate being collected in a water pan for return to an upper end of the evaporator plate by the action of the pump.
With such an ice maker, during the ice forming process the minerals and other impurities remain in the circulating water stream and only pure water solidifies as ice. The impurity rich water is then flushed from the system. The so-called clear ice is then available for withdrawal.
It has been found that when the clear ice melts the resulting product is water having very low impurity content, i.e. substantially pure water, and this water compares favorably to bottled drinking water.
The ice cube making apparatus disclosed in the Barnard et al. patent utilizes an insulated cabinet which is not refrigerated. Therefore, any ice cubes stored in a collecting bin eventually melt to produce clear water. Although such melted water is suitable for drinking, it may be contaminated due to the introduction of impurities or bacteria and the like caused by the removal of ice from the collecting bin by hands or other instruments.
The present invention is directed to solving one or more of the problems set forth above.
SUMMARY OF THE INVENTION
In accordance with the invention, an ice making apparatus is provided with means for storing and dispensing pure water as a by product of the ice.
In accordance with one aspect of the invention, an improvement is disclosed in an ice making apparatus having a cabinet provided with means for forming a plurality of ice bodies and an ice collecting bin therebelow for storing formed ice bodies. The improvement comprises a water storage tank positioned in the ice collecting bin and having an open top portion for receiving a select portion of the plurality of ice bodies formed by the forming means and to melt the same to provide fresh water. The top portion is positioned to prevent entry of ice bodies from the collecting bin. Means are provided for delivering a desired quantity of fresh water from the tank to a water dispenser associated with the cabinet.
It is a feature of the invention that the tank open top portion is of a size selected to determine the relative quality of ice bodies received in the storage tank.
It is another feature of the invention that the tank is removable from the collecting bin.
It is a further feature of the invention that the improvement may further comprise means for heating the water storage tank to facilitate melting of ice bodies received therein.
It is yet another feature of the invention that the delivering means comprises a pump.
In accordance with a further aspect of the invention there is disclosed herein a pure water dispensing apparatus in a slab-type ice maker. The ice maker has a cabinet provided with a inner liner defining an ice collecting bin, a slab-forming evaporator forming an ice slab, and a slab-cutting grid for cutting the slab to provide a plurality of ice bodies which fall into the ice collecting bin. The pure water dispensing apparatus comprises a water storage tank having an open top portion Means are provided for positioning the tank in the collecting bin with the open top portion disposed subjacent a select portion of the slab-cutting grid so that the storage tank receives a select portion of the plurality of ice bodies cut by the slab-cutting grid and to melt the same to provide fresh water. Means are provided for delivering a desired quantity of fresh water from the tank to the water dispenser associated with the cabinet
It is a feature of the invention that the dispensing means comprises a conduit extending between the tank and a spigot mounted on the cabinet.
It is another feature of the invention that the apparatus further comprises means associated with the storage tank for preventing entry of ice from the collecting bin.
It is yet another feature of the invention that the storage tank is positioned to permit overflow of pure water into the collecting bin.
In accordance with yet a further aspect of the invention there is disclosed herein a combined ice cube maker and pure water dispensing apparatus. The apparatus includes a cabinet provided with an inner liner defining an ice collecting bin, an access opening for providing access to the collecting bin and a door for closing the opening. An ice maker is mounted in the cabinet including a slab-forming evaporator forming an ice slab, and a slab-cutting grid for cutting the slab to provide a plurality of ice cubes which fall into the ice collecting bin. A water storage tank has an open top portion. Means are provided for mounting the tank in the collecting bin with the open top portion disposed subjacent a select portion of the slab-cutting grid so that the storage tank receives a select portion of the plurality of ice cubes cut by the slab-cutting grid and to melt the same to provide fresh water. Means are provided for delivering a desired quality of the fresh water from the tank to a water dispenser associated with the cabinet.
There is disclosed herein in accordance with yet a further aspect of the invention a pure water dispensing apparatus insert kit for use with a slab-type ice maker. The slab-type ice maker has a cabinet provided with an inner liner defining an ice collecting bin, a slab-forming evaporator forming an ice slab, and a slab-cutting grid for cutting the slab to provide a plurality of ice parties which fall into the ice collecting bin. The pure water dispensing apparatus insert kit comprises a water storage tank having a bottom wall connected to a peripheral side wall to provide an open top portion, the tank being positionable in the collecting bin with the open top portion disposed subjacent a select portion of the slab-cutting grid so that the storage tank receives a select portion of the plurality of ice bodies cut by the slab-cutting grid to melt the same to provide fresh water. A pump is removably mounted in the storage tank. Means are provided for delivering a desired quantity of fresh water from the tank via the pump to a water dispenser mountable to the cabinet.
More specifically, there is disclosed herein an ice maker and pure water dispenser wherein ice is produced by circulating tap water over a below-freezing evaporator, and the minerals and other impurities remain in the circulating water stream and only pure water solidifies as ice. The impurity rich water is flushed from the system. A pure water storage tank intercepts a portion of each batch of ice released by a cutter grid which divides each slab of ice into cubes. In this arrangement, the contents of the storage tank will not be affected by any contamination of the otherwise stored ice. A heater, which may be located in the storage tank, may be used to increase the rate of water production. The purified water may be available through a water fitting when a glass is pressed against a water dispenser level A dispensing pump is used to transfer water from the tank to the water fitting.
Further features and advantages of the invention will readily be apparent from the specification and from the drawings
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a combined ice cube making and pure water dispensing apparatus according to the invention;
FIG. 2 is an exploded perspective view of the relative positioning between a water storage tank and slab-cutting grid of the apparatus of FIG. 1;
FIG. 3 is a partial sectional side elevational view of the apparatus of FIG. 1;
FIG. 4 is an elevational view of the water storage tank of FIG. 2;
FIG. 5 is a plan view of the water storage tank of FIG. 2;
FIG. 6 is a detailed view of a pump mounting structure in the water storage tank of FIG. 2:
FIG. 7 is a sectional view taken along the line 7--7 of FIG. 6;
FIG. 8 is a side view of a pump for mounting in the storage tank of FIG. 2;
FIG. 9 is a side view illustrating water and electrical connections to a water dispenser of the apparatus of FIG. 1;
FIG. 10 is a front elevational view of a grid panel including the water dispensing apparatus;
FIG. 11 is a bottom plan view of the grid panel of FIG. 10;
FIG. 12 is an electrical schematic illustrating connections for the water dispensing apparatus;
FIGS. 13-16 illustrate removal of the water storage tank from the apparatus of FIG. 1; and
FIG. 17 is a view similar of that to FIG. 3 according to an alternative embodiment to the invention.
DESCRIPTION OF THE INVENTION
In the illustrated embodiment of the invention a slab-type ice maker and water dispenser apparatus generally designated 10 comprises a cabinet 12 having a front opening 14 selectively closed by an outer door 16 and an inner door 17 for providing controlled access to an ice cube collecting bin 18. The cabinet 12 may be further provided with conventional control knobs 20 for manually adjusting the operation of the apparatus 10.
Referring now to FIGS. 2 and 3, the apparatus 10 comprises a slab-type ice maker having a refrigerated plate evaporator 24 which is adapted to be refrigerated by a conventional means as is well known to those skilled in the art. Water is circulated over the evaporator 24 by a pump 26 driven by a suitable electrical motor 28 connected to a distributor 30 by means of a conduit 32. After flowing over the evaporator 24 the water is returned to a subjacent water pan 34 having a sump portion 36 receiving the pump 26 for recirculation of the water to the distributor 30.
During normal operation of the apparatus 10, the flow of water over the refrigerated evaporator 24 slowly builds up a slab of ice on the upper surface of the evaporator 24. When the slab reaches a predetermined thickness, as may be determined by conventional controls means well known to those skilled in the art, the flow of water is terminated and the evaporator 24 is heated so as to release the slab from the evaporator 24. The plate is inclined downwardly toward a cutting grid 38 so that upon release of the slab from the evaporator 24, the slab falls onto a plurality of heated electric wires 40 forming a grid within a box frame 42. The heated wires 40 cut through the ice slab so as to cause the slab to be formed into a plurality of cube 44 which fall through the cutting grid 38 into the subjacent ice cube collecting bin 18.
The interior of the cabinet 12 is provided with a plastic liner 46 formed to generally conform to the shape of the cabinet and to define the collecting bin 18, as is specifically illustrated in FIG. 3. Although not shown, a suitable insulation layer is provided between the cabinet 12 and the liner 46. The liner 46 is provided with means for mounting the evaporator 24, the cutting grid 38 and the water pan 34 in the cabinet 12, as is more particularly illustrated in Barnard et al U.S. Pat. No. 4,009,595, assigned to the assignee of the present invention, and the specification of which is hereby incorporated by reference herein.
In operation, the apparatus 10 provides an endless supply of ice and is capable of forming, for example, 50 pounds of ice per day. However, suitable means are provided for preventing overflow in the collecting bin 18. As is conventional with such ice makers, the cabinet 12 is not itself refrigerated. Indeed, the only cooling provided within the cabinet is the radiant cooling provided by the evaporator 24, as well as the cooling provided by the ice cubes 44 within the collecting bin 18. Owing to the lack of refrigeration, the ice cubes 44 eventually melt and the resulting water is disposed through a drain 48 formed in the liner 46.
It has been found that the water produced by the melted ice cubes is generally pure, i.e. has impurity contents substantially lower than that of tap water. More specifically, the impurity content of such water compares favorably to bottled drinking water. This is due to the fact that during the process of forming a slab on the evaporator 24, the impurities do not freeze, but rather run off into the water pan 34 from which the impurity laden water is periodically flushed from the system and disposed of by any known means through the drain 48.
In accordance with the invention, the apparatus 10 includes pure water dispensing apparatus in the form of a water tank 50, a pump 52, a conduit 54, a spigot 56 and a dispenser lever 58.
The water storage tank 50, which is particularly illustrated with reference to FIG. 4-7, includes a bottom wall 60 connecting a peripheral side wall 62. The peripheral side wall 62 includes a vertically upwardly, forwardly angled front wall 64, opposite parallel outer side walls 66 and 68, and a rear wall 70 including an indent portion 72. An intermediate top wall 74 is connected between the rear wall 70 and spaced inner side walls 76 and 78 which are in turn connected to the respective outer side walls 66 and 68 by ledges 80 and 82. An upwardly extending neck 84 including an open top portion 86 is formed by the top of the front wall 64, an intermediate rear wall 88, connected to the intermediate top wall 74, and opposite neck side walls 90 and 92 which extend from the respective ledges 80 and 82. The configuration of the tank 50 is selected to fit within the collecting bin 18. Particularly, the intermediate top wall 74 is spaced from the bottom wall 60 so that it fits beneath the water pan 34. The rear wall indent 72 is provided for extending around water supply and drain lines not shown.
The tank 50 is positioned in relation to the liner 46 within the collecting bin 18 so that the open top portion 86 is disposed beneath the rearmost portion of the cutting grid 38, as illustrated in FIGS. 2 and 3. As such, ice cubes 44 cut by the heated wires 40 will fall either into the collecting bin 18 or into the storage tank 50 through the open top portion 86. The cubes 44 which fall into the storage tank 50 will melt to provide pure water, as discussed above However, the tank side wall 62 prevents intermixing between the cubes within the tank 50 and those within the collecting bin 18, outside of the tank 50. As a result, the cubes 44 within the storage tank 50 are not contaminated by hands or other instruments used to remove ice cubes 44 from the collecting bin 18. However, overflow of water or ice from the tank 50 will spill into the collecting bin 18.
In order to dispense pure water from the tank 50, the tank first ledge 80 is provided with a generally circular opening 94 including opposite notches 96. The ledge 80 is formed with suitable ridges 98 to strengthen the same and to hold the pump 52.
With reference to FIG. 8, the pump 52 comprises a submersible pump having a lower portion 100 which is inserted into the tank 50 through the opening 94. Top and bottom ears 102 are used for aligning the pump within the notches 96. Upon subsequent rotation of the pump 52 the ears 102 lock the pump 52 in place between the notches 98. Specifically, the upper ears 102 engage the underside of an indent 104 between the notches 98, see FIG. 7. The pump lower portion 100 includes opposite inlet openings 104 for receiving pure water, and an outlet 106 which connects to the conduit 54. Specifically, the conduit 54 is inserted through an opening 108 in the first ledge 80 to then extend downwardly into the tank 50. The pure water is pumped through the conduit 54 where it exits through the spigot 56 connected thereto
With reference to FIGS. 9-11, the spigot 56 is mounted to a grid panel 110 which is mounted to the front of the cutting grid box frame 42, as shown in FIGS. 2-3. The grid panel 110 also supports the lever assembly 58 which is actuated by a suitable container (not shown) for receiving pure water. The dispenser 58 actuates an electrical switch 112 mounted at the rear side of the grid panel 110, which is operable to energize the pump 52.
With reference also to FIG. 12, an electrical schematic illustrates electrical connections used for operation of the water dispensing apparatus.
The apparatus 10 receives power via a cord and socket 114, see FIG. 1. A step down transformer 116 transforms 115 volt AC Power to low voltage AC Power. For example, in the illustrated embodiment, the voltage is reduced to approximately 8.5 volts. A bin light 118 is connected in series with a door switch 120 across the secondary of the transformer 116. The door switch is actuated upon opening the door 16 to energize the bin light 118 and illuminate the collecting bin 18.
The switch 112 includes a movable contact 122 connected via a conductor 124, through a socket 126, see FIG. 9, to one side of the secondary of the transformer 116. The switch 112 also includes a first fixed contact 128 and a second fixed contact 130. The first fixed contact 128 is connected via a conductor 132, through a plug 134, see FIG. 9, to the cutter grid 38. The other side of the cutter grid 38 is connected through a conductor 136, between plugs 126 and 134, see FIG. 9, to the other side of the secondary of the transformer 116. The switch second fixed contact 130 is connected via a conductor 138, through a socket 140 and pump plug 142, see FIG. 9, to the pump 52. The opposite side of the pump 52 is connected through the plug 142 and socket 140 to a conductor 144 which is connected through the socket 126 to the secondary of the transformer 116.
In operation, the switch 112 is normally positioned so that the movable contact 122 makes electrical contact with the first fixed contact 128. Thus, the cutter grid 38 is normally connected across the secondary of the transformer 116 and is thus energized. If it is desired to dispense pure water through the spigot 56, a container is used to operate the dispenser lever 58 which causes the movable contact 122 to break contact with the first fixed contact 128 and make contact with the second fixed contact 130. As a result, the pump 52 is connected across the secondary of the transformer 116 and is thus energized. Energization of the pump 52 causes pure water to be pumped through the water conduit 54 and out the spigot 56 to the subjacent container which is actuating the dispenser lever 58.
In accordance with the invention, the pure water dispenser apparatus is adapted so that in addition to being factory installed, it may be sold as a field installation kit for installation in existing ice making apparatus of the form generally described in the Barnard et al patent incorporated by reference herein.
Specifically, with such a kit the water storage tank 50, including the pump 52 inserted therein, can be positioned within the collecting bin 18. A grid panel, similar to the grid panel 110 except without the spigot 56 and lever 58, on the existing ice maker is then removed and replaced with the grid panel 110 illustrated in FIG. 9 including the wire harness and suitable plugs and sockets, to replace an existing wire harness in the icemaker which connects the cutter grid 38 to the transformer 116. Thus, the existing ice maker is converted to a combined ice maker and pure water dispenser.
In order to provide for periodic service of the water dispensing apparatus, the tank 50 and pump 52 are removable. Specifically, and with reference to FIGS. 13-16, a procedure for removing same as illustrated.
To remove the tank 50, the inner door 17 is flexed and removed as particularly illustrated in FIG. 13. Next, two thumb screws 146 holding the grid panel 110 to the cutter grid box frame 42 are removed, as illustrated in FIG. 14. Thereafter, the plug 134 to the cutting grid 38 is disconnected, as is the socket 140 and the plug 142 to disconnect the cutting grid 38 and pump 52, as illustrated in FIG. 15. Finally, the water tank 50 is titled forwardly and pulled outwardly as illustrated in FIG. 16. In order to completely remove the tank 50, the conduit 54 must be removed from the pump outlet 106. Thereafter, the tank 50 and pump 52 may be serviced as necessary then reinstalled following the reverse procedure.
The procedure for installing a pure water dispensing kit is similar to the procedure for reinstalling the tank 50 and the pump 52 after servicing, with the added step of replacing the grid panel 110 including the cable harness and water conduit 54 connected thereto, as a substitute for the grid panel in the existing ice maker apparatus.
With reference to FIG. 17, an apparatus 10' according to an alternative embodiment to the invention is illustrated. The apparatus 10' is generally similar to the apparatus 10 shown in FIGS. 1-16, except that the pump 52 is eliminated and an optional heater 148 is included for facilitating melting of ice in the storage tank 50'.
For simplicity, primed reference numerals are used to refer to elements similar to elements referenced to unprimed numerals in FIG. 3.
The storage tank 50' differs from the storage tank 50 in eliminating the requirement for the ledge openings 94 and 108 due to the elimination of the pump 52. Instead, a suitable opening 108' is provided in the bottom wall 60' for connection to a conduit 54' which extends to a combined valve and dispenser 150 on the cabinet 12' below the door 16'. As a result, pure water is gravity fed from the storage tank 50' through the conduit 54' and out the dispenser 150 upon actuation of the same, as is apparent. The heater 148 is mounted in the bottom of the storage tank 50' and, although not shown, is preferably connected in parallel with the cutter grid 38'. Thus, the heater 148 facilitates the melting of ice to provide pure water.
Thus, in accordance with the invention, a combined ice maker and water dispensing apparatus 10 is operable to form clear ice cubes and to melt a select portion of the same to provide substantially pure water. By suitably selecting the size and/or position of the open top portion 86 of the water storage tank 50, the relative ratio of ice cubes 44 which fall into the storage tank 50 and into the collecting bin 18 can be selected. The particular ratio would be selected in order to satisfy normal requirements of both ice and water.
Further, in accordance with the invention, the storage tank 50 is positioned with its open top portion 86 in close proximity to the cutting grid 38 to prevent ice cubes 44 that fall into the collecting bin 18, outside of the storage tank 50, from subsequently entering into the storage tank 50. Further, there is no intermixing of melted water from the collecting bin 18 with that in the storage tank 50. As a result, the water in the storage tank 50 will not be contaminated.
The illustrated embodiments of the invention comprehend the broad inventive concepts contemplated by the invention.
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An improvement is disclosed in an ice making apparatus having a cabinet provided with means for forming a plurality of ice bodies and an ice collecting bin therebelow for storing formed ice bodies. The improvement comprises a water storage tank positioned in the ice collecting bin and having an open top portion for receiving a select portion of the plurality of ice bodies formed by the forming means and to melt the same to provide fresh water. The top portion is positioned to prevent entry of ice bodies from the collecting bin. Means are provided for delivering a desired quantity of fresh water from the tank to a water dispenser associated with the cabinet.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a film which comprises at least one transparent replicating layer having a diffractive relief structure and a reflective layer, a method for the production of such a film and a use of the film.
[0002] Films of the type mentioned at the outset are known and are used for securing and decorating articles, documents, packagings and the like. Metallic or nonmetallic inorganic reflective layers are used in order optimally to accentuate an optically variable effect produced by the diffractive relief structure. Such an optically variable effect manifests itself in that an observer perceives different appearances of the film at different viewing angles, such as different color impressions and/or image motifs and/or characters and/or dullness. Inter alia, holograms, holographic displays with kinematic effects and the like are recognizable.
[0003] For specific fields of use, the known films have proved to be not very suitable since the optically variable effects produced are too striking, are too strongly reflective and/or irritate the human eye. This is the case, for example, with components in the interior of a motor vehicle which are present in the direct field of view of the driver, in the case of motor vehicle number plates or the case of pieces of furniture, packagings, certain valuable documents and the like.
[0004] For these applications, films which have other security features or decorative elements are therefore relied upon.
[0005] An example of use in the area of motor vehicle number plates, which however is substantially also applicable to the other abovementioned applications, is described in more detail below by way of illustration.
[0006] Motor vehicle number plates consist as a rule of a support plate, which usually consists of an aluminum or steel sheet. A raised character legend is embossed in the support plate by means of a mechanical embossing process. The character legend usually consists of alphanumeric characters, which, for example in Germany, indicate the place of registration of the motor vehicle, and form an individual number. In order to make the character legend of the embossed motor vehicle number plate readily visible, the raised embossed areas are provided with a colored coating. A corresponding ink transfer by means of a blocking film which consists of a substrate film which is bonded to a colored decorative layer detachable therefrom is usually carried out for this purpose. During the ink transfer, the substrate film is brought into mechanical contact with the raised embossed areas of the motor vehicle number plate and the decorative layer is transferred thereto under pressure, optionally also under pressure and at elevated temperature.
[0007] In order to increase the recognizability of the character legend, the support plate is generally laminated over the whole area with a retroreflective film formed in a contrasting color to the character legend. In the case of the motor vehicle number plates usual in Germany, the front of the support plates are for this purpose laminated with a white, retroreflective film, while a black decorative film is pressed onto the character legend.
[0008] Owing to the increasing requirements with respect to the forgery protection of motor vehicle number plates, the retroreflective films laminated with the support plate of a motor vehicle number plate or the decorative films have already been provided with additional security features which are not directly recognizable with the naked human eye and therefore do not impair the appearance of the motor vehicle number plate and the readability thereof. For this purpose, the security features are formed, for example, particularly small and are introduced so that they are visible only from very specific viewing angles.
[0009] Thus, DE 102 41 803 A1 discloses a blocking film with a substrate film and a decorative layer detachable therefrom for stamping a motor vehicle number plate in the area of the character legend. The blocking film is individualized by introducing security features by removing areas of the decorative layer, changing the color of said areas or bonding said areas nondetachably to the substrate film.
[0010] Such additional security features have, however, proved to be relatively easy to copy, so that there is still a need to provide a forgery-proof film for coating the character legend. In particular, the optically variable effects which are produced by one of the films mentioned at the outset, which comprise at least one transparent replicating layer having a diffractive relief structure and a reflective layer would be of particular interest as additional security features owing to their high level of protection against forgery and/or impressive decorative effect.
[0011] This applies not only to motor vehicle number plates but also to the abovementioned components in the interior of a motor vehicle, in the case of pieces of furniture, packagings and certain valuable documents such as in the area of a magnetic stripe of a bank card and the like. There is therefore generally the need for forgery-proof and/or decorative films which, for these specific applications, substantially preserve the usual appearance of the articles coated therewith.
SUMMARY OF THE INVENTION
[0012] It is therefore the object of the invention to provide a film which has a diffractive relief structure producing an optically variable effect, the optically variable effect being recognizable or becoming recognizable to an observer only on closer examination of the film, and to provide a method for the production thereof.
[0013] The object is achieved for the film which comprises at least one transparent replicating layer having a diffractive relief structure and a reflective layer by forming the reflective layer by means of at least one pigmented lake layer which is arranged directly adjacent to the diffractive relief structure, a refractive index n 1 of the at least one lake layer and a refractive index n 2 of the replicating layer being chosen so that a contribution of a difference between imaginary parts of the refractive indices n 1 and n 2 is in the range of 0.05 to 0.7, and a lightness L* of the at least one lake layer being in the range of 0 to 90, the film showing a latent optically variable effect produced by the diffractive relief structure.
[0014] A “latent” optically variable effect is understood as meaning that the optically variable effect is recognizable for an observer of the film only under certain external conditions. In comparison with optically variable effects which are recognizable on films having metallic reflective layers, the film according to the invention shows only a weak or discrete optically variable effect which is optionally evident only under illumination by a suitable light source.
[0015] Thus, an observer recognizes not only the color effect of the at least one lake layer but furthermore an optically variable effect which is produced by the diffractive relief structure, increases the protection against forgery and/or has decorative properties, preferably only on assessment of the film according to the invention on a side of the replicating layer which faces away from the diffractive relief structure under standard illumination and at a first distance of not more than about 0.5 m from the film and/or with illumination of the film by a suitable light source or point light source, wherein recognizability may also be possible at an even greater distance with such illumination.
[0016] At the same time, however, substantially only the color effect of the lake layer is recognizable for an observer under normal illumination and at a second distance of greater than about 0.5 m from the film, in particular at a distance of at least 1 m to 2 m from the film. The optically variable effect produced by the diffractive relief structure is no longer recognizable or substantially no longer recognizable, so that the optical appearance of the article coated with a film according to the invention does not deviate or deviates only to an insignificant extent from that of a conventional, colored article.
[0017] Viewing under standard illumination is understood here as being in particular viewing of the film according to the invention in a color matching cabinet, such as, for example, byko-spectra version 2, the standard illuminant D65 being used for illumination.
[0018] The use of a pigmented lake layer instead of a metallic or nonmetallic inorganic reflective layer therefore permits the formation of a film which has latent optically variable effects which are not striking or are only slightly striking when viewed normally and do not or scarcely dazzle or irritate the eye.
[0019] The refractive index of a material is composed of a real part and an imaginary part, the imaginary part being responsible for the light absorption of the material. With the use of the at least one lake layer instead of a conventional reflective layer, the light diffraction in reflection is also partly caused by the imaginary part of the refractive index of the lake layer. The diffraction efficiencies of relief structures in the form of first order diffraction gratings are typically in the range of 0.2 to 2% here. The real part of the refractive index of a lake layer usually differs slightly from the real part of the refractive index of a replicating layer. The light diffracted by the diffractive relief structure owing to the differences in the refractive indices of the at least one lake layer and the replicating layer in reflection is furthermore superposed by the light scattered by the lake layer, with the result that the diffraction effect is weakened. The match between the light diffracted at the interface between the at least one lake layer and the replicating layer and the light scattered back by the at least one lake layer permits the formation of the latent optically variable effect. In principle, all colors can be used for coloring the at least one lake layer, but the superposition of the diffracted light with the back-scattered light is all the weaker the greater the extent to which the lake layer absorbs incident light.
[0020] A film according to the invention has the advantage that the presence of a forgery-proof or particularly attractive film is not imparted to an observer on viewing the film from a certain distance and/or on superficial viewing, but only the presence of a simple colored coating. Only on closer inspection of the film at a small distance from the film and/or under special illumination of the film or more strongly by special illumination of the film are the optically variable effects produced by the diffractive relief structure clearly recognizable, it being necessary here to assume diffraction effects which tend to be not very striking or have relatively little luminosity in comparison with the strong color effect of the pigmented lake layer.
[0021] The lightness L* of the lake layer used is determined in particular by means of the CIE-LAB Datacolor SF 600 measuring system, which is based on a spectrophotometer. In the calorimetric determination of color differences in the case of surface colors according to the CIELAB formula L*a*b*, the value L* represents the light/dark axis, the value a* represents the red/green axis and the value b* represents the yellow/blue axis. The L*a*b* color space is thus described as a three-dimensional coordinate system, the L* axis describing the lightness and possibly assuming a value between 0 and 100.
[0022] The measurement of the lightness L* is effected here under the following conditions:
Geometry of measurement: diffuse/8° according to DIN 5033 and ISO 2496 Diameter of measuring opening: 26 mm Spectral range: 360-700 nm according to DIN 6174 Standard illuminant: D65
[0027] In particular, point light sources in the form of torches, halogen lamps or motor vehicle headlights are suitable as light sources for illuminating the film according to the invention and for visualizing the optically variable effects. However, directly incident sunlight is optionally also suitable as a light source.
[0028] Preferred configurations of the film according to the invention are described below.
[0029] Here, lake layer is understood as meaning not only layers formed from colored lakes but also colored adhesive or plastic layers. The at least one lake layer is applied to the replicating layer in particular by printing, casting, applying with a doctor blade, spraying on! applying by extrusion, etc.
[0030] The layer thickness of a lake layer is in particular in the range of 1 μm to 50 μm, preferably in the range of 2 μm to 10 μm.
[0031] For the formation of a replicating layer, coating layers, in particular comprising radiation-crosslinking coatings (such as UV coatings) or thermally crosslinking coatings, are preferably used. However, thermoplastics or conventional positive or negative photoresists can also be used.
[0032] The layer thickness of a replicating layer is in particular in the range of 0.1 μm to 50 μm, preferably in the range of 0.2 μm to 1 μm. The replicating layer can, however, also serve as a self-supporting substrate film for the application of further layers, such as the at least one lake layer, and may be far thicker, for example in the range of up to 3 mm thickness.
[0033] Depending on the material chosen for the replicating layer, the relief structure is introduced into the replicating layer in particular by means of a tool appropriately profiled on its surface, such as a punch or a roll, lithographic process or laser ablation. A possible variant is provided by UV replication, in which a profiled transparent tool is brought into contact with a replicating layer comprising a UV coating and at the same time curing of the UV coating by means of a UV radiation source is effected. Thermal replication, in which a heated profiled tool is brought into contact with a replicating layer comprising thermoplastic material, is particularly preferred.
[0034] It has proved useful regarding the film if the pigmentation of the at least one lake layer is chosen so that a pigmentation number PN is in the range of 1.5 to 120 cm 3 /g, in particular in the range of 5 to 120 cm 3 /g, the pigmentation number PN being calculated according to
[0000]
P
N
=
∑
1
x
(
m
P
×
f
)
x
(
m
B
M
+
m
A
)
and
f
=
ON
d
,
[0000] the following being applicable:
m P =mass of a pigment in the lake layer in g, m BM =constant; mass of a binder in the lake layer in g, m A =constant; mass of solids of the additives in the lake layer in g, ON=oil absorption number of a pigment (according to DIN 53199), d=density of a pigment (according to DIN 53193), x=running variable, corresponding to the number of different pigments in the lake layer.
[0041] In this way, starting from a composition found to be suitable for a lake layer, further possible pigmentations differing therefrom can be calculated rapidly and in an uncomplicated manner.
[0042] It has proved to be advantageous if pigmentation of the at least one lake layer is chosen so that a transmittance T of visible light through the at least one lake layer is <75%.
[0043] The transmittance T, i.e. the degree of transmission of the at least one lake layer, is determined in particular by means of a spectrophotometer, for example of the Hitachi U-2000 type, measurement being effected in a wavelength range between 360 and 700 nm.
[0044] The greater the transmittance T of the pigmented lake layer, the less pronounced is the optically variable effect and the lower its degree of recognizability.
[0045] Furthermore, it has proved to be advantageous if the transmittance T of visible light through the at least one lake layer is in the range of 1 to 75%, in particular in the range of 1 to 50%, particularly preferably in the range of 1 to 25%.
[0046] It is particularly advantageous if the optically variable effect produced by the diffractive relief structure is recognizable for the observer on viewing the film on that side of the replicating layer which faces away from the diffractive relief structure, under standard illumination at a first distance of not more than about 0.5 m from the film and additionally with illumination of the film by a suitable light source. The use of a simple point light source available to everyone, for example in the form of a torch, is suitable for simple and economical monitoring of the genuineness of the film, even by an untrained person.
[0047] The optically variable effect latently produced by the diffractive relief structure manifests itself in particular in that the film, when viewed from different viewing angles, shows different colors and/or different image motifs and/or different alphanumeric characters and/or different dullnesses and the like. Optically variable elements which are present in the form of holograms, holographic displays with kinematic effect, lens elements or matt structures which are produced by means of the diffractive relief structure are particularly preferably formed. optically variable elements produced by means of linear or cross gratings have also proved useful.
[0048] A diffractive relief structure is determined in particular by parameters such as spatial frequency, azimuth, profile shape, profile height h, etc. A film according to the invention may contain two or more different types of diffractive relief structures which differ with respect to these parameters.
[0049] In general, symmetrical or asymmetrical relief structures, in particular having a sinusoidal, rectangular, sawtooth-like, etc. profile, are suitable as diffractive relief structures. The relief structure may form a diffraction grating, such as a linear grating, a cross grating, a blaze grating, a lens structure comprising concentric or nonconcentric ring structures and the like.
[0050] The spatial frequency of a diffraction grating is preferably chosen in the range of 50 to 4000 lines/mm, a range of 100 lines/mm to about 3000 lines/mm being preferred.
[0051] The geometric profile height h of a diffractive relief structure has in particular a value in the range of 50 to 5000 nm, when viewed in the cross section of the replicating layer, preferred values being in the range of 75 to 2000 nm. The profile height h is determined by determining the height difference between the highest point and the lowest point adjacent thereto of a relief structure. The highest point is so to speak defined by the peak of a mountain and the lowest point by the bottom of a valley which forms the relief structure.
[0052] The use of diffractive relief structures which have a complex surface profile with locally different profile heights is also possible. Such surface profiles may also be stochastic surface profiles which form matt structures.
[0053] On the microscopic scale, matt structures possess fine relief structure elements which determine the scattering power and can be described only by statistical characteristics, such as, for example, center line average value Ra, correlation length lc, etc., the values for the center line average value Ra being in the range of 20 nm to 5000 nm, with preferred values in the range of 50 nm to 1000 nm, while the correlation length lc in at least one direction has values in the range of 200 nm to 50 000 nm, preferably in the range of 500 nm to 10 000 nm.
[0054] The microscopically fine relief structure elements of an isotropic matt structure have no azimuthal preferred direction, and it is for this reason that the scattered light having an intensity greater than a predetermined limit, for example specified by the visual recognizability, is uniformly distributed in a solid angle predetermined by the scattering power of the matt structure, in all azimuthal directions, and the surface element appears white to grey in daylight. In the case of a change in the angle of tilt away from the vertical, the surface element appears dark. Strongly scattering matt structures distribute the scattered light in a larger solid angle than weakly scattering matt structures. If the relief elements of the matt structure have a preferred direction, such as, for example, asymmetric matt structures, the scattered light has an anisotropic distribution.
[0055] As already mentioned above, in the case of light, strongly scattering lake layers, the diffraction effects appear comparatively weak owing to the back-scattered light, whereas the diffraction effects appear strong in the case of dark, strongly absorbing colors since scarcely any light is scattered back by the lake layer. Thus, with the use of a light-pigmented lake layer, the recognizability of the latent optically variable effects is under certain circumstances so greatly impaired by the light scattered back by the at least one lake layer in the direction of the observer that the optically variable effect becomes evident only at very specific viewing angles or with special illumination and/or luminous intensity. It has therefore proved useful if with increasing lightness L* of the at least one lake layer, the contribution of the difference between the imaginary parts of the refractive indices n 1 and n 2 increases proportionally. This means that, with the use of a dark-colored lake layer, the imaginary parts of the refractive indices of the lake layer and of the replicating layer can be relatively close together without the recognizability of the latent optically variable effect of the film being impaired from a small distance and optionally with special illumination. With the use of a light-colored lake layer, on the other hand, it has proved to be advantageous if the imaginary parts of the refractive indices of the lake layer and of the replicating layer are not so close together so that the latent optically variable effect of the film is recognizable from a small distance and optionally with special illumination.
[0056] It has proved to be useful if the contribution of the difference between the imaginary parts of the refractive indices n 1 and n 2 is in the range of 0.05 to 0.7 in the case of a lightness L* of the at least one lake layer in the range of 0 to about 50, which corresponds to a dark hue, and if the contribution of the difference between the imaginary parts of the refractive indices n 1 and n 2 is in the range of 0.3 to 0.7 in the case of a lightness L* of the at least one lake layer in the range of about 50 to 90, which corresponds to a light hue.
[0057] The relationship which is preferred for the film between the lightness L* of the lake layer and the contribution of a difference between the imaginary parts of the refractive indices n 1 and n 2 is shown by way of example in FIG. 1 .
[0058] The film may provide further security features in order further to increase its protection against forgery. Thus, it has proved to be useful if the film contains a machine-readable code. A code is preferably used in order to collate information in coded form on the film, which information can be evaluated, for example, for monitoring purposes.
[0059] Thus, for example, it is possible to encrypt the alphanumeric characters of a character legend of a motor vehicle number plate, for example in relation to the place of registration, by means of a secret encryption algorithm and use the result of this encryption as a code. In the course of a check by the police, it is then possible, for example, to determine whether the code present actually contains the motor vehicle number plate information belonging to the character legend monitored.
[0060] Security-relevant data, such as, for example, information on the holder of the motor vehicle or on the motor vehicle itself in the case of the motor vehicle number plate, can also be coded as information. As a result, the data are not accessible to the public. In the course a check by the police, the information present can then be decoded and evaluated by means of suitable apparatuses.
[0061] The machine-readable code can be provided, for example, by the diffractive relief structure and may be present, for example, in the form of a one- or a two-dimensional barcode, a microtext, etc.
[0062] The machine-readable code can additionally or alternatively also be provided by the pigmentation of the at least one lake layer, by forming said layer, for example, partly differently and/or with particular properties. Thus, an individual lake layer may have conductive pigments and/or magnetic pigments and/or luminescent pigments and/or thermochromic pigments, etc., which provide or supplement the code.
[0063] The use of a plurality of different lake layers side by side on the transparent replicating layer is readily possible. Thus, different lake layers can be used in any combination with one another. Different lake layers may contain different pigments comprising materials which have different colors or which have the same color but are otherwise distinguishable. Thus, lake layers with the same color can be distinguished by specific pigments which can be recognized only under specific conditions, such as, for example, luminescent pigments, magnetic pigments, electrically conductive pigments, thermochromic pigments, etc.
[0064] A first lake layer may have only colored pigments and a further lake layer may have the same color but additionally contain at least one specific pigment. Two lake layers having the same color may contain in each case specific pigments which differ in their properties, such as an excitation wavelength, the magnetic properties and the like.
[0065] All colored pigments which are usually used in gravure printing can be used in the at least one lake layer. These usually have a particle diameter in the range of 20 nm to 5 μm.
[0066] With the use of different lake layers, formation of demanding patterns, for example in the form of guilloches, micro inscription, symbols, logos, one- and two-dimensional bar codes and the like, is possible. These patterns may be visible under standard lumination and/or are recognizable under specific conditions, such as UV irradiation, heating, etc.
[0067] It has proved useful if, viewed perpendicularly to the plane of the transparent replicating layer, at least two different lake layers are arranged in different regions of the diffractive relief structure, which lake layers differ in their refractive indices and/or in their lightness L* and/or in their pigmentation number PN and/or in their transmittance T. As a result, it is possible to create areas, in particular pattern-like areas, in which the latent optically variable effects of the diffractive relief structure are more strongly evident than in adjacent areas on viewing close-up.
[0068] Furthermore, it has proved useful if, viewed perpendicularly to the plane of the transparent replicating layer, at least one further colored or colorless coating layer whose refractive index n 3 does not differ or differs by less than 0.05 from the refractive index n 1 of the transparent replicating layer is present at least in a region of the transparent replicating layer, in particular in a region of the diffractive relief structure. Such a colored or colorless coating layer results in complete extinction of the optically variable effect of the diffractive relief structure since the incident light is not refracted or is not refracted to a significant extent at the interface between the replicating layer and the colored or colorless coating layer.
[0069] It is therefore possible to produce films which show the latent optically variable effect only in pattern-like areas, i.e. only from area to area, although the relief structure is present everywhere. A contour of the pattern-like areas in which the latent optically variable effect is present can thereby form a further readable security feature of the film.
[0070] Alternatively, the relief structure may be present only in areas of the replicating layer in order to achieve the same effect.
[0071] The film is in particular in the form of a self-supporting laminated film or in the form of transfer film which has a substrate film and a transfer layer detachable therefrom and comprising the replicating layer and the at least one lake layer. A laminated film has in particular a transparent substrate film on which the replicating layer, the at least one lake layer and optionally an adhesive layer are arranged. If the replicating layer is self-supporting, the laminated film can, however, also comprise only the replicating layer, the at least one lake layer and optionally the adhesive layer. Substrate films are usually formed in a layer thickness in the range of 4.5 μm to 100 μm, preferably in the range of 12 μm to 50 μm.
[0072] The object is achieved for the method for the production of a film according to the invention comprising the following steps:
[0073] formation of the transparent replicating layer having the refractive index n 1 ,
[0074] formation of the diffractive relief structure on one side of the replicating layer,
[0075] formation of the at least one pigmented lake layer having the refractive index n 2 and the lightness L* on the replicating layer and directly adjacent to the diffractive relief structure by means of at least one pigmented composition, the at least one pigmented composition being applied in the flowable state and not impairing the replicating layer.
[0076] The pigmented composition is formed in particular so that it does not attack, partly dissolve or completely dissolve the replicating layer, so that the relief structure is preserved unchanged. The composition for the formation of the at least one lake layer can thus neither extinguish, round or otherwise impair the diffractive relief structure formed in the replicating layer. The profile shape of the relief structure is satisfactorily preserved.
[0077] The at least one lake layer is formed on a solidified replicating layer in which the diffractive relief structure is formed. Whether the solidification of the replicating layer is effected by a chemical curing process, by cooling or by simple drying, optionally with supply of air and/or heat, optionally with simultaneous formation of the relief structure, is not important.
[0078] Preferably, the transparent replicating layer is formed by a transparent replicating coating in the form of a thermoplastic coating, a thermally crosslinking coating or a chemically crosslinking coating, in particular a UV-crosslinking coating or a two-component coating system comprising a resin and a curing agent.
[0079] It is preferable if, for the formation of a lake layer, a pigmented composition is formed from a pigmented lake of the following composition:
0-50% by weight of water 1-10% by weight of organic solvent or solvent mixture 1-40% by weight of colored pigment(s) 0.1-5% by weight of additive for stabilizing the pigment dispersion/emulsion 0.5-10% by weight of dispersing additive 0.5-10% by weight of inorganic filler or filler mixture 25-90% by weight of polymer dispersion and/or polymer emulsion and/or polymer solution
[0087] In particular, the pigmented lake is formed with the following composition:
25-35% by of water weight 4-8% by weight of organic solvent or solvent mixture 5-10% by weight of colored pigment(s) 0.5-1% by weight of additive for stabilizing the pigment dispersion/emulsion 0.5-2% by weight of dispersing additive 0.5-3% by weight of inorganic filler or filler mixture 35-60% by weight of polymer dispersion and/or polymer emulsion and/or polymer solution
[0095] The polymer dispersion and/or polymer emulsion and/or polymer solution acts here in particular as a film former.
[0096] It has proved useful if an acrylate polymer emulsion, an acrylate copolymer emulsion or an anionic acrylate copolymer emulsion is used as the polymer emulsion.
[0097] Furthermore, it has proved useful if a polyurethane dispersion or a polyester resin dispersion or a vinyl acetate-ethylene copolymer dispersion is used as the polymer dispersion.
[0098] A water-soluble or water-dilutable urea resin, dissolved in or diluted with water, is preferably used as the polymer solution, it also being possible for the resin to be dissolved in water and organic solvent or to be diluted with water and organic solvent. However, other film-forming polymer solutions, based on water and/or based on solvent, can also be used.
[0099] In particular, the use of an emulsion or of a dispersion having a solids content of at least 30% by weight and a density d in the range of 1.01 to 1.1 g/cm 3 have proved useful.
[0100] For the formation of the pigmented lake, in particular an acrylate copolymer emulsion having a solids content of 38%, a density of 1.05 g/cm 3 and a glass transition temperature T g of about 15° C. have proved suitable as the film-former.
[0101] Alternatively, all film formers which, owing to their formulation, do not impair the replicating layer and have sufficient adhesion to the replicating layer, such as, for example, water-based systems, UV-curing systems, etc., are suitable. Solvent-based systems can also be used provided that a replicating layer is formed from a crosslinked plastic.
[0102] The use of a film according to the invention for coating motor vehicle number plates with formation of the character legend which contains alphanumeric characters is ideal.
[0103] However, the use of a film according the invention for coating packagings, plastic parts for the interior of motor vehicles, pieces of furniture and valuable documents, such as bank cards, tickets or lottery tickets, has also proved useful. In the case of bank cards, such as EC cards or credit cards, which have a magnetic stripe, the magnetic stripe is preferably formed by a film according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0104] FIGS. 1 to 6 are intended to illustrate the invention by way of example. Thus,
[0105] FIG. 1 shows a diagram of the preferred relationship between the lightness L* of a lake layer and the contribution of the difference An between the refractive indices of a replicating layer and of a lake layer, this corresponding to the difference between the imaginary parts of the refractive indices;
[0106] FIG. 2 shows a first film in cross section;
[0107] FIG. 3 shows a second film in the form of a laminated film in cross section;
[0108] FIG. 4 shows a third film in the form of a transfer film in cross section;
[0109] FIG. 5 shows a cross section Y-Y′ through a motor vehicle number plate according to FIG. 6 ; and
[0110] FIG. 6 shows a motor vehicle number plate in plan view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0111] FIG. 1 shows a diagram for the preferred relationship between the lightness L* of a lake layer and the contribution of the difference between the refractive indices An of a replicating layer and of a lake layer. In this example, the real part of the refractive index n 1 of the lake layer and of the real part of the refractive index n 2 of the replicating layer are equal, so that the real parts of the refractive indices n 1 , n 2 can be neglected and the contribution of An in the diagram gives only the difference between the imaginary parts of the refractive indices n 1 , n 2 . The lightness L* is shown for lake layers (a) to (e) comprising different colored pigments.
[0112] The letters (a) to (e) in FIG. 1 represent lake layers having different colors:
(a)=black or grey lake layer having lightness L* in the range of 0-50 (b)=blue lake layer having lightness L* in the range of 10-90 (c)=red lake layer having lightness L* in the range of 20-90 (d)=green lake layer having lightness L* in the range of 10-90 (e)=yellow lake layer having lightness L* in the range of 50-90.
[0118] The value |Δn|, i.e. the contribution of the difference between the imaginary parts of the refractive index n 1 of the replicating layer and of the refractive index n 2 of a pigmented lake layer, is preferably in the range of 0.05 to 0.7 for a black lake layer (a).
[0119] This means that, in the case of a black-pigmented lake layer, the latent optically variable effect is still recognizable even when the imaginary parts of the refractive indices of the replicating layer and lake layer differ by only 0.05. The lighter the coloring of the pigmented lake layer, the greater the chosen value |Δn| is to be so that the latent optically variable effect is still recognizable with the naked eye without problems.
[0120] This is clear from the shape of the curve |Δn| min over the lightness L* of the lake layer with a coloring of black (a) through blue (b), red (c), green (d) to yellow (e).
[0121] Thus, the curve |Δn| min increases with increasing lightness L* of the lake layer. In the case of a yellow lake layer, the value |Δn| is in the range of 0.4 to 0.7.
[0122] This means that the imaginary parts of the refractive indices of replicating layer and yellow lake layer should be chosen so that they differ by at least 0.4 in order for the latent optically variable effect to be recognizable and not to be made unrecognizable or only poorly perceptible owing to the light scattered back from the yellow lake layer in the direction of the observer.
[0123] Examples of compositions for the formation of a replicating layer and differently colored lake layers (a) to (e) are given below.
[0124] The replicating layer has been formed, for example, from a lake with the following composition (in g):
[0125] 17 000 of methyl ethyl ketone
[0126] 1000 of diacetone alcohol
[0127] 1500 of acrylic polymer based on methyl methacrylate (density d=1.19 g/cm 3 )
[0128] 2750 of cellulose nitrate moistened with denatured ethanol, 65% (density d=1.25 g/cm 3 )
[0129] 1500 of polyisocyanate based on isophorone diisocyanate
Lake for the Formation of a Black Lake Layer (a) With Minimum Pigmentation (in g):
[0130] 2500 of water
[0131] 2500 of organic solvent isopropyl alcohol
[0132] 200 of basic additive, 25% in water (volatile)
[0133] 400 of dispersing additive, solids: 40%
[0134] 200 of silicon dioxide filler, mean particle size: 16 nm
[0135] 100 of silicon dioxide filler, mean particle size: 7.5 μm
[0136] 50 of carbon black pigment, density d=1.8 g/cm 3 , ON=230
[0137] 2500 of binder I: acrylate copolymer emulsion, solids: 37.5%
[0138] 4000 of binder II: acrylate copolymer emulsion, solids: 55%
[0139] The following is applicable to this black lake:
[0000]
P
N
=
∑
i
x
(
m
P
×
f
)
x
(
m
B
M
+
m
A
)
=
50
g
×
127.8
cm
3
g
3137.5
g
+
160
g
=
1.9
cm
3
g
[0000] where m P =50 g of carbon black
f=ON/d=230/1.8 g/cm 3 =127.8 cm 3 /g (for carbon black) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =0.4·400 g of dispersing additive=160 g of solids of the dispersing additive
Lake for the Formation of a Black Lake Layer (a) With Maximum Pigmentation (in g):
[0144] 2500 of water
[0145] 2500 of organic solvent isopropyl alcohol
[0146] 200 of basic additive, 25% in water (volatile)
[0147] 400 of dispersing additive, solids: 40%
[0148] 200 of silicon dioxide filler, mean particle size: 16 nm
[0149] 100 of silicon dioxide filler, mean particle size: 7.5 μm
[0150] 2500 of carbon black pigment, density d=1.8 g/cm 3 , ON=230
[0151] 2500 of binder I: acrylate copolymer emulsion, solids: 37.5%
[0152] 4000 of binder II: acrylate copolymer emulsion, solids: 55%
[0153] The following is applicable to this black lake:
[0000]
P
N
=
∑
1
x
(
m
P
×
f
)
x
(
m
B
M
+
m
A
)
=
2500
g
×
127.8
cm
3
g
3137.5
g
+
160
g
=
96.9
[0000] where m P =2500 g of carbon black
f=ON/d=230/1.8 g/cm 3 =127.8 cm 3 /g (for carbon black) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 k of dispersing additive)=160 g of solids of the dispersing additive
Lake for the Formation of a Blue Lake Layer (b) (in g):
[0158] L*= 33.58 a*= 0.54 b*=− 30.23
[0159] 2500 of water
[0160] 2500 of organic solvent isopropyl alcohol
[0161] 200 of basic additive, 25% in water (volatile)
[0162] 400 of dispersing additive, solids: 40%
[0163] 200 of silicon dioxide filler, mean particle size: 16 nm
[0164] 100 of silicon dioxide filler, mean particle size: 7.5 μm
[0165] 1200 of phthalocyanine blue pigment, density d=1.5 g/cm 3 , ON=43
[0166] 2500 of binder I: acrylate copolymer emulsion, solids: 37.5%
[0167] 4000 of binder II: acrylate copolymer emulsion, solids: 55%
[0168] The following is applicable to this blue lake:
[0000]
P
N
=
∑
1
x
(
m
P
×
f
)
x
(
m
B
M
+
m
A
)
=
1200
g
×
28.7
cm
3
g
3137.5
g
+
160
g
=
10.4
[0000] where m P =1200 g of phthalocyanine blue pigment
f=ON/d=43/1.5 g/cm 3 =28.7 cm 3 /g (for phthalocyanine blue pigment) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
Lake for the Formation of a Red Lake Layer (c) (in g):
[0173] L*= 38.43 a*= 44.23 b*= 20.44
[0174] 2500 of water
[0175] 2500 of organic solvent isopropyl alcohol
[0176] 200 of basic additive, 25% in water (volatile)
[0177] 400 of dispersing additive, solids: 40%
[0178] 200 of silicon dioxide filler, mean particle size: 16 nm
[0179] 100 of silicon dioxide filler, mean particle size: 7.5 μm
[0180] 1200 of diketopyrrolopyrrole pigment, density d=1.35 g/cm 3 , ON=49
[0181] 2500 of binder I: acrylate copolymer emulsion, solids: 37.5%
[0182] 4000 of binder II: acrylate copolymer emulsion, solids: 55%
[0183] The following is applicable to this red lake:
[0000]
P
N
=
∑
1
x
(
m
P
×
f
)
x
(
m
B
M
+
m
A
)
=
1200
g
×
36.3
cm
3
g
3137.5
g
+
160
g
=
13.2
cm
3
g
[0000] where m P =1200 g of diketopyrrolopyrrole pigment
f=ON/d=49/1.35 g/cm 3 =36.3 cm 3 /g (for diketopyrrolopyrrole pigment) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
Lake for the Formation of a Dark Green Lake Layer (d) (in g)
[0188] L*= 14.52 a*=− 49.34 b*= 10.91
[0189] 2500 of water
[0190] 2500 of organic solvent isopropyl alcohol
[0191] 200 of basic additive, 25% in water (volatile)
[0192] 400 of dispersing additive, solids: 40%
[0193] 200 of silicon dioxide filler, mean particle size: 16 nm
[0194] 100 of silicon dioxide filler, mean particle size: 7.5 μm
[0195] 1200 of chlorinated copper phthalocyanine pigment, density d=2.03 g/cm 3 , ON=30
[0196] 2500 of binder I: acrylate copolymer emulsion, solids: 37.5%
[0197] 4000 of binder II: acrylate copolymer emulsion, solids: 55%
[0198] The following is applicable to this dark green lake:
[0000]
P
N
=
∑
1
x
(
m
P
×
f
)
x
(
m
B
M
+
m
A
)
=
1200
g
×
14.8
cm
3
g
3137.5
g
+
160
g
=
5.4
cm
3
g
[0000] where m P =1200 g of chlorinated copper phthalocyanine pigment
f=ON/d=30/2.03 g/cm 3 =14.8 cm 3 /g (for chlorinated copper phthalocyanine pigment) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
Lake for the Formation of a Yellow Lake Layer (e) (in g):
[0203] L*= 86.35 a*= 1.91 b*= 89.79
[0204] 2500 of water
[0205] 2500 of organic solvent isopropyl alcohol
[0206] 200 of basic additive, 25% in water (volatile)
[0207] 400 of dispersing additive, solids: 40%
[0208] 200 of silicon dioxide filler, mean particle size: 16 nm
[0209] 100 of silicon dioxide filler, mean particle size: 7.5 μm
[0210] 1200 of monoazo-benzimidazolone pigment, density d=1.57 g/cm 3 , ON=56
[0211] 2500 of binder I: acrylate copolymer emulsion, solids: 37.5%
[0212] 4000 of binder II: acrylate copolymer emulsion, solids: 55%
[0213] The following is applicable to this yellow lake:
[0000]
P
N
=
∑
1
x
(
m
P
×
f
)
x
(
m
B
M
+
m
A
)
=
1200
g
×
35.7
cm
3
g
3137.5
g
+
160
g
=
13
cm
3
g
[0000] where m P =1200 g of monoazo-benzimidazolone pigment
f=ON/d=56/1.57 g/cm 3 =35.7 cm 3 /g (for monoazo-benzimidazolone pigment) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
[0218] FIG. 2 shows a first film 1 in cross section, which has a transparent replicating layer 2 having a diffractive relief structure 3 and a colored lake layer 4 . The lake layer 4 is directly adjacent to that side of the replicating layer 2 on which the diffractive relief structure 3 is present. The replicating layer 2 has a layer thickness of 0.5 μm, while the lake layer has a layer thickness of 3 μm.
[0219] Here, the replicating layer 2 is thermoplastic and has been formed from a coating of the following composition already mentioned above (in g):
[0220] 17 000 of methyl ethyl ketone
[0221] 1000 of diacetone alcohol
[0222] 1500 of acrylic polymer based on methyl methacrylate (density d=1.19 g/cm 3 )
[0223] 2750 of cellulose nitrate moistened with denatured ethanol, 65% (density d=1.25 g/cm 3 )
[0224] 1500 of polyisocyanate based on isophorone diisocyanate
[0225] The diffractive relief structure 3 has been stamped in the form of a linear grating having a sinusoidal profile and a spatial frequency of 1000 lines/mm into the replicating layer 2 by means of a heated, profiled tool.
[0226] Here, the lake layer 4 has been formed from a black lake of the following composition (in g);
[0227] 2500 of water
[0228] 2500 of organic solvent isopropyl alcohol
[0229] 200 of basic additive, 25% by weight in water (volatile)
[0230] 400 of dispersing additive, solids: 40% by weight
[0231] 200 of silicon dioxide filler (mean particle size: 16 nm)
[0232] 100 of silicon dioxide filler (mean particle size: 7.5 nm)
[0233] 1000 of carbon black pigment, density d=1.8 g/cm 3 , oil number ON=230
[0234] 2500 of binder I (acrylate copolymer emulsion, solids: 37.5% by weight)
[0235] 4000 of binder II (acrylate copolymer emulsion, solids: 55% by weight)
[0236] The following is applicable to this black lake:
[0000]
P
N
=
∑
1
x
(
m
P
×
f
)
x
(
m
B
M
+
m
A
)
=
1000
g
×
127.8
cm
3
g
3137.5
g
+
160
g
=
38.7
cm
3
g
[0000] where m P =1000 g of carbon black
f=ON/d=230/1.8 g/cm 3 =127.8 cm 3 /g (for carbon black) m BM =(0.375·2500 g of binder I)+(0.55·4000 g of binder II)
=937.5 g of binder I+2200 g of binder II=3137.5 g of binder
m A =(0.4·400 g of dispersing additive)=160 g of solids of the dispersing additive
[0241] When the film 1 is viewed on the sides of the replicating layer 2 , a latent optically variable effect is seen.
[0242] FIG. 3 shows a second film 1 ′ in the form of a laminated film in cross section. The laminated film has a self-supporting transparent substrate film 10 comprising PET in a film thickness of 19 μm, adjacent to this the replicating layer 2 having the diffractive relief structure 3 and furthermore the lake layer 4 . The replicating layer 2 and the lake layer 4 are formed as described in FIG. 2 . The laminated film is applied to a substrate, not shown here, in such a way that the lake layer 4 is bonded to the substrate, in particular by means of an adhesive layer. The adhesive layer can be applied to the substrate and/or to the lake layer 4 . The substrate film 10 is permanently bonded to the replicating layer 2 and remains as a protective layer over the replicating layer 2 and the lake layer 4 on the substrate. When the film 1 ′ is viewed on the sides of the substrate film 10 , a latent optically variable effect is seen.
[0243] FIG. 4 shows a third film 1 ″ in the form of a transfer film in cross section. The transfer film has a substrate film 11 detachable from a transfer layer and comprising PET and having a layer thickness of 19 μm.
[0244] Arranged between the transfer layer and the detachable substrate film 11 is optionally a release layer 6 which permits or promotes separation of substrate film 11 and transfer layer. Such a release layer 6 is usually formed from wax, silicone or the like and frequently has a layer thickness in the range of 1 nm to 1.5 μm, in particular in the range of 4 nm to 12 nm.
[0245] Furthermore, a protective lacquer layer, for example having a layer thickness in the range of 0.5 μm to 15 μm, in particular in the range of 1 μm to 3 μm, can be arranged between the detachable substrate film 11 and the transfer layer or between the release layer 6 and the transfer layer, which protective lacquer layer remains on the transfer layer after detachment of the substrate film 11 and protects the surface thereof from mechanical and/or chemical attacks.
[0246] Such a protective lacquer layer may be formed, for example, from a lacquer of the following composition (in g):
[0247] 2200 of methyl ethyl ketone
[0248] 300 of butanol
[0249] 1500 of acrylic polymer based on methyl methacrylate
[0250] 30 of UV absorber
[0251] 10 of light stabilizer
[0252] 120 of feldspar, density d=2.6 g/m 3
[0253] The transfer layer of the transfer film according to FIG. 4 thus comprises, in this sequence, an optional protective lacquer layer, the replicating layer 2 , the lake layer 4 and an adhesive layer 5 which is arranged on that side of the lake layer 4 which faces away from the substrate film 11 . This may be a hotmelt adhesive layer or a cold adhesive layer. The adhesive layer 5 has in particular a layer thickness in the range of 0.2 to 10 μm, preferably in the range of 1 to 2.5 μm.
[0254] The transfer film according to FIG. 4 is arranged on a substrate so that the adhesive layer 5 faces the substrate. Thereafter, the adhesive of the adhesive layer 5 is activated and is bonded to the substrate. This can be effected over the whole area or only in regions, so that the transfer layer is adhering to the substrate completely or only in regions when the substrate film 11 is peeled off. If the transfer layer of the transfer film is transferred only in regions to a substrate, those regions of the transfer layer which are not fixed to the substrate by means of the adhesive layer 5 remain on the substrate film 11 and are removed with it.
[0255] FIG. 5 shows a first film according to FIG. 2 , applied to a substrate 7 in the form of a motor vehicle number plate 100 , in cross section Y-Y′ (cf. FIG. 6 ). The lake layer 4 is permanently adhesively bonded to the substrate 7 .
[0256] FIG. 6 shows the the motor vehicle number plate 100 from FIG. 5 in plan view. The motor vehicle number plate consists of a support plate 101 which is provided with a white, retroreflective coating and usually consisting of an aluminum or steel sheet. A raised character legend 102 is stamped into the support plate 101 by means of a mechanical stamping process. The character legend 102 consists of alphanumeric characters 102 a, 102 b, 102 c, 102 d, which, for example in Germany, indicate the place of registration of the motor vehicle and form an individual number. In order to make the character legend 102 of the stamped motor vehicle number plate 100 readily visible, the raised stamped regions are coated in color with a black film having a latent optically variable effect, the presence of which is indicated by the dotted white lines. A stamped raised border 103 of the motor vehicle number plate 100 , which is likewise coated with the black film having a latent optically variable effect, is furthermore provided. For this purpose, an appropriate transfer of colored film is carried out by means of a transfer film which consists of a substrate film and a transfer layer detachable therefrom, as described, for example, in FIG. 4 . In the case of the transfer of the transfer layer in regions, the transfer film is brought into mechanical contact with the raised stamped regions of the support plate 101 of the motor vehicle number plate 100 and the transfer layer is transferred in the exact position to the raised regions under pressure, optionally also under pressure and at elevated temperature.
[0257] However, other fields of use for the film, as described above, for example on surfaces of pieces of furniture, valuable documents, motor vehicle interior parts and the like, are of course also advantageous.
|
A film ( 1 ) which comprises at least one transparent replicating layer ( 2 ) having a diffractive relief structure ( 3 ) and a reflective layer, the reflective layer being formed by at least one pigmented lake layer ( 4 ), and the film ( 1, 1′, 1″ ) showing a latent optically variable effect produced by the diffractive relief structure ( 3 ), and the use thereof. The invention furthermore relates to a method for the production of such a film.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This present application is a continuation application, and thus claims benefit pursuant to 35 U.S.C. §120. of U.S. patent application Ser. No. 12/897,519 filed Oct. 4, 2010, currently pending, which claims priority under 35 U.S.C. §119(e), to U.S. patent application Ser. No. 61/251,124, filed on Oct. 13, 2009, which is assigned to the present assignee and herein incorporated by reference in its entirety.
BACKGROUND
1. Field of the Disclosure
Embodiments disclosed herein relate generally to wedge thread connections. More particularly, embodiments disclosed herein relate to wedge threads having a solid lubricant coating permanently bonded thereon and related methods of permanently bonding the solid lubricant coating on the wedge threads.
2. Background Art
One type of threaded connection commonly used in oil country tubular goods is known as a wedge thread. Referring initially to FIGS. 1A and 1B , a prior art tubular connection 100 having a wedge thread is shown. As used herein, “wedge threads” are threads, regardless of a particular thread form, that increase in width (i.e., axial distance between load flanks 225 and 226 and stab flanks 232 and 231 ) in opposite directions on a pin member 101 and a box member 102 . The rate at which the threads change in width along the connection is defined by a variable known as the “wedge ratio.” As used herein, “wedge ratio,” although technically not a ratio, refers to the difference between the stab flank lead and the load flank lead, which causes the width of the threads to vary along the connection. Furthermore, as used herein, a thread “lead” refers to the differential distance between components of a thread on consecutive threads. As such, the “stab lead” is the distance between stab flanks of consecutive thread pitches along the axial length of the connection.
A detailed discussion of wedge ratios is provided in U.S. Pat. No. 6,206,436, issued to Mallis, assigned to the assignee of the present disclosure, and incorporated by reference in its entirety herein. Furthermore, wedge threads are extensively disclosed in U.S. Pat. No. RE 30,647 issued to Blose, U.S. Pat. No. RE 34,467 issued to Reeves, U.S. Pat. No. 4,703,954 issued to Ortloff, and U.S. Pat. No. 5,454,605 issued to Mott, all assigned to the assignee of the present disclosure and incorporated herein by reference in their entirety.
Referring still to FIGS. 1A and 1B , in wedge threads, a thread seal may be accomplished through contact pressure caused by interference that occurs at make-up over at least a portion of connection 100 between pin load flank 226 and box load flank 225 and between pin stab flank 232 and box stab flank 231 . Close proximity or interference between roots 292 and 221 and crests 222 and 291 complete the thread seal when occurring proximate to such flank interference. Generally, higher pressures may be contained either by increasing interference between the roots and crests (“root/crest interference”) on pin member 101 and box member 102 or by increasing the aforementioned flank interference.
Prior to make-up, a flowing joint compound commonly referred to as “pipe dope” is typically applied to surfaces of a threaded connection to improve the thread seals and provide lubrication during make-up of the connection. For example, the pipe dope may assist a wedge-threaded connection in achieving a thread seal between load and stab flanks thereof, e.g., as disclosed in U.S. Pat. No. RE 34,467 issued to Reeves. Further, pipe dope may protect the threads of the pin and box members from friction galling during make-up and break-out.
A flowing joint compound such as pipe dope may be used in wedge thread connections because of the close-fitting manner in which wedge threads make-up. As previously mentioned, wedge threads rely on a full surface contact theory, which means that each contact surface, i.e., corresponding roots/crests and stab and load flank surfaces are either in close proximity or full interference. Thus, due to the tight-fitting characteristics of wedge threads from multiple thread surface interferences, a pipe dope is used so that as the connection is made up and corresponding thread surfaces come together, the pipe dope may be squeezed out so as not to impede the proper engagement of the thread surfaces.
The use of pipe dope in wedge thread connections is not without certain deficiencies. When a wedge thread connection is made-up, excess pipe dope may become trapped (rather than being squeezed out) between the pin threads and the box threads, which may either cause false elevated torque readings (leading to insufficient make-up or “stand-off”) or, in certain circumstances, damage the connection. Attempts to mitigate pipe stand-off have come in the form of providing features in the thread form to reduce a build-up in pressure of pipe dope used in the make-up of the threaded connections, e.g., U.S. Publication No. 2008/0054633, assigned to the assignee of the present application and incorporated herein by reference in its entirety. In addition, problems associated with excess pipe dope on wedge-threaded connections may be avoided by restricting the amount of pipe dope applied and by controlling the speed at which the wedge-threaded connection is made-up. Limiting the make-up speed of a wedge-threaded connection allows the pipe dope to travel and squeeze out before it becomes trapped within the connection at high pressures. However, limiting the make-up speed of the connection slows down the overall process of assembling the drillstring.
Pipe stand-off due to inadequate evacuation of pipe dope is detrimental to the structural integrity of wedge thread connections. As the pressure build-up may bleed off during use, the connection is at risk of accidentally backing-off during use. Therefore, stand-off in wedge thread connections is of particular concern as it may lead to loss of seal integrity or even mechanical separation of two connected members. Furthermore, pipe stand-off may be particularly problematic in strings used at elevated downhole service temperatures (i.e., the temperature a tubular would be expected to experience in service). Particularly, in high temperature service (e.g., temperatures greater than 250° F., a steam-flood string, or a geothermal string), even a small amount of stand-off may be deleterious. For example, if a made up wedge thread connection having even an infinitesimal amount of stand-off is deployed to a high temperature well, the pipe dope may flow out of the wedge thread connection, thus reducing the integrity of the thread seal. Further, use of a flowing pipe dope in wedge threads may lead to thread seal leaks, particularly at elevated pressures, as the viscosity of the pipe dope increases.
Larger OD wedge threads, which utilize pipe dope, may typically require a second application of torque to insure a complete make-up of the threaded connection. Because of the length and configuration of the wedge thread, the larger diameter connections may be susceptible to hydraulic lock and require extra torque to push the thread dope (i.e., force the thread dope to flow) along the length of the connection. Such a procedure is commonly known as “double bumping” a connection because torque is applied a number of times to “squeeze” the pipe dope along the threads. Notably, double bumping increases connection make-up time.
Accordingly, there exists a need for a thread lubricant capable of being used in tight-fitting wedge thread connections that substantially reduces pipe stand-off concerns and is effective at elevated downhole temperatures.
SUMMARY OF THE DISCLOSURE
In one aspect, embodiments disclosed herein relate to a tubular connection including a pin member having external wedge threads configured to engage a box member having corresponding internal wedge threads and a solid lubricant coating permanently bonded on at least one of the internal and external wedge threads.
In other aspects, embodiments disclosed herein relate to a method of manufacturing a connection having wedge threads, the method including machining internal wedge threads on a box member and external wedge threads on a pin member, wherein the internal and external wedge threads are configured to correspond and permanently bonding a solid lubricant coating on at least one of the internal and external wedge threads.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1A and 1B show cross-sectional views of a prior art tubular connection having wedge threads.
FIG. 2 shows a cross-sectional view of a solid lubricant coating on a wedge thread in accordance with embodiments of the present disclosure.
FIG. 3 shows an enlarged detail view of a solid lubricant coating near the thread surface in accordance with embodiments of the present disclosure.
FIG. 4 shows an enlarged detail view of an alternative solid lubricant coating near the thread surface in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
In one aspect, embodiments disclosed herein relate to a wedge thread connection with a solid lubricant coating permanently bonded thereon and related methods of permanently bonding the solid lubricant coating to the wedge threads. The threaded connection may include a corresponding pin member and box member having wedge threads formed thereon. The solid lubricant coating may be permanently bonded on the pin member, the box member, or both the pin and box members prior to make-up of the connection. One or more layers of the solid lubricant coating may be used depending on the type of end configurations of the connection (i.e., full length pin, full length box, or coupling).
Referring now to FIG. 2 , a cross-sectional view of a wedge thread 300 having a solid lubricant coating 310 permanently bonded thereon is shown in accordance with embodiments of the present disclosure. The wedge thread 300 is formed on a tubular member 301 , which may be either a pin member or box member. As shown, solid lubricant coating 310 may be permanently bonded to an entire surface of the wedge thread 300 , including thread roots 302 , thread crests 304 , stab flanks 306 , and load flanks 308 .
As used herein, permanently bonded refers to adhesion of the solid lubricant coating to the wedge thread surfaces after the coating is properly cured, such that the solid lubricant coating 310 does not “flow” during makeup of the connection, but rather, remains as a rigid structure. As such, during make-up of the wedge thread connection the solid lubricant coating 310 behaves as a solid structure and does not flow as a typical pipe dope lubricant would due to forces created by contacting thread roots 302 and thread crests 304 , and stab flanks 306 and load flanks 308 . While the solid lubricant does not flow, the solid lubricant coating may be a pliable compound and somewhat resilient, so that upon make-up of the wedge thread connection the solid lubricant coating 310 may deform slightly to fill voids in the thread flanks (caused by imperfections in the flanks) over multiple make-ups and break-outs of the connection. Unlike a flowing thread compound, which may rely on surface tension to fill the voids in the thread flanks for sealability, the solid lubricant coating 310 of one or more embodiments disclosed herein permanently adheres to and/or bonds to the wedge thread surfaces.
A magnification of a composition of solid lubricant coating 310 is shown in FIG. 3 in accordance with embodiments of the present disclosure. As shown, an uncoated surface of wedge thread 300 ( FIG. 2 ) may have an average surface roughness Ra of between about 2 and 6 μm. In certain embodiments, the uncoated thread surface may have an average surface roughness of between 1 and 10 μm. Surface treatment or preparation of the base metal of the wedge thread surfaces may be required to prepare the thread surface and serves as an anchor so the solid lubricant coating properly adheres to and is permanently bonded to the wedge threads. Surface treatment of the wedge thread surfaces may include abrasive blasting and/or phosphate coating.
After surface preparation of the wedge thread surfaces (if needed), a first solid coating (a uniform or substantially constant thickness layer) may be applied and permanently bonded on the wedge thread surface. The first solid coating may be comprised of an epoxy resin containing particles of zinc (Zn). In certain embodiments, the first solid coating may be a corrosion inhibiting coating, or have corrosion inhibiting properties. The content of the particles of zinc in the epoxy resin may be equal to or greater than about 80% by mass. In certain embodiments, the zinc particles may have at least 99% purity. In other embodiments, the zinc particles may have at least 97.5% purity. The first coating 312 may have a thickness value of between about 15 and 35 μm. In certain embodiments, the first coating 312 may have a thickness value of between 20 and 30 μm.
A second solid coating 314 (e.g., a solid dry lubricant coating) may be subsequently applied and permanently bonded on the first coating 312 and/or the wedge thread surfaces. In one embodiment, the second coating 314 may be comprised of a mixture of molybdenum disulfide (MoS 2 ) and other solid lubricants in an inorganic binder. Other solid lubricants may include, but are not limited to, graphite, tungsten disulfide, boron nitride, and polytetrafluoroethylene (“PTFE”). In one or more embodiments disclosed herein, the type of binder in which the solid lubricants are dispersed may include organic, inorganic, metallic, and ceramic. One of ordinary skill in the art will understand selection of the type of binder in which the solid lubricant may be dispersed based on mechanical properties of materials of the threaded connection.
The second coating 314 may have a thickness of between about 5 and 25 μm. In certain embodiments, the first coating 312 may have a thickness value of between 10 and 20 μm. First coating 312 may be applied to the wedge threads by spraying, brushing, dipping or any other method known in the art in which the coating thickness can be controlled. Similarly, the second coating 314 may be applied to the wedge threads by spraying, brushing, dipping or any other method known in the art in which the coating thickness can be controlled once the first coating 312 is fully cured and/or dried.
Referring now to FIG. 4 , an enlarged view of solid lubricant coating 310 ( FIG. 2 ) is shown in accordance with alternate embodiments of the present disclosure. In certain embodiments of the present disclosure, the first coating 312 and the second coating 314 of the embodiment shown in FIG. 3 may be combined into one solid coating 316 . In one embodiment, the combined solid coating 316 may be a uniform layer of a dry corrosion inhibiting coating, which has a dispersion of particles of solid lubricant mixed therein, as shown in FIG. 4 . Solid lubricants may include, but are not limited to, molybdenum disulfide (MoS 2 ) graphite, tungsten disulfide, boron nitride, and polytetrafluoroethylene (“PTFE”). Those skilled in the art will be familiar with combining the dry corrosion inhibiting coating with particles of solid lubricant prior to applying and bonding the coating to the wedge threads.
The thickness of the combined dry corrosion inhibiting coating 316 may be between about 15 and 35 μm. In certain embodiments, dry corrosion inhibiting coating 312 may have a thickness value of between 20 and 30 μm. The layer of dry corrosion inhibiting coating 316 containing the dispersion of particles of solid lubricant may be applied by spraying, brushing, dipping or any other method known in the art in which the coating thickness can be controlled. Additional discussion of solid lubricant coatings may be found in International Application PCT/EP2003/011238 and U.S. Publication No. 2008/129044, both of which are assigned to Tenaris Connections and incorporated herein by reference in their entirety.
The solid lubricant coating may be effective at elevated temperatures as well as ambient temperatures. Solid lubricant coatings may be able to withstand much higher temperatures (e.g., 200° C.-350° C.) and not break down. Thus sealing capabilities are maintained at elevated temperatures, unlike grease-based thread compounds, which may lose viscosity at elevated temperatures and substantially reduces the thread compound's resistance to flow. Solid lubricants of embodiments disclosed herein are formulated to perform over a range of elevated temperatures as well as at an ambient temperature.
The solid lubricant coating of embodiments disclosed herein may provide a number of advantages. In particular, the connection may experience improved sealing characteristics over the currently used grease-based (i.e., flowing) thread lubricants as follows. First, the solid lubricant coating will not continue to flow through the threads over time or with loading of the connection, which for greases reduces the sealing capability and resistance to breakout torque. Second, the solid lubricant coating will not disintegrate or lose viscosity at elevated temperature, which for greases reduces or even eliminates the sealing capability. Finally, the solid lubricant coating, when applied on one or both members may have the ability to laminate (e.g., fill in) imperfections or small amounts of damage caused during multiple make-ups and break-outs of the connection.
Additionally, embodiments of the present disclosure may provide a solid lubricant for wedge threads that eliminates the possibility of pipe stand-off due to dope entrapment and subsequent bleed-off because of the solid lubricant's resistance to flow. Furthermore, Applicant has advantageously found that the solid lubricant coating disclosed in embodiments herein may be used with wedge threads without affecting the tight tolerances between engaging thread surfaces, which are typically associated with the structure and makeup of wedge threads. Finally, the solid lubricant coating of one or more embodiments disclosed herein may be precisely applied through controlled application of the solid lubricant coating onto the wedge thread surfaces, as opposed to brushing on by hand flowing pipe dope compounds, so as to apply a more even coating on the thread surfaces.
Further, the connections disclosed herein may be able to withstand increased torque during make-up. Occasionally, connections may be made up to higher torques than are recommended. As such, the wedge thread connection having the solid lubricant was subjected to an excessive amount of torque. For example, a 13.625 inch wedge thread connection was made-up with a 25% increase in torque while a 4.50 inch wedge thread connection was made-up with a 50% increase in torque. Further, the connections were subjected to multiple make-ups and break-outs (e.g., 12 consecutive make and break operations). Results showed that neither connection experienced any galling or deformation in the threaded sections. Thus, the solid lubricant coated threaded connection may be able to withstand higher make-up torques without damage to the connection.
Further still, the solid lubricant coating on the threads may advantageously reduce the total running time of the drillstring. First, embodiments disclosed herein allow for slightly more misalignment between pin and box members during make-up than previously. For example, a pin and box member of a 4.5 inch wedge thread connection having a solid lubricant thereon was misaligned at make-up up to about 15 degrees. After ten complete make-ups and break-outs of the connection, only minimal to no thread damage was observed on initial threads of the pin and box members.
Next, because a solid lubricant coating is used in place of the flowing pipe dope, the commonly used double bumping procedure during make-up is no longer required to squeeze flowing pipe dope out of the threads. As previously described, larger outer diameter wedge threads that utilize standard thread dope typically require a second application of torque to insure a complete make-up. Because of the length and configuration of the wedge thread, the larger diameter connections may be susceptible to hydraulic lock and require extra torque to push the thread dope along the length of the connection. With the removal of dope from the connection and its replacement by the solid lubricant coating in accordance with embodiments disclosed herein, hydraulic lock may no longer be an issue.
In addition, because the solid lubricant is permanently bonded on the threads, a dope compound does not have to be applied prior to make-up, thus reducing the total amount of running time and increasing the productivity of the rig. With a solid lubricant permanently bonded on the wedge threads, application of dope is no longer required, thereby eliminating an assembly step during the make-up procedure. In sum, the overall productivity of the rig may be increased. For example, during rig trials, total make-up time was studied using a 4.5 inch wedge thread connection having a solid lubricant thereon in accordance with embodiments disclosed herein. The average revolutions per minute (“RPM”) during make-up was approximately 19 RPM's while the average RPM during break-out was approximately 21 RPM's. The average cycle time (i.e., the total time to make-up and then break-out the connection) was approximately two minutes, while a standard doped connection would have an average cycle time of 4 to 5 minutes.
While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims.
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A tubular connection includes a pin member having external wedge threads configured to engage a box member having corresponding internal wedge threads, and a solid lubricant coating applied on at least one of the internal and external wedge threads wherein the solid lubricant coating comprises a first uniform layer of a dry corrosion inhibiting coating made of an epoxy resin containing particles of zinc and a second uniform layer of a dry lubricant coating covering the first uniform layer.
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BACKGROUND: FIELD OF THE INVENTION
The present invention relates chiefly to teeth clenching and grinding and, more specifically, to a method and devices for treating, diagnosing, and preventing bruxism.
BACKGROUND: NATURE AND INCIDENCE OF BRUXISM
Bruxism can be defined as excessive grinding or clenching of teeth. This behavioral pattern is often unconscious and involuntary, and can take place while the patient is asleep or awake.
It is hard to come up with hard figures for the incidence of bruxism. Most people unconsciously grind or clench their teeth now and then, so the key to diagnosis is not the presence or absence of the habit, but such things as its frequency, destructiveness, social discomfort, or physical symptoms (Kydd and Daly, 1985). Moreover, some 80% to 95% of all bruxers are unaware of the habit (Thompson, Blount, and Krumholtz, 1994), or ashamed of it, so they may dismiss evidence that they do in fact engage in self-inflicted wearing away of teeth. Also, it may take years for the first visible signs of worn teeth to appear, yet, in most cases it is these signs which lead to a diagnosis of bruxism. For these reasons, current estimate that 5-20% of all Americans brux may be on the low side.
In any event, and regardless of the exact number, it is inarguably the case that bruxism is a widespread behavioral pattern which adversely affects a significant fraction of the world's population. Thus, there is an urgent need for the development of effective therapies for treating this condition--any advance in this field will help improve the quality of life of millions.
BACKGROUND: CONSEQUENCES AND SYMPTOMS OF BRUXISM
Sleep bruxism often exerts surprisingly powerful forces on teeth, gums, and joints. With no consciousness of the action, and with no food to moderate it, the pressure exerted on teeth can be ten times higher, by some calculations, than the pressure of chewing--powerful enough to crack a walnut (Sedgwick, 1995). While not a life-threatening condition, chronic bruxism often impairs the quality of life of affected individuals. Some suspected symptoms and consequences of this habit will be listed below. (Note: because bruxism is believed to be one of the leading causes [Glaros, Tabacchi, and Glass, 1998] of temporomandibular disorders [TMDs], some symptoms of TMDs will be listed here as well):
tooth abrasion, fractures, mobility, or loss (McGuire and Nunn, 1996)
dental caries (grinding or clenching break down the enamel, permitting bacteria to penetrate the dentin, eventually producing a cavity)
alveolar bone loss
headaches
clicking sounds when opening the jaws or while eating
difficulties in fully opening the mouth
earaches and hearing loss (for a review and a fascinating case study, see Bubon, 1995)
adverse, cumulative, irreversible effect on dental implants (Perel 1994) and aesthetic restorations
neuralgia (an acute paroxismal pain radiating along the courses of one or more nerves)
tenderness, pain, or fatigue of facial muscles
diminished facial height which may in turn change one's appearance and cause mandibular overclosure (Thompson, Blount, and Krumholtz, 1994)
hypertrophy of the masseter muscle, which in turn can adversely affect one's appearance (Rijsdijk et al. 1998), or block the parotid duct and lead to parotitis-like or sialolithiasis-like syndromes (Thompson, Blount, and Krumholtz, 1994)
higher levels of mercury in the blood (Isacsson et al., 1997) of some bruxers with mercury fillings
source of annoyance to anyone within hearing range (grinders only; Blount et al., 1982; Watson, 1993).
over a lifetime, tremendous cost to patient or employer
reduction in the overall quality of life of long-term sufferers.
BACKGROUND: ETIOLOGY OF BRUXISM
The causes of bruxism are controversial and subject to much theorizing and little hard science (Ellison and Stanziani, 1993; Thompson, Blount, and Krumholtz, 1994). At present, the causes are suspected to be many, to overlap each other, and to vary from one patient to another.
One theory traces bruxism to stress, emotions, and other psychological factors (Murray, 1998; but see Westrup, 1992). There is indeed evidence that stress increases the frequency of bruxing episodes (reviewed in Hartmann, 1994), although this of course does not prove that stress led to the onset of this behavioral pattern in the first place, nor that removal of stress will provide a cure.
The central nervous system may be involved, as is suggested, for example, by the high incidence of bruxism in mentally retarded individuals and by the fact that the uptake of some drugs induces bruxism.
In some cases, bruxism may be traceable to drugs or the excessive consumption of alcohol (Hartmann, 1994). In one study (Ellison and Stanziani, 1993), for example, both the drugs fluoxetine and sertraline were shown to initiate nocturnal bruxism, while buspirone led to its cessation.
Bruxism may be ascribable to a nutritional deficiency (Ploceniak, 1990).
In some cases, bruxism may be traceable to malformations of the jaw or to abnormal dental occlusion (the way the upper and lower teeth fit together when the person closes the mouth; Yustin et al., 1993). Thus, Buds-Jorgensen (1981) showed that artificially-induced malocclusion led to emotional stress and bruxism in monkeys. Similarly, Takeda et al. (1989) showed that the artificial production of occlusal interference in normal subjects in the area of the first molar may have induced bruxism (but see Rugh et al., 1984).
In some cases, bruxism may be a byproduct of dental manipulation of a patient's mouth--the physical handling, the use of removable or fixed dental appliances, or the permanent introduction into the mouth of a variety of foreign substances such as mercury and porcelain. This hypothesis is not borne out by direct evidence, but by the observation that the somewhat related condition of the burning mouth syndrome has been traceable in some cases to denture design faults and to denture material (Huang, Rothe, and Grant-Kels, 1996).
Klineberg (1994) and many others view bruxism as an evolutionary relic, a residue from a remote past when our ancestors needed sharp teeth to defend themselves and retrieve food. A related explanation may view some manifestations of bruxism as a genetically programmed behavioral counterpart of the aging process. Indeed, clinical experience points to a familial pattern (Hartman, 1994). The role of heredity in causing bruxism receives additional support from a higher concordance in the incidence of bruxism among identical twins than among fraternal twins (Hori, 1997, p. 119).
BACKGROUND: DIAGNOSIS OF BRUXISM
The diagnosis of bruxism also presents difficulties. Here it is perhaps convenient to distinguish between grinders and clenchers. In the case of grinders who share living quarters with other people, reports of bruxism might be fairly reliable (but see Marbach et al., 1990). For grinders who live alone, and for clenchers, diagnosis is primarily based on tooth attrition. In the case of both grinders and clenchers, positive proof of bruxing is lacking, and patients may go on disbelieving their dentist or family members for years. It is often only in advanced stages of the disease, when much damage to the teeth has already been wrought, and when TMD or other problems stare them in the face, that many patients concede the existence of a problem. This is exacerbated by their belief that bruxism is rare, by the mistaken belief that it is necessarily a sign of severe emotional problems (witness the original name--still in use in some quarters--bruxomania), and by the insidiously slow process of destruction.
Thus, current diagnostic procedures typically rely on visible damage to teeth, or on devices like the bruxcore plate, which is not necessarily reliable (Pierce and Gale, 1989), and which requires a special appliance, expert analysis, and high costs.
These diagnostic difficulties explain in part the typical neglect of bruxism, at least until some dentition is irreversibly destroyed and the habit is firmly entrenched.
BACKGROUND: TREATMENT OF BRUXISM
Despite almost one century of research, and despite well over one thousand publications on the subject, effective remediation of bruxism still eludes us. Ellison and Stanziani (1993), for example, remark that "no entirely satisfactory treatment has been identified" (p.433/2). Klineberg (1994) says that "the aetiology of bruxism and therefore its management is poorly understood by dentists and their focus on a local dental cause has lead to much unnecessary irreversible dental treatment, with little impact on the incidence of bruxism."
Its seeming simplicity notwithstanding, bruxism indeed presents formidable challenges to both sufferer and therapist. Like snoring, it is unconscious, and hence not under the control of the patient. The symptoms are rarely obvious, and often years elapse between the onset of the problem and its first clinical manifestations. To admit the presence of this problem--in face of the prevailing paradigm in both dental and psychiatric circles--is to concede some serious psychological problems. The most common response therefore is to deny the problem until denial is no longer tenable. Needless to say, by then much irreversible damage has been inflicted, and the habit--regardless of its etiology--is entrenched.
By far the most common treatment regime for bruxism relies on the time-honored procedure (e.g., Matthews, 1942) of interocclusal orthopedic appliances (Rugh et al. 1989). In the United State alone, some 3.6 million nightguards (or occlusal splints) are annually prescribed by dentists in an effort to combat bruxism (1.6 million), myofacial pain (0.9 million), and TMJ pain (1.1 million)--a $1 billion industry (Pierce et al., 1995). Much current research on the treatment of bruxism has been centered on the use of such dental appliances. Many patent applications describe splints for the treatment of bruxism (e.g., U.S. Pat. Nos. 5,666,973 and 5,823,193). Here, a patient is often fitted with a customized, hard acrylic bite guard or splint. At times, the bite guard is made of soft, rubber-like, elastomeric material. Another variation is the hydrostatic splint, a water-bearing pressure-equalizing appliance sold under the commercial name "Aqualizer" and manufactured by Jumar Corp., Arizona (see also U.S. Pat. No. 4,211,008).
It may be worth while to cite the views of several writers on splint therapy: "The most common `treatment` is a rubber device, worn over the teeth at night, called a mouthguard. This does not actually prevent or cure the bruxism, but it will prevent damage to the teeth when bruxism occurs" (Hartmann, 1994, p. 601). "Occlusal splints worn at night did not significantly reduce bruxing-clenching activity in bruxing subjects" (Kydd and Daly, 1985). Pierce and Gale (1988) found that bruxing decreased by about 50% during two weeks of splint therapy, but that, following withdrawal of treatment, it returned to baseline levels. Klineberg (1994) concludes that occlusal splints "will protect the teeth, but will not alter the habit in the long term." According to Rugh et al. (1989), splint therapy is effective at first, but "the usual trend with longer treatment is to lose its effects. In other words, one usually sees a dramatic decrease or increase in EMG activity the first few nights of splint usage, followed by a gradual return to pretreatment EMG values." The comparative ineffectiveness of the traditional splint is also "borne out by the common clinical finding that patients may bite large teeth marks into night bite guards and frequently fracture appliances" (Trenouth, 1979). Moreover, the use of such splints may sometimes adversely affect the patient's occlusion, e.g., cause an open bite (Ahlin, 1991; Wiygul, 1991).
Many other, less popular, extant approaches to the treatment of bruxism will be mentioned here, although they too are controversial and only provide, at best, partial remediation.
Thus, one intrusive and irreversible dental approach tries to correct malocclusion through orthodontic adjustment of the bite pattern. Yet, the majority of practitioners seem by now to agree that "occlusal equilibriation is costly and relatively ineffective" (Shatkin, 1992).
Another approach involves ingestion of substances such as nutritional supplements, anti-anxiety agents, and muscle relaxers. According to Ploceniak (1990), for instance, prolonged magnesium administration nearly always provides a cure for bruxism. Most authorities, however, feel that, at best, drugs and nutritional supplements are of limited value in the treatment of bruxism, and that they often involve, moreover, untoward side effects.
Still another approach involves psychotherapy and teaching patients how to interrupt muscle tension by relaxing their jaws and breathing deeply (Murray, 1998; see also below). Related and occasionally successful approaches involve hypnotherapy (Clarke and Reynolds, 1991; LaCrosse, 1994), as well as visual imagery and autosuggestion.
Another related and controversial approach is the so-called massed negative practice, a scholarly variation of the folk principle of reverse psychology. Here the patient is told to voluntarily clench the jaw for five seconds, relax it for five seconds, and repeat this procedure five times in succession, six different times a day, for two weeks (Thompson, Blount, and Krumholtz, 1994).
Quinn (1995) suggests isokinetic and stretching exercises of the mandible. Long (1998) describes an apparatus which prevents the creation of vacuum in the mouth; this is based on the belief that vacuum is a necessary condition for jaw clenching.
A more promising approach involves biofeedback. Two variants will be mentioned here. The first, as we have seen, assumes that bruxism is the result of stress, and that stress is often manifested by tense muscles, especially facial muscles. This approach strives to reduce stress by monitoring the tenseness of muscles, and transmitting this information to the patient. Gradually, by becoming alert to the presence of muscle tension, patients develop techniques for reducing that tension, hence stress, and hence, bruxism. Such therapeutic claims are controversial, however, and there is little evidence that they are of much help to the unaware or sleeping bruxer.
The second biofeedback variant assumes, in its simplest terms, that--exact etiology notwithstanding--the habit of bruxism could develop in the first place because it is not accompanied by immediate sensations of pain. In this case, nature failed to provide the pain or awareness signal which often blocks or minimizes self-destructive behavior. This second variant attempts to artificially reintroduce this missing signal.
This variant is often used to treat other disorders. For instance, idiopathic primary enuresis (bedwetting--another sleep disorder) can sometimes be cured by sounding an alarm when urine is released (Broughton, 1994, p. 395; cf U.S. Pat. No. 1,772,232).
This variant is sometimes used to treat bruxism. At times, this involves electromyographic (EMG)-activated alarms (Cassisi, McGlynn, and Belles, 1987; U.S. Pat. No. 4,934,378). One obvious problem with this type of therapy is that "numerous other types of orofacial movements unrelated to bruxism . . . can easily be confused with bruxism if only EMG criteria are used for scoring" (Miguel et al., 1992).
Many United States patents still rely on an alarm system, but take the more reliable bruxing activity itself as their point of departure (U.S. Pat. Nos. 4,220,142; 4,976,618; 4,979,516; 4,989,616; 4,995,404; 5,078,153; 5,190,051; 5,586,562). A commercially available device, the OralSensor, manufactured by Cycura Corp. of Rocklin, Calif., similarly produces an audible tone to make the patient aware that bruxing is taking place.
Feedback approaches employing sound alarms suffer from machine breakdowns and are often unsightly, invasive, intimidating, and expensive; they thus do not lend themselves readily to wide use, and especially not to long-term use. As well, they are only partially effective. In evaluating EMG-activated studies, Pierce and Gale (1988) found that bruxing decreased by about 50% during two weeks of biofeedback therapy, but that, following withdrawal of treatment, the condition returned to baseline levels. Piccione et al. (1982), to cite another example, found that "biofeedback does not appear to be effective in reducing nocturnal bruxing," probably because, over time, subjects learned to ignore the tone and go on sleeping.
In another biofeedback embodiment, bruxism is followed by electrical stimulation to the jaw (U.S. Pat. No. 4,669,477), neck (U.S. Pat. No. 4,715,367), lip (Clark et al., 1993), mouth (U.S. Pat. Nos. 4,995,404; 6,490,520), or tooth (U.S. Pat. No. 5,553,626).
In another interesting psychological approach, the feedback is provided directly by humans, not by machines. In one long-term experiment (Watson, 1993), the spouses of two young people who had recently developed a habit of grinding their teeth were instructed to record the bruxing behavior for a few days, then to alternate periods of not waking their grinding spouse up, waking them up when they heard them grinding, and waking them up followed by overcorrection (a ten-minute period of enforced wakefulness) by the grinding spouse. Follow-up recordings were taken at intervals up to 18 months post-treatment. In both individuals, almost complete cessation of grinding was observed. In a similar study (Blount, 1982), ice was applied to the cheeks of two profoundly retarded diurnal grinders, leading to significant long-term reductions in the incidence of bruxism. But, even if such behavioral approaches are shown to be effective in a large-scale study, they suffer from obvious shortcomings. They are inapplicable to clenchers. Moreover, the four individuals in these two studies may have simply learned to grind inaudibly or to clench instead. Such approaches depend on the presence of another individual nearby, and on the willingness of that individual to provide the needed feedback over a period of many months.
It should be noted that young children typically require different therapeutic approaches from adults. To begin with, the damage to the teeth is transitory, for only the primary teeth suffer damage in this case, not the permanent teeth. Moreover, bruxism in children usually resolves spontaneously. Thus, "observation and reassurance, rather than intervention, are warranted in most cases" (Thompson, Blount, and Krumholtz, 1994).
One feels instinctively that such a seemingly simple behavioral problem as bruxism should be capable of a solution, or at least inexpensive and convenient remediation, especially since the great majority of patients are normal individuals (in my experience, one cannot start a conversation about bruxism in a roomful of people without finding some sufferers of this syndrome who are, one might add, often dissatisfied with existing modes of therapy). Yet an effective treatment program so far is unavailable.
BACKGROUND: CONDITIONED FLAVOR AVERSION
The pioneering studies on conditioned taste aversion (to which this invention owes its greatest intellectual debt) are often attributed to Garcia et al. (1966). By 1993, over 2000 scholarly articles, and dozens of monographs and symposia volumes, have been published in this field (Bures, 1993). Of particular interest in the present context are four key findings (Bernstein, 1991):
First, rats can learn to avoid a particular taste even when they are under deep anesthesia.
Second, the learning is rapid (often involving just one exposure), long-lasting, and resistant to extinction.
Third, such learning is selective. For example, the association between flavors and subsequent gastrointestinal discomfort is more readily learned than the less natural association between sound and gastrointestinal discomfort.
Fourth, humans of all ages (Chambers and Bernstein, 1995) show conditioned taste aversion.
These findings raise the intriguing possibility that unlearned, instinctive flavor aversion can serve in turn as a powerfully aversive, readily associable, stimulus in sleeping humans. Known therapeutic practices lend additional support to this last possibility. Thus, the childhood syndrome of finger sucking, especially when it persists after the permanent teeth begin to erupt, besides being unsightly and unsanitary, can cause severe orthodontic problems, speech defects, psychological problems, and deformation of fingers (Josell 1995). A home remedy of hot sauce or vinegar painted on the finger is a long-standing preventive practice, and commercial solutions containing denatonium benzoate or sucrose octaacetate are also available (U.S. Pat. No. 5,474,093).
SUMMARY, OBJECTS, AND ADVANTAGES
Prior art has been directed to the treatment of bruxism through splints, stress reduction, muscle relaxation, sound alarms, electrical stimulation, drugs, and nutritional supplements. The present invention seeks chiefly to treat bruxism through the more promising, convenient, appealing, safe, and inexpensive procedure of taste aversion. It further seeks to employ the intraoral device(s) of this invention in the diagnosis of bruxism and in the sustained release of other substances. Among the objects of this invention are:
(a) To provide simple, safe, inexpensive means of treating and preventing teeth clenching and grinding.
(b) To provide means of readily diagnosing bruxism.
(c) To provide means of convincing patients that they brux, thereby motivating them to undertake preventive action.
(d) To provide means for the sustained release of medications and odor-masking substances into the oral cavity.
To treat teeth clenching and grinding, an unpleasant-tasting, safe, substance is released into the mouth whenever a patient attempts to brux, thereby drawing the patient's conscious attention to, and forestalling, teeth clenching or grinding. More specifically, the preferred embodiment employs three elements:
an unpleasant-tasting liquid derived from one or more natural or synthetic, palatable, materials such as hot peppers (capsaicinoids), horseradish, quinine, mustard, ginger, garlic, onion, salt, or denatonium benzoate,
two small, identical, bilaterally-sleeved, plastic bags,
a wrought iron or cast, comfortable, safe, dental appliance which is specially designed to introduce into the mouth, and support therein, the liquid-filled bags
More precisely, the liquid in which the unpleasant-tasting substance is dissolved or suspended can be any appropriate solvent such as water, alcohol, vinegar, or other safe, digestible, barely-compressible, fluids. Horseradish extracts, for example, can be suspended in water, alcohol, or vinegar. In all cases, just enough of the aversive substance is used to reach a predetermined level of taste intensity.
The solution is then inserted into, and sealed in, one or more soft- or hard-shelled containers, bags, or capsules. These capsules can be comfortably worn inside the mouth and are made of such materials as polyethylene or wax, which are safe and non-irritating, yet capable of breaking or rupturing when bruxing pressure is applied, thereby releasing their contents into the mouth.
The liquid-filled capsules are then joined to a specially constructed dental appliance. The joined liquid-filled capsules and appliance are inserted into the mouth before going to sleep or whenever teeth clenching and grinding are suspected to occur. The appliance is so designed that the capsules are positioned between the lower and upper teeth and are evenly balanced on each side of the mouth. Whenever the user attempts to brux, the capsules release their disagreeable constituents.
The design and construction of each individual component of the present invention are well-known in the art. The dental appliance, in particular, can come in variety of designs. At present it is molded or cast to fit the mouth of each patient. In the future, a suitable generic design, which fits into the mouths of most patients, may be used.
The appliance and liquid-filled capsules can be used by bruxers wishing to treat their condition, by bruxers and non-bruxers alike to prevent pressure on teeth in special situations when such pressure is particularly counterindicated (e.g., before and after a TMJ or tooth implant operations), or by non-bruxers for a few days to prevent the habit of bruxing from forming in the first place.
In all these conditions and variations, the aversive liquid is released into the mouth under pressure, drawing the patient's conscious attention to, and precluding, teeth clenching or grinding.
To diagnose bruxism and convince patients that they do indeed grind, the sleeved bags of the preferred embodiment may be filled with wax, gum, or some other malleable material. The bags are joined to the same dental appliance as in the treatment variation above. As before, bags and appliance are now inserted into the mouth, so that the capsules are positioned between the lower and upper teeth. Bruxing in turn produces deformations in the impressionable materials, thereby helping to confirm the occurrence of bruxism for both therapist and patient. Thus, both diagnosis and treatment can be effected by essentially the same appliance.
To provide means for the sustained release of medications and odor-masking substances into the mouth, the sleeved bag(s) contain one or more such medications and substances. The bags are again attached to the dental appliance. Bags and appliance are then inserted into the mouth, where the bags sustainably release one or more of the needed medications and odor-masking substances.
In the preferred embodiment of the bruxism treatment program, a customized, safe, minimally-intrusive, dental appliance is constructed. In the confirmatory, diagnostic stage of the program, two identical dental wax pellets are inserted into polyethylene sleeved bags. The bags are then attached to the appliance, which the user wears whenever bruxism is suspected to occur. After the existence of bruxism is confirmed through markings and structural alterations in the wax, the same appliance is used to lodge two identical, small, sleeved, plastic bags filled with a barely-compressible sealed capsaicin solution. When the user clenches or grinds his or her teeth, the pressure within the bag increases and one or two of the bags rupture and wake up the user. The ensuing intraoral release of the aversive, safe, capsaicin whenever bruxing is attempted draws the user's conscious attention to, and forestalls, teeth clenching or grinding. Users then rinse their mouth with cold water, milk, or sucrose/fructose solution, replace the bag(s), and resume sleep. Similarly, when daytime users unconsciously brux, one or two bags rupture, thereby alerting them to the occurrence of bruxing. Users rinse their mouth, replace the bag(s), and resume their activities.
While my invention combines, or improves upon, elements which are known in the prior art, it achieves a radically novel and synergistic result. Despite the tremendous potential of this approach, despite the prevalence of bruxism and its untoward symptoms, despite the fact that bruxism takes place in the mouth and lends itself to taste biofeedback, despite the success of taste aversion in treating other mouth-related conditions such as finger-sucking (Umberger and Van Reenen, 1995), and despite the overwhelming evidence from learning psychology that taste aversion may be particularly suitable to treat sleeping or unaware patients, no one has ever employed a taste modality to treat bruxism. Moreover, the mouth appliance described here has been specifically designed to treat and diagnose bruxism. Moreover, one key segment of prior art references--those involving taste aversion learning--is from an entirely different field. Moreover, theoretical considerations given above, as well as some preliminary clinical data, suggest that the therapy proposed here might well be more effective, more convenient, and cheaper than any current therapeutic device or approach. In particular,
Although the invention combines the well-known prior art of extracting and dissolving solids, inserting and sealing liquids in capsules, constructing dental appliances, conditioned flavor aversion (Garcia et al., 1966), taste aversion therapy, and biofeedback, the combination employed in this invention is not implied by, or even imagined in, the prior art. Among the countless articles in these fields, not even one anticipates the advantages of taste aversion in the treatment of bruxism.
The combination proposed herein relies on different and distinct technical fields.
Although the invention herein employs established technologies, it combines them in a unique way such that the results are greater than their constituent elements.
This invention provides the single most promising approach for inexpensively treating a condition which adversely affects the lives of millions.
Upon further study of the specification and appended claims, additional objects, embodiments, and advantages of this invention will become apparent.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete valuation of the invention and many of its attendant advantages and uses may be realized by reference to the following, sequential views of the preferred embodiment:
FIG. 1 shows a bilaterally-sleeved capsule.
FIG. 2 shows a wrought iron dental appliance.
FIG. 3 shows attachments of a pair of capsules of FIG. 1 to the dental appliance of FIG. 2.
FIG. 4 shows an in-situ placement of the attached capsules and dental appliance of FIG. 3.
REFERENCE NUMERALS IN DRAWINGS
10 small capsule, container, bag, or reservoir
14 constituents of capsule
18 sleeve of capsule
22 posterior rod of a mandibular dental appliance to which a capsule can be attached
26 curl in one posterior rod to prevent slippage of capsule
30 hinge of appliance to secure it to teeth
34 anterior connection of two sides of appliance
DETAILED DESCRIPTION OF THE INVENTION
All the aversive liquids used in the present invention have one characteristic in common: when released into the oral cavity they produce a sensation strong enough to wake up the sleeping bruxist, and to induce immediate rinsing of the mouth and replacement of the punctured bag(s) with new one(s). The same liquids, albeit less aversive, can be used with awake bruxers.
The substances, which can be used singly or in combination, include table salt, onion, garlic, capsaicin and other members of the capsaicinoids family, horseradish (cf. U.S. Pat. No. 5,485,734), mustard, garlic, onion, zingerone, quinine, or denatonium benzoate. The active ingredients of these substances can in some cases be purchased commercially, or they can be directly extracted by using such suitable solvents as ethyl alcohol, vinegar, or water. The choice of substance, dose, and solvent can be tailored to the needs and preferences of each patient. The choice may be determined as well by individual tastes, e.g., a cauliflower extracts for individuals who detest cauliflowers; a saline solution for patients who need not limit their salt consumption and who prefer mildly aversive substances.
In any given case, the choice of substance(s) and their intensity is subject to ongoing revision. If they are too painful, the intensity is reduced or another substance is tried. If the patient wakes up with ruptured, empty capsules (suggesting that the break-up of the capsules failed to induce arousal), the intensity is raised or other substance(s) are tried.
Turning first to FIG. 1, the preferred embodiment discloses one means of enclosing the aversive substance. It involves small polyethylene bags 10 in which the constituents 14 are enclosed. In the preferred treatment, the constituents comprise a sealed liquid capable of waking a user from deep sleep if the bag ruptures under pressure. Not including the sleeves, the bags are approximately 6 to 13 mm wide, 6 to 25 mm long, and 0.04 to 0.1 mm (about 2.7 mil) thick. They contain little or no air. At their center, the liquid is high enough (roughly from 3 to 7 mm) to rupture the bags when the user clenches or grinds, but is not so high as to seriously inconvenience the user or prevent lip contact. Experience suggests that such bags contain enough liquid to reach many taste buds, but not enough to produce discomfort other than the one associated with unpleasant taste. Each bag contains two sleeves 18, one on each side. The sleeves 18 allow the joining of the bags with the dental appliance.
The manufacture of such bags, capsules, and containers is well known in the art. For instance, U.S. Pat. No. 5,208,085 describes a device for deterring vandalism to exposed exterior surfaces; a device consisting of liquid dye-containing plastic nodules which rupture upon impact. Similarly, U.S. Pat. No. 5,137,176 describes a self-defense method which involves a wax capsule containing concentrated citric acid solution which can be inconspicuously carried in the mouth. In the event of an attack, the user chews through the wall of the wax container, releases the citric acid, and expectorates into the eyes of a would be attacker. Similarly in the present invention, the liquid-bearing capsules may be made of wax and other materials.
Turning next to FIG. 2, the invention discloses a dental appliance for securely introducing a pair of objects into the mouth. The appliance is made of two posterior pairs of straight rods 22, of which the exterior one is curled 26 to prevent dislodgment of the bags. Anteriorly, the appliance is provided on each side with a set of soldered four hinges 30 which help keep it comfortably in place. The two sides of the appliance are connected to each other anteriorly 34 to preclude mobility or swallowing of the appliance.
Turning next to FIG. 3, the invention discloses the way the liquid-filled 14 containers 10 of FIG. 1 and the appliance of FIG. 2 are joined.
Turning now to FIG. 4, the invention discloses the way the complete appliance and containers of FIG. 3 fit into a user's mouth. If bruxing is attempted, one or two of the bags 10 burst, releasing their constituents 14 into the mouth. The sleeping patient wakes up, removes the appliance, rinses the mouth with cold water or other soothing liquid, rinses the appliance with detergent or other suitable solvent, rinses with water, replaces the broken bag(s), reinserts the appliance in the mouth, and goes back to sleep. Alternatively, a second appliance may be used to minimize sleep interruption. An awake user similarly becomes aware of bruxing, rinses mouth and appliance, replaces the bags, reinserts the appliance, and resumes normal activities.
Turning to FIG. 1 again, it is clear that the constituents 14 of the small capsules 10 can be made of wax or other pliable materials which can serve to diagnose or confirm bruxing behavior, and which can help convince the patient of the existence of the problem and of the need for treatment.
Turning to FIG. 1 again, it is clear that the constituents 14 of the small capsules 10 can be made of medications and other substances which require sustained intraoral release, such as nitroglycerin or odor-masking substances.
EXAMPLE 1
One Optional, Extensive, Treatment Program
First Interview
When patients show up at the office, they are asked to fill a questionnaire which places particular emphasis on the history of bruxism, food allergies, nutritional preferences, stress level, and tolerance to such substances as hot pepper, horseradish, or salt.
There follows an interview explaining the nature of bruxism, incidence, and putative causes. In an effort to encourage compliance, motivation, and resolve, particular emphasis is placed on expounding the long-term consequences of bruxism. If the patient evinces sufficient interest, this is followed by an explanation of available treatment approaches, their advantages and pitfalls. If the patient opts for the taste-based approach, the prospective substance(s) and their concentrations are chosen through a trial and error process.
Maxillary and mandibular alginate impressions are taken, and a second appointment is scheduled.
Optional: Suspected audible nighttime grinders may be given a sound-activated tape recorder (which is activated at 53 dB or less), asked to use it for 3-5 nights at home, and, on each morning, to listen to it and record the duration of audible grinding. This optional step establishes a baseline. It also serves as an awareness and motivational tool--after listening to oneself grind, one can no longer deny grinding and one gains a better appreciation for the plight of one's sleeping companions.
Second Interview
On the second interview the appliance is fitted. The patient is given a week's supply of waxy pellets and instructed to attach a fresh pair to the appliance every night before going to sleep (for nocturnal bruxers), or at any other time when bruxing is suspected or known to occur. At this time, care of the appliance, and means of disinfecting it, are discussed. At this time as well, grinders return the tape recorders and discuss their grinding log with the clinician.
Third Interview
A week later the patient returns with the waxy pellets and the evidence for bruxism is analyzed by comparing these pellets to unused ones. This step serves to confirm the condition. It also helps to convince the patient that a potentially serious problem exists. The patient proceeds to the treatment phase itself only after clear evidence of bruxing is obtained (flattened and corrugated pellets). Lack of evidence is open to at least two interpretations. First, the patient may not be a bruxer, in which case no treatment is necessary. Second, it is very likely that the introduction of the appliance--just like the introduction of a splint--temporarily diminishes or eliminates bruxing behavior (Rugh et al., 1984). Such patients continue to wear the diagnostic appliance until there is clear indication that bruxing resumes.
If evidence of bruxing is observed, the same dental appliance is fitted with two bags of water and the patient is asked to grind or clench his/her teeth (depending on the suspected problem) to make sure that this causes one of the bags to burst. This is repeated several times. As a final step, the patient attaches the appliance to a pair of bags filled with the agreed-upon aversive liquid, and attempts to grind or clench. If the taste is subjectively deemed not too painful, yet sufficiently strong to wake the patient during sleep (or to draw attention to the problem for a day bruxer), the patient is given a supply of liquid-filled bags and proceeds to the treatment phase.
At-Home Treatment Program
From that point on, the patient's progress is monitored about once a week, typically through phone consultation, e-mail, or face-to-face interviews.
Particular attention is paid throughout the treatment to the capacity of the liquid to wake the patient from deep sleep, and to the similar problem of habituation (but see Green and Lawless, 1991). If the patient wakes in the morning and finds that the bags have ruptured during the night without causing arousal, the intensity of the favor is increased, or a switch is made to a new substance or to a combination of substances.
When a bag ruptures, the sleeping patient wakes up, rinses his/her mouth with cold water, washes the appliance, replaces the bag(s), and goes back to sleep. A wakeful patient is instructed to act in like manner, but to resume his/her prior activities.
If and when bruxism nearly ceases (two or less bursts per week), the patient continues wearing the appliance for a few more months.
Before discontinuing use, the patient reverts for one week to wearing the appliance with the wax pellets. If little or no evidence of bruxism is seen, the treatment discontinues.
If bruxing behavior is suspected to have returned, the prophylactic measures resume.
The present invention focuses on a taste-based procedure of preventing unconscious clenching and grinding. To achieve a more lasting effect, it may sometimes be necessary to combine the taste-based approach with other treatment modalities.
Needless to say, most patients and therapists might skip many of the time-consuming steps above, focusing, rather, on the indispensable elements the my taste-based approach.
EXAMPLE 2
Case History of One Patient
A 51-year-old man had been told by three dentists over a period of twelve years that his molars were showing signs of bruxism. The patient himself was unaware of the problem and his spouse has never heard him grind his teeth. He ignored the problem for a few years, but became concerned when visible damage (flat short back teeth and crowns) became obvious. Four different dental appliances were tried (a partial, a hydrostatic splint, a soft mandibular splint, and a hard maxillary splint), but they were uncomfortable to wear. As well, the mandibular hard splint permanently and irreversibly damaged the patient's occlusion (changing his bite from a near-perfect one to an annoying open bite) and was particularly hard to clean. Still wearing the hard splint, the patient began to experience the characteristic TMD click and sore jaws, especially upon waking. This was followed by frequent and severe short (5 seconds or less) daytime aches inside his right ear. The pain developed in the right ear only and was particularly sharp and intense. There was no associated vertigo. A subsequent examination revealed a modest degree of hearing loss. At this point, the patient sought the advice of two dentists, a family physician, and two ear-nose-throat specialists. Neither the patient nor these specialists traced the bouts of earaches to the known condition of bruxism. Following their recommendations, he had tried ear drops and spice therapy, but declined a recommendation to undergo rhinoplasty.
At that point the patient replaced the traditional splint with our appliance. The first few nights were stressful, but soon he got used to the idea and slept soundly, while the incidence of arousal episodes rapidly declined. By the third month, a bag would explode and wake him up only about twice a week, often at the point of just falling asleep. Although the patient kept careful records, no obvious correlation to emotional stress was discerned in this case. At this writing, the patient has been wearing the appliance for three months, during which time bruxing was impossible and the earaches and sore jaws vanished.
The patient claims a significant improvement in the quality of his life as a result of using our taste-based approach and being able to control, for the first time in twelve or more years, this destructive and frustrating habit. The patient was particularly concerned about the numbing earache, the possibilities of premature hearing loss (which he felt might be traceable to bruxing), developing a temporomandibular disorder (TMD), and continuing to spend thousands of dollars on crowns and fillings, which events now appear far less likely.
No negative side effects are reported in this case, aside from the inconvenience, especially during the second week, of sleep interruptions when the bags burst, and, to a lesser degree, the mild discomfort caused by the spicy liquid itself (pepper-derived capsaicinoids in his case). Because he found the appliance of this invention far more comfortable and hygienic than the mouthguard he was wearing until then, wearing an appliance posed no problems for him.
OTHER APPLICATIONS, VARIATIONS, AND USES OF THE INVENTION
1. It may be impossible, inconvenient, or undesirable in some instances to lodge the unpleasant-tasting liquid in the mouth. If so desired, the container may be located outside the oral cavity and the liquid conveyed into the oral cavity when the patient bruxes. A similar procedure had been described in U.S. Pat. No. 4,535,724, disclosing a device which facilitates horse training through the introduction of sweet and bitter substances into the horse's mouth.
2. Our preferred embodiment employs an all-or-nothing variant: beyond a certain point, the entire contents of one of the bags spill out. In some situations, however, a slow, sustained release under pressure may be preferable. With appropriate modifications well-known in the art, the present invention lends itself readily to such use.
3. In some cases, it may be desirable to employ a different configuration of the liquid-filled containers. One may, for instance, employ one sealed container inside another. The interior container may contain horseradish particles suspended in vinegar, while the exterior, more resilient, container may contain baking soda. If now tooth pressure is applied, the interior container bursts and the vinegar and baking soda chemically react to release carbon dioxide. The gas pressure then (depending on particular design) either expands the bag to uncomfortable proportions without releasing the liquid, or else ruptures and releases the spicy vinegar into the mouth. In either case, the patient wakes up and replaces the bag.
4. While the invention's chief object is a treatment for bruxism, it can be used to prevent teeth grinding and clenching in other circumstances. For instance, it is particularly important, following such surgical procedures as TMJ operations and implantations of artificial teeth, to prevent any pressure on teeth. The appliance described herein can be used to virtually eliminate such pressure.
5. In view of the surprisingly high incidence of bruxism, it may be worth while to prevent the development of the habit in non-bruxers. The taste-based approach described here can be used as a short-term precautionary measure by non-bruxers to reinforce the habit of keeping teeth apart while not chewing or swallowing.
6. U.S. Pat. No. 4,039,653 describes a device for the sustained release of substances required to mask bad breath and for medications such as local anesthetics, antihistamines, and nitroglycerin. The dental appliance described herein, along with its associated sleeved containers, can be used to accomplish the same goal.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and make various modifications. In particular, the types and combinations of unpleasant-tasting substances, the durable but pressure-sensitive containers associated therewith, the dental appliance to which these containers are attached (Tenti, 1986), the therapeutic approach outlined here, and the types and forms thereof, can be varied within a wide range and using many combinations of substances, vessels, appliances, and approaches, without departing from the spirit and scope of the invention. Hence, the foregoing should be construed as merely illustrative and not restrictive of the scope of the invention.
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A new biofeedback modality for the treatment of bruxism. A mildly aversive, safe, liquid is inserted into, and sealed in, small, bilaterally-sleeved, polyethylene capsules. Two capsules are attached to a specially-constructed dental appliance which comfortably and securely places them between the lower and upper teeth. The appliance and capsules are worn at night or at other times when bruxism is suspected to occur. Whenever a sleeping or an awake patient attempts to brux, the capsules rupture and the liquid is released into the mouth. The liquid then draws the patient's conscious attention to, and forestalls, any attempt of teeth clenching or grinding. Variations of the method and device can be used to diagnose bruxism and to sustainably release medications and odor-masking substances into the mouth,.
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FIELD OF THE INVENTION
The invention concerns a method for producing an electrical connection between at least one conductive pad disposed in an insulating body and at least one electrical contact disposed opposite said electrically conductive pad.
It relates in particular to hybrid (contact and contactless) chip cards.
The invention aims to solve a problem of durability of connections between a module and an antenna disposed in a card body.
PRIOR ART
Patent Application FR 2716281-A1 describes a method for producing a chip card, comprising a step of connection of a chip-card module or integrated-circuit chip to an antenna contained in a card body. Various interconnection means used comprise in particular conductive materials, spring blades and springs. These elements are disposed in cavities or orifices extending from the surface of the body as far as the conductive pads.
The connections are made with conductive glue that is disposed in the cavities. These connections are not sufficiently durable with respect to more demanding bending and/or torsion tests on the card, in particular in the banking sector. In particular, with conductive glue, there is a time needed for polymerisation of the glue before testing or use.
Moreover, it is not practical or industrial to use springs that would be disposed in the cavities or orifices described above. Fitting a helical spring in at least one housing poses a problem of manipulation, introduction into the housing, positioning and holding of the springs in the cavities as far as the step of transferring, connecting and fixing the chip or module to the card body.
The cards cannot be manipulated at rates and with the jolts imposed by the production machines. The springs are liable to be ejected during the movement of the cards and there may then be scrapping of cards because of absence of a spring in the housing.
In order to avoid the above drawbacks relating to electrical connections of the soldering type or with conductive material, there exist contactless connections, in particular by electromagnetic coupling, which consist of producing a radio-frequency module, comprising a radio-frequency chip connected to an antenna that is embedded in a card body containing a passive antenna.
A radio-frequency communication satisfying in particular ISO 14443 or the NFC standard is obtained with antenna turns extending substantially over the peripheral circumference of the card body. The passive antenna is electromagnetically coupled with the module antenna. However, there may be problems of range of communication, the metal contact pads being liable to form a screen to the radio-frequency signals.
The invention aims to solve the above drawbacks.
In particular, the invention relates to a method for producing a contactless function on a device with an integrated-circuit chip and where applicable also a contact function, which is resistant to torsion/bending stresses and has good radio-frequency performance.
SUMMARY OF THE INVENTION
The invention consists in its principle of holding an electrical connection via springs and keeping them in place in the cavities at least during the transfers of the cards from station to station during production and without compromising their ability to compress and freedom of movement in a cavity; these abilities are essential to the production of an elastic electrical contact of durable quality. Preferably, the springs are frustoconical and pointed at their ends in order to facilitate introduction thereof into a housing.
To this end, the subject matter of the invention is an electronic device with an integrated-circuit chip comprising an insulating body containing at least one conductive pad, at least one electrical contact opposite said electrically conductive pad, at least one housing in the body, comprising a bottom and an aperture, said housing emerging at the bottom of the conductive pad and emerging at its aperture on the electrical contact, at least one helical spring disposed in the housing and connecting the conductive pad to the electrical contact, said spring comprising a central portion (C) between its two ends.
The device is distinguished in that it comprises centring and/or holding means configured to facilitate the placing of the spring in its housing and/or to hold it at least by friction of the central part (C) of the spring with respect to the wall of its housing.
According to the invention, the device also comprises other features in accordance with claims 2 to 9 .
The subject matter of the invention is also the method according to claim 10 .
DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a contactless chip card (in transverse section through the middle of the chip-card module) according to one embodiment of the invention;
FIG. 2 illustrates an enlargement of the spring in its housing of the previous figure;
FIG. 3 illustrates the spring all alone of the previous figure;
FIG. 4 illustrates a second embodiment of the device connecting a conductive pad with an electrical contact, in which the spring is configured with a centring and/or holding ring;
FIG. 5 illustrates a third embodiment of the device for connecting a pad with an electrical contact, in which the springs are configured with a centring and/or holding plate;
FIG. 6 illustrates a fourth embodiment of the device for connecting a conductive pad with an electrical contact, in which the housing itself is configured to centre and/or hold the spring;
FIG. 7 illustrates a milling cutter suitable for producing portions of the housings in the previous figure, in particular the bottom;
FIG. 8 illustrates a milling cutter suitable for producing a portion of the housings in FIG. 7 , in particular the central wall and the aperture.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a device according to one embodiment of the invention. It comprises an insulating body 2 containing at least one conductive pad 3 , 4 , at least one electrical contact 5 , 6 opposite said electrically conductive pad, at least one housing 7 , 8 in the body, comprising a bottom 9 , 10 and an aperture 11 , said housing emerging onto (or accessing), through its bottom, the conductive pad 3 , 4 and the electrical contact 5 , 6 through its aperture.
The device is here an integrated-circuit chip card 1 of the contactless type. The card 1 comprises a card body 2 made from insulating material, in particular plastics material. The body may be obtained by moulding or cold rolling or hot from several sheets or layers of material with or without adhesives. The electrical contacts and/or the electrically conductive pads are intended to connect an integrated-circuit chip housed in the module.
Where applicable, the electrical contacts 5 , 6 are the pads of an integrated-circuit chip or electronic or electrical component such as a battery, a display, biometric sensor or keypad. The conductive pads 3 , 4 may be those of any circuit, such as an antenna, capacitor, electrical or electronic component, or pads connected to redirection tracks.
The device may be any other device, in particular an electronic passport, provided that electrical contacts under a main surface of a body are to be connected with other contacts through a cavity or orifice.
The conductive pads represent here the terminal portions of a radio-frequency antenna, in particular wound according to ISO 14443, NFC or of the UHF type. The antenna is connected to the two conductive surfaces of the module 21 via the springs 12 and the module comprises an integrated-circuit chip connected to the electrical contacts 5 , 6 . The module may comprise contact pads 46 on the surface carried by a dielectric support 48 , in order to communicate electrically with a terminal with electrical connector.
The device comprises at least one helical spring (a compression spring with non-contiguous turns) 12 , 13 disposed in the housing 7 , 8 and connecting the conductive pad 3 , 4 to the electrical contact 5 , 6 .
In FIGS. 1 to 3 , the spring comprises a central portion C disposed between its two ends 14 , 15 , end turns 19 , 20 of the spring have a degree of freedom along a longitudinal axis Y of the spring to make it possible to compress the spring and provide an elastic electrical-contact force against the contacts to be interconnected.
According to one feature of the invention, the device comprises means 8 , 16 configured to facilitate the placing of the spring and/or to hold at least by friction the central part C of the spring in the cavity.
According to one embodiment, the cross-section Dmin of an end 14 , 15 of the spring is less than that D0 of the aperture of the housing 7 . This facilitates the introduction of the spring into the orifice for receiving the spring or aperture 11 of the housing 7 .
In the example in FIG. 3 , the spring comprises two portions comprising turns the cross-section of which perpendicular to the axis Y decreases from the central part C towards its two ends. The central portion of the spring may comprise one to three turns 16 larger with respect to the others. The central turns 16 have a cross-section or a diameter Dmax greater than the cross-section or diameter Dmin of the ends 14 , 15 of the spring.
Concerning the chip card, for example, the springs have a length of 0.3 to 0.5 mm at rest, the maximum diameter of the spring (Dmax) is between approximately 0.5 and 1 mm and a minimum diameter (Dmin) is between 0.4 and 0.8 mm. Preferably Dmin is 10% to 50% less compared with Dmax.
The central portion of the spring cooperates with the housing in order to hold the spring in the housing at least by friction with the wall of the housing. The central section is substantially equal or slightly greater in order to compress the central turns radially in the housing (perpendicular to the axis Y).
Thus, once the spring is introduced into its housing, it no longer escapes during the various manipulations of the body 2 before making the interconnection with the electrical contacts 5 , 6 , in this case by embedding the module 21 in the card body in order to contain the springs definitively.
Alternatively, the forms relating to the housing and spring may be reversed so as to preserve the freedom of movement of the turns at the ends. The spring may then be cylindrical while the housing may have a cross-section at the bottom and at the aperture greater than the diameter of the spring.
According to another embodiment in FIG. 4 , the housing 7 may comprise a cross-section that broadens in the direction of the bottom and/or its recess from a central section of the spring or housing.
According to another embodiment, the device may comprise a holding or centring element disposed around the spring and between the spring and the wall of the housing and substantially level with the central part.
The element in question may consist of a ring or skirt 43 which, where applicable, may be frustoconical, in order to facilitate the introduction of the spring therein and to facilitate the insertion of the assembly in the aperture 11 of the housing 8 . The housing is in this case cylindrical with a cross-section larger than that of the spring. The skirt is deformable when it is introduced into the housing.
According to another embodiment in FIG. 5 , the holding or centring element 33 is a plate that receives at least two springs. It is intended to be disposed between the plane of the electrical contacts 5 and that of the conductive pads 4 .
The holding or centring element may comprise a central orifice 47 so as to house therein all or part of a component and/or its enrobing. It may comprise a surface corresponding substantially to that of the cavity C 1 . Cylindrical springs or ones such as those in FIG. 1 may be fixed first to a sheet 33 or support plate. The sheet or plate may comprise two orifices 34 , 35 for receiving the springs and a central orifice corresponding to the enrobing 22 of the module. The sheet is then placed in the cavity level with an intermediate plane P 3 between the conductive pads and electrical contacts.
The module is stuck in the cavity C 1 with a hot-melt film 45 . The module may or may not comprise contact pads 46 on the surface. The orifices 35 in the plate may be conical in order to facilitate the introduction of the springs.
Alternatively, the springs are those in FIG. 3 . The advantage of this element is to effect a machining of the cavities more rapidly and to place the two springs in the cavity at the same time in a single operation since they are pre-assembled via a centring plate.
A description will now be given, in relation to FIGS. 1 , 4 , 5 and 6 , of the method of the invention for producing an electrical connection between at least one conductive pad disposed in an insulating body and at least one electrical contact disposed opposite said electrically conductive pad.
The method comprises the steps of creation, in the body 2 , of a housing comprising a bottom and a recess. The housing is intended to afford access to the outside of the conductive pad through the aperture of the housing.
The method comprises the placing of at least one helical spring 12 , 42 in at least one housing 8 , 35 . The spring comprises a central portion (C) between its two ends, end turns 19 , 20 of the spring having a degree of freedom along the longitudinal axis (Y) in order to compress the spring.
Next the conductive pad 4 is transferred and connected to the electrical contact 5 .
Finally, the method according to the invention comprises a step of configuring the springs and/or the housings in order to facilitate the introduction of the spring and to firmly position the central part of the spring in the cavity. This step is implemented with different centring means illustrated below in the figures.
The method described in FIG. 1 has the advantage of not changing the current method for manufacturing hybrid cards with the exception of a particular configuration of the spring with respect to their housing. The form of the spring comprises a doubly frustoconical form, the base of the two truncated cones being level with the central part.
The conical or pointed part of the spring facilitates its introduction and placing in its housing. The electrical contact is concentrated on a smaller surface at the end of the spring for better contact.
The spring is symmetrical while having a conical portion at the two ends that facilitates its manipulation and avoids errors in orientation when it is gripped by automatic machines for transferring the springs into their housing.
In FIG. 4 , the current operating method for manufacturing a hybrid card is not changed but the housings are broadened a little more than the springs and a centring and/or holding element 43 is used between the spring and the wall of the spring housing. The spring is here configured with its centring ring or skirt. The housing is configured (broadened) to the diameter of the ring or at least slightly less (for example 1% to 10%) for gentle clamping.
In FIG. 5 , for housing the spring centring sheet or plate 33 , a cavity (C 1 ) is produced with a plane P 3 . The springs 42 are configured with the plate and the latter cooperates with the wall of the cavity (C 1 ) in order to position the springs with respect to the contacts and pads to be interconnected. A single cavity is obtained with several stages P 1 , P 2 , P 3 configured so as to receive at least the plate supporting the springs.
In FIG. 6 , the spring has the advantage of being standard and cylindrical and the housing of the spring is configured so that it comprises a broadened part at the bottom and at the aperture. To produce the cavity, successive operating steps are implemented by means of the specific milling cutters illustrated in FIGS. 7 , 8 .
Thus, for example, a milling cutter 22 ( FIG. 7 ) is used that has a portion of revolution 23 splayed in the direction of its gripping axis in order to form a step or clearance around the top turns of the spring adjacent to the module. It also comprises a straight portion of revolution 24 substantially less than or equal to the diameter of the spring in order to form at least the central portion C of the spring.
Another milling cutter ( FIG. 8 ) is also used, which comprises an end portion of revolution 26 wider than the cross-section of a cylindrical spring and a straight portion 27 having a cross-section slightly less than that of the spring (for example less by 10%).
In operation, the planes P 1 and P 2 are first of all produced, corresponding respectively to the bottom of the cavity and the bonding plane of the module. The plane P 1 is substantially level with the conductive pads 3 , 4 . Next, the milling cutter 25 is brought level with the conductive pads, and then is moved laterally until the axis of the milling cutter coincides with that of the spring housings in order to form a kind of lug (recess 32 in plan view) at the cavity.
Next, the milling cutter 22 is used above the axis of the housings towards the bottom of the cavity (C 1 ) as far as the level of the conductive pads in order to form both a central portion of the housing and a splayed (conical) aperture of the housing. Thus the spring, of standard shape, can easily be introduced into the aperture. In addition, it is held in place by its central portion, which corresponds substantially to the cross-section of the central portion of the housing. A cavity is obtained that communicates with the housings of the springs.
There is no risk of the spring escaping laterally in the direction of the cavity of the chip through the recess resulting from the machining of the portion 27 of the milling cutter 25 since the diameter obtained is less than that of the spring.
The invention also provides conductive means for improving the electrical contact of the spring with the elements to be connected electrically. The spring may comprise a solder at at least one of its ends in order to solder the conductive pad and/or the electrical contact. The soldering may be effected hot, in particular with tin/lead, or cold with a conductive material or adhesive, optionally with UV polymerisation and retarder or not.
For hot soldering, the invention may make provision for tinning each end contact to which the soldering relates and/or where applicable also the conductive pad and/or electrical contact concerned.
Each spring is placed in its housing and the soldering/brazing of the spring to the conductive pad is obtained by the addition of energy directly to the spring or of the solder in particular by a laser beam.
The soldering/brazing with the electrical contact may be obtained by heating the contact from outside. Where it is a case of a chip-card module, the brazing may be done by heating the module during a phase of hot-melt embedding and hot pressing of the module.
Where applicable, the ends of the spring comprise an anti-corrosion coating that is a good conductor, such as for example gold or nickel/gold.
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A device having an integrated-circuit chip includes an insulating body containing at least one conductive pad, at least one electrical contact opposite the electrically conductive pad, and at least one recess in the body, including a bottom and one aperture. The recess is connected, at the bottom thereof, to the conductive pad and, at the aperture thereof, to the electrical contact. At least one coil spring is arranged in the recess and connecting the conductive pad to the electrical contact. The installation of the spring in the recess is facilitated by means of the friction of the central portion of the spring relative to the walls of the recess. The invention also relates to a method for producing an electrical connection between at least one conductive pad arranged in an insulating body and at least one electrical contact arranged opposite the electrically conductive pad.
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BACKGROUND
This disclosure relates to a metering valve for a fuel metering system.
Gas turbine engines are known, and typically include a compressor compressing air and delivering it to a combustor. The compressed air is mixed with fuel in the combustor, combusted, and the products of combustion pass downstream over turbine rotors, driving the rotors to create power.
The metering valve provides metered flow to the combustor, provides position feedback to the full authority digital engine controller (FADEC), moves in response to a FADEC command, shuts fuel flow off in response to a FADEC command and provides pressure signals to various fuel system components.
SUMMARY
In one exemplary embodiment, a metering valve for a gas turbine engine fuel system includes a sleeve including first, second, third, fourth, fifth and sixth ports respectively axially spaced apart from one another. A spool is slidably received in the sleeve and includes first, second and third seal lands. The first seal land selectively connects the first and second ports to one another, and the third seal land selectively connects the third and fourth ports to one another and the fifth and sixth ports to one another.
In another exemplary embodiment, a fuel system for a gas turbine engine includes a pump configured to pump fuel from a tank. A metering valve is fluidly connected to and arranged downstream from the pump. The metering valve includes a sleeve including first, second, third, fourth, fifth and sixth ports respectively axially spaced apart from one another. A spool is slidably received in the sleeve and includes first, second and third seal lands. The first seal land selectively connects the first and second ports to one another, and the third seal land selectively connects the third and fourth ports to one another and the fifth and sixth ports to one another. The first and fourth ports are fluidly connected to one another irrespective of spool position. The second port is fluidly connected to and downstream from the pump.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is a schematic of a portion of a fuel system for a gas turbine engine.
FIG. 2A is a cross-sectional view of a metering valve with a housing, sleeve and spool.
FIG. 2B is a perspective view of the sleeve illustrating various ports.
FIG. 3A is a cross-sectional view of the metering valve with the spool in a position permitting partial flow through a P 2 port in the sleeve.
FIG. 3B is a cross-sectional perspective view of the metering valve with the spool in a position permitting flow through a P 2 port in the sleeve to a PGI port.
FIG. 4A is a cross-sectional view of the metering valve with the spool in the position fully blocking flow through the P 2 port.
FIG. 4B is a cross-sectional view of the metering valve with the spool in the position permitting full flow through the P 2 port.
FIG. 5A is a cross-sectional perspective view of the metering valve with the spool in a position permitting flow through a PR port in the sleeve to a BDCV port.
FIG. 5B is an enlarged cross-sectional perspective view of the metering valve illustrating the unblocked BDCV port.
FIG. 6 graphically depicts the flow regulating area of various ports at particular spool positions; graph A depicts the flow regulating area connecting the P 1 and P 2 ports; graph B depicts the flow regulating area connecting the P 2 and PGI ports; graph C depicts the flow regulating area connecting the PR and BDCV ports.
DETAILED DESCRIPTION
A highly schematic view of a fuel system 10 for a gas turbine engine 30 is shown in FIG. 1 . It should be understood that various fluid connections and components are omitted from the schematic for clarity. The fuel flowing in the various lines within the system 10 are labeled with the prefix “P.”
The system 10 includes a pump 14 that pumps fuel from a tank 12 . Fuel from the pump 14 flows through the main filter 18 to the metering valve (MV) 26 and the pressure regulating valve (PRV) 28 . The pump 14 also supplies fuel PFA to fueldraulic actuators 21 and the servo pressure regulator (SPRV) 24 .
Upstream fuel P 1 from the pump 14 is provided to a metering valve (MV) 26 . The MV 26 is responsive to main gear pump inlet fuel PGI, SPRV regulated pressure fuel PR, and a modulated pressure PM. The regulated pressure fuel PR is provided by a servo pressure regulator (SPR) 24 that is responsive to the main gear pump inlet fuel PGI and pump outlet fuel PFA. The modulated pressure PM is from a servo valve 22 that responds to FADEC commands for positioning the MV 26 . The MV 26 produces a downstream pressure P 2 that is provided to the engine combustor. The PRV 28 is also responsive to the upstream fuel P 1 via port 44 and downstream fuel pressure P 2 via port 42 to produce a bypass flow, discharge pressure fuel PDI. This bypass flow is sent to a bypass directional control valve (BDCV) 32 , which sends the bypass flow back to one of two possible low pressure locations upstream of the pump, depending on the state of the BDCV. The BDVC 32 is also responsive to the pressure regulator fuel PR, the PBDCV signal from the MV and PGI.
The ports and their respective flow directions are shown in FIGS. 2A and 2B . A FADEC 39 is in communication with the MV 26 through a servo valve 22 which positions the MV using the modulated pressure PM. The FADEC also receives MV position information through an LVDT connected to the MV.
The MV 26 includes a housing 34 , which contains various fuel lines, schematically depicted in FIG. 1 . A sleeve 36 is received in the housing 34 and sealed relative thereto by seals, such as O-rings, to fluidly separate the fuel inlets and outlets provided in the housing 34 . A spool 38 is slidably received within the sleeve 36 and is responsive to fuel pressures acting on the spool 38 to selectively communicate fuel to various components within the system 10 . To this end, the spool 38 includes first, second and third seal lands 56 , 58 , 60 . The first and third seal lands 56 , 60 selectively block and unblock some of the ports 40 - 54 .
Referring to FIG. 3A , the sleeve 36 includes a first P 1 port selectively in fluid communication with the first P 2 port 42 . In particular, the first seal land 56 selectively fluidly connects the first P 1 port through the annular space between the first and second seal lands 56 , 58 when the first seal land 56 moves from the fully blocked position ( FIG. 4A ) to the fully open position ( FIG. 4B ). The timing of this event is determined in part by the first diameter D 1 , first W 1 and position L 1 of the first seal land 56 relative to the left end of the spool 38 . In the example, the ratio L 1 /W 1 is 1.40-1.50, and for example, 1.44; the ratio W 1 /D 1 is 0.58-0.68, and for example, 0.63.
The second P 2 port 46 is fluidly connected to the first P 2 port 42 through housing plumbing lines.
The first P 2 port 42 includes two windows having a total area of 0.261 inch 2 (0.66 cm 2 ) with axially elongated portions that permits a gradual flow (as the spool 38 moves from right to left in the figure) before becoming fully opened, as graphically depicted in FIG. 6A . The first P 1 port 40 includes four windows that are generally rectangular in shape to maximize flow through the port during the entire opening stroke of the spool 38 . The first P 1 port 40 includes a total area of 1.712 inch 2 (4.35 cm 2 ).
Referring to FIG. 3B , the second P 2 port 46 and the PGI port 48 are fluidly connected (with the spool 38 all the way to the right in the figure) and the first P 2 port 42 fully blocked. In this position, the BDCV port 50 is blocked by the third seal land 60 . The third seal land 60 is at a second position L 2 from the left end and includes a second width W 2 and a second diameter D 2 . The ratio of D 2 /W 2 is 6.32-6.42, and for example, 6.37; the ratio of W 2 /D 2 is 0.95-1.10, and for example 1.05. The timing of the fluid connection and change in flow regulating area between the second P 2 port 46 and the PGI port 48 is graphically shown in FIG. 6B .
Referring to FIGS. 5A and 5B , the PR port 52 and the BDCV port 50 are fluidly connected with the spool 38 to the left. The BDCV port 50 is rectangular in shape to maximize flow through the port. The total area of the BDCV port 50 is less than the total area of the PR port 52 . The timing of the fluid connection and change in flow regulating area between the PR port 52 and the BDCV port 50 is graphically shown in FIG. 6C .
Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For example, part areas may be within +/−5% of the specified areas. For that reason, the following claims should be studied to determine their true scope and content.
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A metering valve for a gas turbine engine fuel system includes a sleeve including first, second, third, fourth, fifth and sixth ports respectively axially spaced apart from one another. A spool is slidably received in the sleeve and includes first, second and third seal lands. The first seal land selectively connects the first and second ports to one another, and the third seal land selectively connects the third and fourth ports to one another and the fifth and sixth ports to one another.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of provisional patent application Ser. No. 61/122,392, filed 2008 Dec. 14 by the present inventor.
BACKGROUND
Prior Art
The following is a tabulation of some prior art that presently appears relevant:
U.S. Patents
Pat. No.
Kind Code
Issue Date
Patentee
2,692,430
A
1954-10-26
Kraft et al.
3,187,432
A
1965-06-08
Cuomo
3,277,574
A
1966-10-11
Giasi
3,980,235
A
1976-09-14
Kuhlman
4,599,928
A
1986-07-15
Oker
4,620,838
A
1986-11-04
Miller et al.
4,646,602
A
1987-03-03
Bleick
5,425,307
A
1995-06-20
Rush et al.
5,723,158
A
1998-03-03
Fager et al.
5,967,434
A
1999-10-19
Virk
6,340,490
B1
2002-01-22
Owens
6,561,067
B2
2003-05-13
Arrasmith
6,549,823
B1
2003-04-15
Hicks et al.
D537304
S
2007-02-27
Wong et al.
7,377,201
B2
2008-05-27
Chen
7,429,010
B2
2008-09-30
McCormick et al.
NONPATENT LITERATURE DOCUMENTS
Viking Machine & Design, Inc., http://www.vikingmachine.com/bluecheese.html, “Blue Cheese→Specialty Blue Cheese Equipment→Cheese Crumbler”.
Cabinplant A/S, http://www.cabinplant.com/products_solutions/select_a_processmachine/cutting_and_trimming/cheese_dicer/, “PRODUCTS AND SOLUTIONS→Cutting and trimming→Cheese dicer”.
Urschel Laboratories, Inc., http://www.urschel.com/Model_RAD — 9229bc966a962c135f3b6f.html “Machines→Dicers→Model RA-D Dicer”.
There are a number of popular cheeses that are typically served in crumbled form. Several examples are feta cheese, blue cheese, and Gorgonzola cheese. These cheeses are typically crumbled by hand, a process which can be messy as well as difficult to control. This is especially inconvenient at the serving table, since the person crumbling the cheese has to leave the table to clean their hands, both before and after doing the crumbling.
There are no products currently available which can be used in a kitchen or serving table environment which produce irregularly shaped cheese crumbles such as those that would be produced by hand crumbling. The existing products for processing cheese in a kitchen or at a serving table employ either a grating or slicing action. Cheese graters or shredders, such as in U.S. Pat. No. 5,967,434 (1999), U.S. Pat. No. 4,620,838 (1986), and D537,304 (2007), even when used with the largest available holes, will produce long, thin slices of cheese as opposed to crumbles. Portable cheese cutters employing wires or blades, such as in U.S. Pat. No. 3,277,574 (1966), U.S. Pat. No. 4,599,928 (1986), and U.S. Pat. No. 4,646,602 (1987), produce uniform slices or cubes of cheese. Many of these portable devices must be placed on a surface for proper operation, preventing the disbursement of the crumbled cheese particles directly onto a dining plate or into a food container.
There are a number of patents on cheese processing devices and machines that are designed for use in a commercial food processing and manufacturing setting. These devices are not portable for use at a serving table or a typical home or restaurant kitchen, and usually require electric motors in their operation. Many of these devices, such as in U.S. Pat. No. 2,692,430 (1954), U.S. Pat. No. 3,187,432 (1965), U.S. Pat. No. 3,980,235 (1976), U.S. Pat. No. 5,723,158 (1998), U.S. Pat. No. 6,340,490 (2002), U.S. Pat. No. 6,561,067 (2003), U.S. Pat. No. 6,549,823 (2003), and U.S. Pat. No. 7,377,201 (2008), employ blades, wires, or shredders to process the cheese in such a way that they are not capable of producing irregularly shaped cheese particles. U.S. Pat. No. 5,425,307 (1995) and U.S. Pat. No. 7,429,010 (2008) present devices which can produce irregularly shaped cheese particles. However, in addition to not being portable for use at serving tables and typical home or restaurant kitchens, these devices employ a series of knife assemblies which do not perform a hand-crumbling type of action.
There are several commercially available products that feature the ability to dice or crumble cheeses that are normally served in a crumbled form, such as the Cheese Crumbler from Viking Machine, the Cheese Dicer from Cabinplant, and the Model RA-D Dicer from Urschel Laboratories. All of these products are large, non-portable, motor-driven machines designed for use in a commercial setting, and all of them use cutting blades or screens which do not perform a hand crumbling type of action.
Another drawback of the commercial food processing devices is that many of them contain numerous moving parts, are large in size, and contain electric motors that are required in their operation. This combination of attributes make the devices difficult to clean, inconvenient to store, and expensive to manufacture, maintain, and ship.
As I have described, the patented and/or commercially available devices for reducing cheese to small particles suffer from some or all of the following disadvantages:
(a) The processing of the cheese is performed using wires, knife assemblies, or grating surfaces which cut the cheese into uniformly sized and regularly shaped particles that do not match the irregularly shaped particles produced by a hand crumbling action. (b) The devices require an electric motor or other type of powered actuator in their operation. (c) The devices are large, complex machines designed for use in a commercial food processing setting and are not easily portable. (d) The devices have many moving parts and are complicated and expensive to manufacture, clean, maintain, and ship. (e) The devices must be placed on a surface for proper operation, preventing the disbursement of the cheese directly onto a plate or other container of food. (f) The employment of motors or other powered actuators, as well as cutting blades or wires can make the devices dangerous to operate if proper safety procedures are not followed.
SUMMARY
In accordance with one embodiment a cheese crumbling device consists of a tapered chute, with a larger opening on the top and a smaller opening on the bottom, containing two opposing plates with smooth, rounded, finger-like protrusions on the inside of the chute, one stationary and one that is moved up and down in the chute by the user of the device. Cheese or other food that is placed into the top of the chute is processed into progressively smaller particles until it falls out the bottom of the chute.
ADVANTAGES
Accordingly several advantages of one or more aspects are as follows: cheese is processed into crumbles that are similar in consistency to hand-crumbled cheese, the device is safe and easy to operate, the device is easily portable for use at a serving table or typical home or restaurant kitchen, the operator's hands are kept clean while crumbling cheese, crumbled cheese particles can be dispensed directly onto dining plates or into food containers, and the device is easy to clean. Other advantages of one or more aspects will be apparent from a consideration of the drawings and ensuing description.
DRAWINGS
Figures
In the drawings, closely related figures have the same number but different alphabetic suffixes.
FIG. 1 shows a perspective view of a cheese crumbling device, in accordance with one embodiment.
FIG. 2A shows a side view of a cheese crumbling device with the side panel of the chute removed so that the plates with protrusions are visible inside the chute, in accordance with the embodiment shown in FIG. 1 .
FIG. 2B shows the same view and embodiment as in FIG. 2A , with one of the plates moved upwards relative to the other plate.
FIG. 2C shows the same view and embodiment as in FIG. 2A , with the spacing between the plates increased.
FIGS. 3A-3E show a perspective view of one of the plates, with features located on the surface of the plate selected from the group consisting of protrusions, recesses, ridges, grooves, and mixtures thereof, all having smooth, rounded, finger-like shapes, in accordance with the embodiment shown in FIG. 1 .
FIG. 4A shows a front view of a cheese crumbling device that is operated by sliding the moving handle in an up-and-down motion, in accordance with the embodiment shown in FIG. 1 .
FIG. 4B shows a front view of a cheese crumbling device that is operated by sliding the moving handle in a side-to-side motion, in accordance with a second embodiment.
FIG. 4C shows a front view of a cheese crumbling device that is operated by sliding the moving handle in a diagonal motion, in accordance with a third embodiment.
FIG. 5A shows a perspective view of a cheese crumbling device where the moving plate is integrated into the chute structure and in the down position, in accordance with a fourth embodiment.
FIG. 5B shows the same view and embodiment as in FIG. 5A , with the moving plate in the up position.
FIG. 6 shows a perspective view of a cheese crumbling device where both plates are integrated into the chute structure, in accordance with a fifth embodiment.
FIG. 7 shows a front view of a cheese crumbling device that is operated by turning the moving handle in a circular motion, in accordance with a sixth embodiment.
FIG. 8 shows a perspective view of one of the plates having a circular shape, in accordance with the embodiment shown in FIG. 7 .
FIG. 9 shows a perspective view of a cheese crumbling device that is operated by using a motor, in accordance with a seventh embodiment.
FIG. 10 shows a side view of a cheese crumbling device mounted on a stand, in accordance with the embodiment shown in FIG. 1 .
REFERENCE NUMERALS
10
Chute
20
Input
30
Output
40
Stationary handle
50
Moving handle
60
Stationary plate
70
Moving plate
80
Protrusion
81
Recess
82
Ridge
83
Groove
90
Slot
100
Gap control screw
110
Hinge
120
Stand
125
Connector
130
Motor
140
Switch
150
Three-sided housing
155
Track
160
Two-sided housing
DETAILED DESCRIPTION
FIGS. 1 , 2 A-C, 3 A-E, 4 A, 10 —First Embodiment
One embodiment of the device is illustrated in FIGS. 1 (perspective view), 2 A-C (side view), and 4 A (front view). A chute 10 has a larger opening that is used as the input 20 at the top and a smaller opening that is used as the output 30 at the bottom. A stationary plate 60 is covered with a plurality of features selected from the group consisting of protrusions 80 , recesses 81 , ridges 82 , grooves 83 , and mixtures thereof, all having smooth, rounded, finger-like shapes ( FIGS. 3A-E ). Stationary plate 60 is attached to one side of the inside of chute 10 , and completely covers the width and mostly covers the height of that side. A stationary handle 40 is attached to the outside of chute 10 , on the same side as stationary plate 60 . A moving plate 70 is covered with a plurality of features selected from the group consisting of protrusions 80 , recesses 81 , ridges 82 , grooves 83 , and mixtures thereof, all having smooth, rounded, finger-like shapes. Moving plate 70 moves up ( FIG. 2B ) and down ( FIG. 2A ) on the inside of chute 10 on the opposing side from stationary plate 60 , and completely covers the width and mostly covers the height of that side. A moving handle 50 on the outside of chute 10 is attached to moving plate 70 through slot 90 . A gap control screw 100 adjusts the distance between moving plate 70 and stationary plate 60 ( FIGS. 2A and 2C ) at the bottom of chute 10 . A set of hinges 110 connect moving handle 50 to moving plate 70 and allow the angle between moving plate 70 and the side of chute 10 to change when gap control screw 100 is turned.
As shown in FIG. 10 , the device can be attached to an optional stand 120 using one or more connectors 125 . Stand 120 is weighted sufficiently to hold the device in place when moving handle 50 is moved up and down.
Operation—FIGS. 2 A-C, 4 A, 10
A typical mode of operation of this embodiment of the device is as follows: a chunk of cheese or other food is placed into input 20 of chute 10 . The user holds stationary handle 40 with one hand and moves moving handle 50 up and down in slot 90 ( FIG. 4A ) with the other hand. FIG. 2A shows moving handle 50 in the down position and FIG. 2B shows moving handle 50 in the up position. The cheese is rubbed by protrusions 80 on stationary plate 60 and moving plate 70 . Protrusions 80 break down the cheese into progressively smaller particles as the cheese moves down chute 10 . Once the crumbled cheese particles are small enough to fit through the gap between stationary plate 60 and moving plate 70 at the bottom of chute 10 the particles drop through output 30 .
By turning gap control screw 100 , which changes the size of the gap between stationary plate 60 and moving plate 70 , the user can control the size of the particles that are produced by the device. FIG. 2C shows moving plate 70 moved further away from stationary plate 60 than in FIG. 2 A.
The device is sized appropriately to allow it to be held and used by a person at a serving table or in a home or restaurant kitchen, and easily cleaned in a kitchen sink or a dishwasher.
When the device is attached to stand 120 with connectors 125 ( FIG. 10 ), chute 10 is held in place by stand 120 while the user moves moving handle 50 up and down in slot 90 . The device is operated with one hand in this mode of operation.
FIG. 4 B—Second Embodiment
An additional embodiment is shown in FIG. 4B . In this embodiment slots 90 have a horizontal orientation, allowing the device to be operated by sliding moving handle 50 in a side-to-side motion.
FIG. 4 C—Third Embodiment
An additional embodiment is shown in FIG. 4C . In this embodiment slots 90 have a diagonal orientation, allowing the device to be operated by sliding moving handle 50 in a diagonal motion.
FIGS. 5 A, 5 B—Fourth Embodiment
An additional embodiment is shown in FIGS. 5A and 5B . In this embodiment moving plate 70 is attached to three-sided housing 150 to form a structure with a chute shape. Moving plate 70 is attached using tracks 155 which allow moving plate 70 to slide up and down for proper operation of the device. FIG. 5A shows moving plate 70 in the down position and FIG. 5B shows moving plate 70 in the up position.
FIG. 6 —Fifth Embodiment
An additional embodiment is shown in FIG. 6 . In this embodiment moving plate 70 and stationary plate 60 are attached to two-sided housing 160 to form a structure with a chute shape. Moving plate 70 is attached using tracks 155 which allow moving plate 70 to slide up and down for proper operation of the device.
FIGS. 7 , 8 —Sixth Embodiment
An additional embodiment is shown in FIGS. 7 and 8 . In this embodiment the lower portion of chute 10 has a semicircular shape and moving plate 70 and slot 90 have a circular shape. The device is operated by turning moving handle 50 in a circular motion.
FIG. 9 —Seventh Embodiment
An additional embodiment is shown in FIG. 9 . In this embodiment a motor 130 is attached to chute 10 on the side with moving handle 50 . When turned on with switch 140 , motor 130 moves moving handle 50 up and down, replacing the manual motion provided by the user in the other embodiments described here. Motor 130 can be detached from chute 10 , allowing the device to be submerged in water or placed in a dishwasher for cleaning.
When this embodiment is used with stand 120 , the user does not have to hold the device at all, freeing their hands for other activities such as feeding cheese into input 20 or holding dining plates or food containers under output 30 .
Advantages
From the description above, a number of advantages of some embodiments of my cheese crumbling device become evident:
(a) The size and operating method of the device allow it to be used to efficiently crumble cheese in a home or restaurant kitchen during food preparation. (b) The crumbled food particles can be dispensed directly onto dining plates or food containers in the kitchen or at the serving table. (c) The user of the device can keep their hands clean while crumbling cheese. (d) The protrusions on the opposing plates provide a similar crumbling action to a person crumbling cheese with their fingers, resulting in a crumble consistency similar to hand-crumbled cheese. (e) The desired crumbled food particle size is selectable by the user. (f) The device is safe and easy to operate, with no knife assemblies, wires, shredding cutters, or grating cutters that can injure the user. (g) The device can be used by multiple people to dispense crumbled food particles directly onto their dining plates, without any of the users touching the cheese, preventing the spread of germs. (h) The user can stop crumbling once they have a sufficient amount of cheese on their dining plate, then invert the device to remove the uncrumbled cheese, preserving it for later use. (i) The device can be placed on a stand or used with a motor for easy one-handed operation, or can be placed on a stand and used with a motor for hands-free operation. (j) The compact size and light weight of the device allow it to be easily stored and conveniently used in a kitchen or at a serving or eating table, as well as easily packed and shipped. (k) The device is easy to clean, durable, and dishwasher-safe.
CONCLUSION, RAMIFICATIONS, AND SCOPE
As shown in the various embodiments of the cheese crumbling device described here, the device allows the user to quickly and efficiently crumble popular cheeses such as blue cheese, feta cheese, and Gorgonzola cheese while keeping their hands clean. The crumbles are produced with a motion and surfaces that simulate hand-crumbling. The surfaces used to crumble the cheese are safe for the user, as they do not perform any type of cutting action. The compact size and simple construction of the device allow it to be easily manufactured, shipped, cleaned, maintained, and stored. The compact size also allows the device to be easily used at a serving table or in a typical home or restaurant kitchen.
The size of the crumbled cheese particles produced by the device is easily selectable by the user by turning a conveniently located gap control screw. The device can be place on an optional stand for easy one-handed operation, and a motor can be used in place of manual operation to actuate the crumbling action. When the stand and motor are used in combination, the device does not need to be held at all by the user while it is operating.
Although the description above contains many specificities, these should not be construed as limiting the scope of the embodiments but as merely providing illustrations of some of several embodiments. For example, the specific motions of the moving plate that are described can be used in various combinations to achieve a similar crumbling action; the rounded protrusions, recesses, ridges, and grooves shown in the figures can be replaced with a variety of alternately shaped protrusions, recesses, ridges, and grooves, as long as the smooth, rounded surfaces of the features, required to provide a hand crumbling action, are maintained; the gap control screw can be replaced with other mechanisms for controlling the spacing between the plates such as an adjustable lever arm, positionable bearings, or swappable spacers which vary in size; the handles can be attached in different orientations; different patterns of protrusions, recesses, ridges, and grooves can be used on the opposing plates; the device can be used to crumble other types of foods or materials with similar consistency as the cheeses mentioned above.
Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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An apparatus and method for crumbling a food product such as a block of cheese into irregularly shaped food particles. One embodiment of the apparatus consists of a chute-shaped housing that contains two opposing plates with a plurality of smooth, rounded, finger-like protrusions on their faces, where the plates are closer together towards the bottom of the chute. When food is inserted into the top of the chute and one of the plates is moved in an up-and-down motion, the protrusions on the opposing plates crumble the food into progressively smaller food particles until the crumbled particles drop through the gap between the bottoms of the plates and out the bottom of the chute. Other embodiments are described and shown.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an optical scanner with a heat transfer function and an image forming apparatus including the same, such as a digital copier or a laser printer.
[0003] 2. Description of the Related Art
[0004] Image forming apparatuses are increasingly capable of producing images with higher speed and higher density. Accordingly, image forming apparatuses are equipped with optical scanners including polygon scanners that rotate at a rotational speed of 30,000 rpm-50,000 rpm.
[0005] When polygon scanners rotate at high speed, heat is generated due to friction of a rotation driving unit. Furthermore, the current increases in the circuit, which causes even more heat. As a result, the temperature near the polygon scanner rises. Moreover, a hissing sound caused by the rotation of a polygon mirror becomes louder.
[0006] Optical boxes are often made by molding a low-cost resin material. However, because thermal conductivity of resin is low, it is difficult for heat to be released outside from such an optical box made of resin, when the temperature rises near the polygon scanner. This shortens the service life of the polygon scanner and/or deforms the optical box and/or an imaging element, thus degrading optical properties.
[0007] One approach is disclosed in Patent Document 1. Specifically, a deflector (rotating mirror) is covered by an aluminum die-cast cap in such a manner that part of the cap is exposed to the atmosphere outside an optical scanner. However, such a metal cap is extremely expensive. Furthermore, the deflector is usually arranged in the center of the optical scanner in a main scanning direction. Therefore, it is difficult to lay out a flow passage such that airflow for cooling the exposed part of the cap is guided toward the cap and the warmed air colliding against the cap is released outside.
[0008] In one example of an optical scanner, plural light fluxes from different directions are incident on one deflector and are deflected by the deflector. The light fluxes then pass through plural imaging elements arranged substantially symmetrically with respect to the deflector to scan plural surfaces (imaging surfaces). In such an optical scanner, the deflector is arranged in the center of a large area of the optical scanner. Therefore, it is extremely difficult to secure a sufficient amount of space for installing a duct and a fan for guiding airflow toward the deflector. Accordingly, even if extra funds are spent and a large space is reserved for providing radiating fins near the deflector, a sufficient cooling effect cannot be achieved. Furthermore, in an effort to reduce the size of the image forming apparatus, components are increasingly being arranged close to each other, which is disadvantageous in terms of the layout for heat radiation. Moreover, the usage of a cooling fan increases power consumption and generates noise, which have a great impact on the environment.
[0009] Meanwhile, in a method disclosed in Patent Document 2, the space around the deflector is not enclosed, so that the air in the entire space inside an optical scanner can be mixed with airflows generated by the rotation of a deflector. Therefore, the temperature of the deflector does not rise. However, in this method, the warmed air near the deflector is directly blown onto a scanning imaging element, and the temperature inside the entire optical scanner changes rapidly. As a result, the scanning imaging element may be deformed due to changes in the temperature, and optical properties are considerably degraded due to changes in the positions and/or tilt angles of the optical elements. Furthermore, the hissing sound caused by the rotation of the deflector is not sufficiently reduced, and the noise can be heard outside the optical scanner.
[0010] Patent Document 1: Japanese Laid-Open Patent Application No. H9-105881
[0011] Patent Document 2: Japanese Laid-Open Patent Application No. 2005-92119
SUMMARY OF THE INVENTION
[0012] The present invention provides an optical scanner and an image forming apparatus including the same in which one or more of the above-described disadvantages are eliminated.
[0013] A preferred embodiment of the present invention provides an optical scanner in which the inside of the optical scanner can be cooled at low cost and a hissing sound caused by the rotation of a deflector can be sufficiently reduced.
[0014] An embodiment of the present invention provides an optical scanner including a light source configured to emit a light beam; a deflector configured to deflect the light beam emitted by the light source; a scanning imaging element configured to image and scan the light beam deflected by the deflector as a light spot on an imaging surface; and an optical box configured to contain at least the deflector and the scanning imaging element, the optical box being substantially sealed from outside; wherein the deflector is substantially sealed so as to be substantially insulated from the scanning imaging element in the optical box, and among outer walls of the optical box insulating a space inside the optical box from the outside, at least an outer wall positioned above the deflector includes an upside-down U-shaped cross-sectional shape portion.
[0015] An embodiment of the present invention provides an optical scanner including a light source configured to emit a light beam; a deflector configured to deflect the light beam emitted by the light source; a scanning imaging element configured to image and scan the light beam deflected by the deflector as a light spot on an imaging surface; and an optical box configured to contain at least the deflector and the scanning imaging element, the optical box being substantially sealed from outside; wherein the deflector is substantially sealed so as to be substantially insulated from the scanning imaging element in the optical box, and among outer walls of the optical box insulating a space inside the optical box from the outside, at least an outer wall positioned above the deflector is made of a material that has higher heat conductivity than the other outer walls.
[0016] An embodiment of the present invention provides an optical scanner including a light source configured to emit a light beam; a deflector configured to deflect the light beam emitted by the light source; one or more scanning imaging elements configured to image and scan the light beam deflected by the deflector as a light spot on an imaging surface; and an optical box configured to contain at least the deflector and the one or more scanning imaging elements; wherein the deflector is substantially sealed so as to be substantially insulated from the one or more scanning imaging elements in the optical box, and among the one or more scanning imaging elements, at least a scanning imaging element arranged near the deflector is made of a resin material and a bottom side thereof is spaced apart from the optical box with a gap therebetween.
[0017] According to one embodiment of the present invention, a deflector is substantially sealed to be insulated from scanning imaging elements, so that the inside of an optical scanner can be cooled at low cost by taking advantage of natural convection generated within the optical scanner, and hissing sounds generated by the deflector can be sufficiently reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:
[0019] FIG. 1 is a perspective view of an optical scanner according to a first embodiment of the present invention;
[0020] FIG. 2 is a diagram of a deflector cover;
[0021] FIG. 3 is a cut-away side view in a sub scanning direction of the optical scanner according to the first embodiment of the present invention;
[0022] FIG. 4 is a detailed diagram illustrating the surroundings of a deflector of the optical scanner according to the first embodiment of the present invention;
[0023] FIG. 5 is a detailed diagram illustrating the surroundings of a deflector of an optical scanner according to a second embodiment of the present invention;
[0024] FIG. 6 is a top cover used in the optical scanner according to the second embodiment of the present invention;
[0025] FIG. 7 is a detailed diagram illustrating the surroundings of the deflector of the optical scanner according to the second embodiment of the present invention, in which a top cover sheet metal part includes slanted sections; and
[0026] FIG. 8 is a detailed diagram illustrating the surroundings of a deflector of an optical scanner according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] A description is given, with reference to the accompanying drawings, of an embodiment of the present invention.
[0028] An optical scanner according to a first embodiment of the present invention is described with reference to FIGS. 1-4 . FIG. 1 is a perspective view of the optical scanner according to the first embodiment, FIG. 3 is a cut-away side view in a sub scanning direction, and FIG. 4 is a detailed diagram illustrating the surroundings of a deflector 407 . Referring to FIG. 1 , light fluxes irradiated from four light source units 406 a - 406 d pass through a cylindrical lens 410 and reach a deflector 407 . The light fluxes are deflected by the deflector 407 , which is a rotating polygon mirror. The light fluxes are imaged and scanned on four photoconductors 413 B, 413 C, 413 M, 413 K by first scanning imaging elements 411 and second scanning imaging elements 412 . FIG. 3 illustrates optical paths from the deflector 407 to the photoconductors 413 B- 413 K on which the light fluxes are imaged. After being deflected by the deflector 407 , each of the light fluxes passes through corresponding mirrors 414 (among a total of 3×4=12 mirrors) and a corresponding light irradiating window 422 (covered with dust-proof glass), and reaches a corresponding photoconductor ( 413 B- 413 K). The rotating polygon mirror (deflector 407 ) and the first scanning imaging elements 411 are each configured with two levels, including an upper level arranged on a lower level.
[0029] As shown in FIG. 1 , the 12 mirrors 414 are bridged across a front plate 401 and a rear plate 402 made of sheet metal, and supported therebetween. The mirrors 414 are pressed with springs into holes formed in the front plate 401 and the rear plate 402 so as to be fixed therebetween.
[0030] The front plate 401 and the rear plate 402 are connected to a left plate 403 and a right plate 404 to surround the side surface of the optical scanner. Furthermore, the top and the bottom of the optical scanner are covered by the bottom surface of an internal housing 405 , two bottom covers 408 a , 408 b , and a top cover 416 , so that the optical scanner is substantially sealed and separated from outside.
[0031] The internal housing 405 is made of resin. The light source units 406 a - 406 d , the cylindrical lens 410 , the deflector 407 , and the first scanning imaging elements 411 are held inside the internal housing 405 . The internal housing 405 is bridged across the front plate 401 and the rear plate 402 and held therebetween. The deflector 407 is surrounded by ribs and shield glasses 409 a , 409 b , which are formed integrally with the internal housing 405 . Furthermore, a deflector cover 418 (see FIG. 2 ) made of sheet metal is screwed to the internal housing 405 , so that the top of the deflector 407 is also covered. Accordingly, the deflector 407 is insulated (tightly sealed) from the other spaces within the optical scanner. This sealed space around the deflector 407 is hereinafter referred to as a “deflector room”.
[0032] When the optical scanner is operating, i.e., when the deflector 407 is driven, the bearings and the driving IC of the deflector 407 generate heat. Therefore, the temperature of air inside the deflector room rises. As a result, the temperature of the shield glasses 409 a , 409 b and the deflector cover 418 serving as walls of the deflector room rises. Accordingly, the temperature of air outside the deflector room near the shield glasses 409 a , 409 b and the deflector cover 418 rises. As a result, as shown in FIG. 4 , upward currents are generated due to natural convection along the shield glasses 409 a , 409 b and/or above the deflector cover 418 . Ribs 417 a , 417 b are provided inside (beneath) the top cover 416 to form a U-shape (upside down) as shown in FIG. 4 . Therefore, the warmed air stays between the ribs 417 a , 417 b , and does not diffuse. Accordingly, it is possible to reduce the amount heat traveling from the deflector 407 to optical elements such as the first scanning imaging elements 411 and the second scanning imaging elements 412 , which elements in particular have a large impact on optical properties when affected by temperature changes. The U-shaped part formed by the ribs 417 a , 417 b can be made of a sheet-metal material in order to increase heat conductivity, so that the amount of heat reaching the deflector 407 can be reduced. The ribs 417 a , 417 b can be formed by bending inward (downward) two edges of the sheet-metal material. The ribs 417 a , 417 b forming part of the U-shaped part are extended in a direction substantially parallel to the main scanning direction. Therefore, the heat held between the ribs 417 a , 417 b of the top cover 416 is transferred outside through the top cover 416 , so that even when the optical scanner operates for a long time, the temperature inside the optical scanner does not rise excessively.
[0033] An optical scanner according to a second embodiment of the present invention is described with reference to FIG. 5 . The second embodiment has substantially the same configuration as the first embodiment, except that the top cover is made of three parts, namely a top cover resin part 419 a , a top cover sheet metal part 419 b , and a top cover resin part 419 c . The top cover sheet metal part 419 b has a higher level of heat conductivity than the top cover resin parts 419 a , 419 c . A counter scanning type optical scanner as shown in FIG. 1 requires a considerably large top cover, under which a single deflector 407 is used to scan light on four imaging surfaces. To fabricate such a large cover by resin molding, a large mold would be required, which increases the cost. However, if the cover is formed by separately fabricating plural portions as shown in FIG. 6 , each mold can be reduced in size. Furthermore, by designing the layout so that the two top cover resin parts 419 a , 419 c on the left and right sides have the same shape, a single compact mold can be used for both of the top cover resin parts 419 a , 419 c . This reduces the cost significantly. Moreover, if each component is small, a container used for shipping the components can be filled with more components. As a result, it costs less to transport the fabricated cover portions to an assembly factory.
[0034] The top cover sheet metal part 419 b arranged above the deflector 407 is made of sheet metal. By bending both edges of the top cover sheet metal part 419 b to obtain bent portions 420 , the same effects can be achieved as those of the ribs 417 a , 417 b of the top cover 416 of the first embodiment. Accordingly, the warmed air stays within the U-shaped part of the top cover sheet metal part 419 b , so that heat is efficiently transferred outside the optical scanner. By providing slanted sections in the top cover sheet metal part 419 b as shown in FIG. 7 , a larger area of the top cover sheet metal part 419 b contacts external air, and the volume of the U-shaped part increases, so that heat transfer efficiency is further enhanced.
[0035] The top cover sheet metal part 419 b is bridged across the front plate 401 and the rear plate 402 and is screwed and fixed thereto. Because the front plate 401 and the rear plate 402 are long, the middle portions thereof may lack rigidity. However, by connecting these portions with a bridge, i.e., the top cover sheet metal part 419 b , the rigidity can be reinforced. Furthermore, the bent portions 420 not only have a function of holding the warmed air, but also contribute significantly to reinforcing the rigidity of the front plate 401 and the rear plate 402 . By making the front plate 401 and the rear plate 402 rigid, optical components, etc., held by these plates can be positioned highly precisely and resistance against vibration can also be enhanced. As a result, in this optical scanner, shapes and positions of beam spots imaged on the imaging surfaces are not deformed or displaced. Furthermore, by directly connecting the top cover sheet metal part 419 b with the front plate 401 and the rear plate 402 that are also made of sheet metal, heat conductivity can be further promoted, and the front plate 401 and the rear plate 402 can also function as heat transferring materials in addition to the top cover sheet metal part 419 b . Hence, the heat generated by the deflector 407 can be transferred highly efficiently.
[0036] By screwing the top cover sheet metal part 419 b onto each of the front plate 401 and the rear plate 402 at least two positions each, the rigidity of the entire optical box is reinforced, so that distortion and deformation are prevented. Rigidity against distortion and deformation can be further reinforced if the top cover sheet metal part 419 b has the widest possible width and the distance between screwed positions is long.
[0037] If the U-shaped part of the top cover sheet metal part 419 b in FIG. 7 has a cross-sectional shape that radially centers around the deflector 407 (a substantially cone-like shape), the air that is warmed near the deflector 407 can be held within such a shape (cone-like shape). Therefore, an increased amount of warm air can be held near the top cover sheet metal part 419 b . Furthermore, the warm air is guided toward both the front plate 401 and the rear plate 402 made of sheet metal that has better heat transfer properties than resin, so that the warm air is transferred outside the optical scanner more efficiently. The mirrors 414 and the second scanning imaging elements 412 have shapes that principally extend in the main scanning direction. Therefore, by guiding the warm air in a direction parallel to the direction in which the optical elements are extended as in the present embodiment, the air current can be smoothly guided without being obstructed by the optical elements.
[0038] An optical scanner according to a third embodiment is described with reference to FIG. 8 . In the third embodiment, gaps 421 are provided between the first scanning imaging elements 411 and the bottom surface of the internal housing 405 . Accordingly, a large flow is generated due to natural convection in the optical scanner, which flow rises near the deflector 407 and falls near both the left plate 403 and the right plate 404 , as shown in FIG. 8 . If there were no gaps between the first scanning imaging elements 411 and the bottom surface of the internal housing 405 as shown in FIG. 4 or 5 , the warmed air would tend to flow upward, but there would be no passages to allow the air to flow downward so as to circulate. Hence, upward currents would not be generated as much as in the case of FIG. 8 . In FIG. 8 , the first scanning imaging elements 411 appear to be floating in midair, but both sides thereof are actually supported in the main scanning direction. The areas of the gaps 421 between the first scanning imaging elements 411 and the bottom surface of the internal housing 405 are preferably as large as possible.
[0039] Application of the present invention is not limited to an optical scanner surrounded by sheet metal side plates. The same effects can be achieved in an optical scanner employing an optical box that is resin molded as one piece, which is often used in the conventional technology.
[0040] According to one embodiment of the present invention, optical elements are not displaced or deformed due to heat generated from a deflector, and therefore, it is possible to realize at low cost an optical scanner in which optical properties are not degraded. Further, the deflector room is sealed so that hissing sounds caused by rotation of the deflector can be reduced outside the deflector room.
[0041] Any one of the optical scanners described in the above embodiments can be provided in a color image forming apparatus. Specifically, the optical scanner writes latent images onto the photoconductors 413 B, 413 C, 413 M, 413 K. Developing units corresponding to the photoconductors 413 B, 413 C, 413 M, 413 K apply toner of a corresponding color among black, cyan, magenta, and yellow to the latent images to produce toner images. The toner images of the respective colors are transferred and superposed onto a sheet of paper, and fixed thereon with a fixing unit, so that a full-color image is formed on the sheet of paper. The temperature around the deflector 407 can be decreased efficiently at low cost, and optical elements are not displaced or deformed due to heat generated from the deflector 407 . As a result, a color image forming apparatus can be realized at low cost, in which optical properties are not degraded so that output images are not degraded. Further, a color image forming apparatus requiring less maintenance can be realized at low cost, because the deflector 407 does not generate excessive heat so that the deflector 407 and the optical scanner are less degraded and do not need to be frequently replaced. Further, a cooling fan, etc., does not need to be provided in order to reduce heat. As a result, a low-cost, energy-saving, and noise-free color image forming apparatus can be provided.
[0042] The present invention is not limited to the specifically disclosed embodiment, and variations and modifications may be made without departing from the scope of the present invention.
[0043] The present application is based on Japanese Priority Patent Application No. 2006-064153, filed on Mar. 9, 2006, the entire contents of which are hereby incorporated by reference.
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A disclosed optical scanner includes a light source, a deflector that deflects a light beam emitted by the light source, a scanning imaging element that images and scans the deflected light beam as a light spot on an imaging surface, and an optical box that contains at least the deflector and the scanning imaging element and that is substantially sealed from outside. The deflector is substantially sealed so as to be substantially insulated from the scanning imaging element in the optical box. Among outer walls of the optical box insulating a space inside the optical box from the outside, at least an outer wall positioned above the deflector includes an upside-down U-shaped cross-sectional shape portion.
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The present invention relates to a fuel injector with piezoelectric actuator.
BACKGROUND OF THE INVENTION
Fuel injectors with piezoelectric actuators have been available for many years now, i.e. fuel injectors provided with a valve that is displaced in a working direction between a closed position and an open position for activating a piezoelectric actuator.
Known piezoelectric actuators, for example of the type described in patent application DE19909451, comprise a fixed frame and an actuator body made of piezoelectric material arranged in alignment with a working direction; the actuator body has a lower base, which is arranged close to the valve, is mechanically linked to the valve itself, and is free to slide with respect to the fixed frame in the working direction, and has an upper base, which is opposite the lower base and is linked to the fixed frame. In use, the actuator body is excited with an electrical field in order to cause it to expand in the working direction and therefore displace the valve in the working direction from the closed position to the open position, in a direction in accordance with the fuel outlet direction. However, such a structure requires that in order for the valve to move from the closed position to the open position, it is displaced towards the outside of the injector putting itself into a configuration that can cause the injector to be soiled, and therefore its functions impaired.
SUMMARY OF THE INVENTION
The objective of the present invention is to produce a fuel injector with piezoelectric actuator, which does not have the drawbacks described above and, in particular, is easy and inexpensive to implement.
According to the present invention, a fuel injector with piezoelectric actuator is produced in accordance with claim 1 .
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described with reference to the attached drawings, which give a non-exhaustive illustration of a few embodiments of the invention, as follows:
FIG. 1 is a diagrammatic view, in side elevation and partial section, of a fuel injector produced according to the present invention;
FIG. 2 is a section, along the line II—II and with a few portions removed for clarity, of the injector in FIG. 1;
FIG. 3 is a diagrammatic view from above and in section of a different embodiment of a fuel injector produced according to the present invention;
FIG. 4 is a partial section along the line IV—IV of the injector in FIG. 4 [sic];
FIG. 5 is a partial section along the line V—V of the injector in FIG. 4 [sic]; and
FIG. 6 is a diagrammatic view, in side elevation and partial section, of another embodiment of a fuel injector produced according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1 and 2, the reference number 1 indicates a fuel injector as a whole, which comprises a container 2 substantially cylindrical in shape, having a central axis of symmetry 3 and a circular section; in correspondence with a lower end of the container 2 there is attached an injection pipe 4 , which is in the form of a cylindrical tube and ends in an injection port 5 regulated by a valve 6 that is moveable along the axis 3 between a closed position and an open position. Inside the container 2 there is arranged, coaxially with the axis 3 , a container 7 , which is cylindrical in shape, has a circular section and is provided with an internal chamber 8 that houses a piezoelectric actuator 9 capable of activating the valve 6 , i.e. capable of displacing the valve 6 between the aforementioned closed and open positions.
The container 7 has a diameter, i.e. a dimension transverse to the axis 3 , that is smaller than the container 2 so as to constitute, between the outer lateral surface 10 of the container 7 and the inner lateral surface 11 of the container 2 , an annular channel 12 through which the fuel can flow freely in a direction parallel to the axis 3 until it reaches the mouth of the injection pipe 4 ; in particular, the fuel is supplied under pressure to an upper portion of the annular channel 12 through a supply pipe 13 ending inside the container 2 .
The container 7 is integral with the container 2 by way of a contact zone 14 produced by welding or similar, so that the container 7 constitutes a fixed frame for the piezoelectric actuator 9 ; the piezoelectric actuator 9 comprises an actuator body 15 made of piezoelectric material, which is arranged in alignment with the axis 3 , is provided with a central hole 16 in alignment with the axis 3 , has a lower base 17 arranged close to the valve 6 and linked to the container 7 , and has an upper base 18 opposite the lower base 17 , which is free to slide with respect to the container 7 along the axis 3 .
As illustrated in FIGS. 1 and 2, the actuator body 15 is defined by two components 19 made of piezoelectric material, physically separated from one another and arranged symmetrically about the central axis 3 . According to another embodiment, not illustrated, the actuator body 15 is constituted [by] a single tubular component made of piezoelectric material arranged coaxially to the axis 3 .
Between the mobile upper base 18 and the valve 6 there is placed a mechanical transmission 20 provided with mobile equipment 21 , which is arranged in contact with the upper base 18 and is connected rigidly to the valve 6 ; in particular, the mobile equipment 21 comprises a plate 22 , which is transverse to the axis 3 , bears against the upper base 18 and is kept bearing against the upper base 18 itself by the pressure exerted along the axis 3 by a spring 23 compressed between the plate 22 and an upper portion 24 of the container 7 . A rod 25 is integral with the plate 22 , which rod is arranged inside the hole 16 along the axis 3 and is connected rigidly to the valve 6 .
Between the plate 22 and the upper base 18 there is placed an annular body 26 provided with a spherical contact surface 27 , so as to make the plate 22 floating with respect to the base 18 in order to be free to perform small oscillations about an axis perpendicular to the axis 3 ; these small free oscillations are necessary in order to allow the plate 22 to absorb without deformation, and therefore without breaking due to fatigue, any expansion differences in the components 19 made of piezoelectric material.
In order to drive the actuator body 15 , electric voltage is supplied to the actuator body 15 itself via an electric cable 28 , which passes through an appropriate open hole 29 in the upper portion 24 of the container 7 , through the central zone of the spring 23 , and through an open hole (not illustrated) in the plate 22 ; the electric cable 28 passes through the open hole (not illustrated) in the plate 22 with a certain amount of play to allow movement of the plate 22 along the axis 3 with respect to the electric cable 28 .
In use, when the actuator body 15 is non-excited, i.e. is not subject to an electrical field, the valve 6 is in the aforementioned closed position in that it is pushed downwards along the axis 3 by the pressure exerted by the spring 23 and transmitted to the valve 6 by the plate 22 and the rod 25 .
When the actuator body 15 is excited, i.e. is subject to an electrical field, the actuator body 15 itself expands along the axis 3 ; for the purposes of this expansion the lower base 17 stays still, since it is linked to the container 7 , while the upper base 18 performs an upward displacement along the axis 3 , which displacement is transmitted to the valve 6 by the plate 22 and the rod 25 and causes a displacement of the valve 6 along the axis 3 from the aforementioned closed position to the aforementioned open position.
As stated above, it is clear that the valve 6 is displaced along the axis 3 from the aforementioned closed position to the aforementioned open position in an opposite direction V 1 to that V 2 in which fuel leaves the supply pipe 13 ; therefore, in order to move from the closed position to the open position, the valve 6 is displaced towards the inside of the supply pipe 13 , putting itself in a configuration that reduces the soiling, and therefore impairment of the functions, of the injector 1 .
The internal chamber 8 of the container 7 is produced in such a way that it is isolated from the fuel; for this purpose the outer lateral surface 10 of the container 7 is continuous and has no opening, and the hole 30 in the lower portion 31 of the container 7 , to allow connection between the valve 6 and the rod 25 , is provided with a deformable holding component 32 .
The container 7 is made of sheet metal with a high thermal transmission coefficient; furthermore, the container 7 is provided with exchange means 33 capable of increasing heat exchange between the fuel and the piezoelectric actuator 9 .
As illustrated in FIGS. 1 and 2, the actuator body 15 has smaller dimensions than the dimensions of the chamber 8 , and the exchange means 33 comprise a plurality of transmission means 34 made of heat-conducting material, which have a shape and dimensions so as to be arranged between the actuator body 15 and an inner lateral surface 35 of the container 7 so as to increase heat transmission between the actuator body 15 and the container 7 . In particular, each transmission body 34 is arranged in contact with either the actuator body 15 or the inner lateral surface 35 of the container 7 .
In an embodiment not illustrated, the exchange means 33 also comprise finning of the outer lateral surface 10 of the container 7 bathed in the fuel.
As stated above, it is clear that the piezoelectric actuator 9 is arranged inside the chamber 8 , which is isolated from the fuel and has its outer lateral surface 10 bathed in the fuel itself; this configuration is particularly advantageous, since it makes it possible either to keep the piezoelectric actuator 9 isolated from the fuel, protecting the piezoelectric actuator 9 itself from the corrosive and soiling action of the fuel, or to ensure, in a simple and extremely economical manner, continuous cooling of the piezoelectric actuator 9 by transmitting the heat produced by the piezoelectric actuator 9 inside the chamber 8 to the fuel lapping the outer lateral surface 10 .
Furthermore, the use of the transmission bodies 34 makes it possible either to increase heat transmission from the piezoelectric actuator 9 to the container 7 , or to ensure correct positioning of the piezoelectric actuator 9 inside the chamber 8 , since the transmission bodies 34 also have the function of filling the empty spaces inside the chamber 8 itself.
In a preferred embodiment, the injector 1 is provided with at least one compensation component 36 having thermal expansion capable of compensating for the various heat expansions of the actuator body 15 and the mechanical transmission 20 ; in other words, through the combined effect of its own dimensions and thermal expansion coefficient (positive or negative), the compensation component 36 has heat expansion that cancels out all the various heat expansions of the actuator body 15 and the mechanical transmission 20 .
The compensation component 36 can be integrated into the container 7 , can be placed between the container 7 and the actuator body 15 (as illustrated in FIG. 1 ), or can be integrated into the mobile equipment 21 .
In a preferred embodiment, the compensator component 36 is made of metal with a low thermal expansion coefficient, particularly Invar.
In FIGS. 3, 4 and 5 the reference number 101 indicates a fuel injector as a whole, which comprises a container 102 substantially cylindrical in shape, having a central axis of symmetry 103 and a circular section; in correspondence with a lower end of the container 102 there is attached an injection pipe 104 , which is in the form of a cylindrical tube and ends in an injection port 105 regulated by a valve 106 that is moveable along the axis 103 between a closed position and an open position. Inside the container 102 there is arranged, coaxially with the axis 103 , a container 107 , which is cylindrical in shape, has an elliptical section and is provided with an internal chamber 108 that houses a piezoelectric actuator 109 capable of activating the valve 106 , i.e. capable of displacing the valve 106 between the aforementioned closed and open positions.
The container 107 has a dimension transverse to the axis 103 that is smaller than the container 102 so as to constitute, between the outer lateral surface 110 of the container 107 and the inner lateral surface 111 of the container 102 , an annular channel 112 through which the fuel can flow freely in a direction parallel to the axis 103 until it reaches the mouth of the injection pipe 104 ; in particular, the fuel is supplied under pressure to an upper portion of the annular channel 112 through a supply pipe 113 ending inside the container 102 .
The container 107 is integral with the container 102 by way of a contact zone 114 produced by welding or similar, so that the container 107 constitutes a fixed frame for the piezoelectric actuator 109 ; the piezoelectric actuator 109 comprises an actuator body 115 made of piezoelectric material, which is arranged in alignment with the axis 103 , has a lower base 117 arranged close to the valve 106 and linked to the container 107 , and has an upper base 118 opposite the lower base 117 and free to slide with respect to the container 107 along the axis 103 . The actuator body 115 is constituted by a single component 119 made of piezoelectric material arranged coaxially to the central axis 103 .
Between the mobile upper base 118 and the valve 106 there is placed a mechanical transmission 120 provided with mobile equipment 121 , which is arranged in contact with the upper base 117 and is connected rigidly to the valve 106 ; in particular, the mobile equipment 121 comprises a ring component 122 substantially rectangular in shape, which is moveable along the axis 3 , is arranged around the actuator body 115 and the container 107 , has an upper transverse side 123 arranged in contact with the upper base 118 , and a transverse side 124 opposite the transverse side 123 and connected rigidly to the valve 106 .
In particular, the ring component 122 is arranged so as to bear against the upper base 118 by means of the interposition of a cylindrical body 125 , and is kept bearing against the upper base 118 itself by the pressure exerted along the axis 103 by a spring 126 compressed between the upper transverse side 123 and an upper portion 127 of the container 102 . The cylindrical body 125 is arranged so as to pass through a hole 128 in the upper portion 129 of the container 107 and is coupled to the hole 128 itself by means of a holding component 130 .
In order to drive the actuator body 115 , electric voltage is supplied to the actuator body 115 itself via an electrical cable 131 , which passes through an appropriate open hole 132 of the container 102 and through an appropriate open hole 133 of the container 107 , which is coupled in a fluid-tight manner with the hole 132 . In use, when the actuator body 115 is non-excited, i.e. is not subject to an electrical field, the valve 106 is in the aforementioned closed position in that it is pushed downwards along the axis 103 by the pressure exerted by the spring 126 and transmitted to the valve 106 by the ring component 122 .
When the actuator body 115 is excited, i.e. is subject to an electrical field, the actuator body 115 itself expands along the axis 103 ; for the purposes of this expansion the lower base 117 stays still, since it is linked to the container 107 , while the upper base 118 performs an upward displacement along the axis 103 , which displacement is transmitted to the valve 106 by the cylindrical body 125 and the ring component 122 and causes a displacement of the valve 106 along the axis 103 from the aforementioned closed position to the aforementioned open position.
In FIG. 6, the reference number 201 indicates a fuel injector as a whole, which comprises a container 202 substantially cylindrical in shape, having a central axis of symmetry 203 and a circular section; in correspondence with a lower end of the container 202 there is attached an injection pipe 204 , which is in the form of a cylindrical tube and ends in an injection port 205 regulated by a valve 206 that is moveable along the axis 203 between a closed position and an open position. Inside the container 202 there is arranged, coaxially with the axis 203 , a container 207 , which is cylindrical in shape, has an circular section and is provided with an internal chamber 208 that houses a piezoelectric actuator 209 capable of activating the valve 206 , i.e. capable of displacing the valve 206 between the aforementioned closed and open positions.
The container 207 has a diameter, i.e. a dimension transverse to the axis 203 , that is smaller than the container 202 so as to constitute, between the outer lateral surface 210 of the container 207 and the inner lateral surface 211 of the container 202 , an annular channel 212 through which the fuel can flow freely in a direction parallel to the axis 203 until it reaches the mouth of the injection pipe 204 ; in particular, the fuel is supplied under pressure to an upper portion of the annular channel 212 through a supply pipe 213 ending inside the container 202 .
The container 207 is integral with the container 202 by way of a contact zone 214 produced by welding or similar, so that the container 207 constitutes a fixed frame for the piezoelectric actuator 209 ; the piezoelectric actuator 209 comprises an actuator body 215 made of piezoelectric material, which is arranged in alignment with the axis 203 , has a lower base 217 arranged close to the valve 206 and free to slide with respect to the container 207 along the axis 203 , and has an upper base 218 opposite the lower base 217 and linked to the container 207 . The actuator body 215 is constituted by a single component 219 made of piezoelectric material arranged coaxially to the central axis 203 .
Between the mobile lower base 217 and the valve 206 there is placed a mechanical transmission 220 , which is capable of inverting the direction of displacement produced by the expansion of the piezoelectric actuator 209 along the axis 203 so that, to a first displacement produced by the expansion of the piezoelectric actuator 209 along the axis 203 , there corresponds a second displacement of the valve 206 along the axis 203 in the opposite direction to the first displacement.
The mechanical transmission 220 is provided with mobile equipment 221 , which is linked to the lower base 217 and connected to the valve 206 , and is provided with a system 222 for inverting the rocking movement, which is capable to transforming a first displacement produced by the expansion of the piezoelectric actuator 209 along the axis 203 into a second displacement of the valve 206 along the axis 203 in the opposite direction to the first displacement.
The system 222 for inverting movement comprises a pair of rockers 223 arranged symmetrically on either side of the axis 203 ; each rocker 223 is supported on a respective fixed fulcrum 224 constituted by a spherical body projecting from a lower portion 226 of the container 202 , and is provided with an arm 226 arranged in contact with the mobile equipment 221 and by an arm 227 arranged in contact with a counterpart component 228 integral with the valve 206 .
The arms 226 and 227 of each rocker 223 bear against either the mobile equipment 221 or the counterpart component 228 , and are held in that condition by the pressure exerted along the axis 203 by a spring 229 compressed between the mobile equipment 221 and the counterpart component 228 .
In particular, the mobile equipment 221 comprises a plate 230 transverse to the axis 203 and integral with the lower base 217 ; integral with the plate 230 is a cylindrical body 231 , which passes through an open hole 232 of a lower portion 233 of the container 207 with the interposition of a holding component 234 . The body 231 supports a fork 235 , with two symmetrical branches 236 , each of which is held so as to bear against the end of a respective arm 226 .
In order to drive the actuator body 215 , electric voltage is supplied to the actuator body 215 itself via an electrical cable 237 .
In use, when the actuator body 215 is non-excited, i.e. is not subject to an electrical field, the valve 206 is in the aforementioned closed position in that it is pushed downwards along the axis 203 by the pressure exerted by the spring 229 .
When the actuator body 215 is excited, i.e. is subject to an electrical field, the actuator body 215 itself expands along the axis 203 ; for the purposes of this expansion the upper base 218 stays still, since it is linked to the container 207 , while the lower base 217 performs a downward displacement along the axis 203 , which displacement is transmitted to the valve 206 by the mechanical transmission 220 and causes a displacement of the valve 206 along the axis 203 from the aforementioned closed position to the aforementioned open position.
On the basis of the dimensional relationship between the arms 226 and 227 of each rocker 223 , it is possible to impose a given transmission ratio less than, greater than or equal to unity on the mechanical transmission 220 ; in particular, as illustrated in FIG. 6, the mechanical transmission 220 has an amplification factor that amplifies the displacement produced by the expansion of the actuator body 15 .
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Fuel injector provided with a piezoelectric actuator, a valve activated by the piezoelectric actuator and regulating a fuel supply that flows in a working direction, and a mechanical transmission placed between the piezoelectric actuator and the valve; an expansion of the piezoelectric actuator displaces the valve in the working direction from a closed position to an open position in an opposite direction to that of the fuel outlet.
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BACKGROUND OF THE INVENTION
The invention relates to scalding prevention means for sanitary installations, in particular showers.
It frequently happens that, owing to irregularities in water pressure and/or heating, the temperature of mixed water as adjusted within a sanitary installation will vary, and that scalding may result if the cold water supply is insufficient or fails altogether.
This occurs in many instances when a large volume of cold water is used in one location in a building while a person is attempting to use a mixture of hot and cold water in another location thereof. Since a temperature change in a mixture of hot and cold water can be quite sudden and unexpected when the cold water supply thereto becomes insufficient, scalding can easily occur.
SUMMARY OF THE INVENTION
A principal object of the invention is to provide scalding prevention means for a mixed hot/cold water supply such as a shower.
In accordance with this object of the invention, a valve is provided in a mixed water supply line to a tap. A temperature-sensitive element is provided for controlling the operation of the valve. When the temperature of the water exceeds a preselected level, the valve closes and the water supply is substantially shut off. Preferably some water passes through the valve to indicate that the fixture has not been permanently shut off.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional of a first embodiment of the invention including a disk valve;
FIG. 2 is a sectional view of a second embodiment of the invention including a diaphragm valve;
FIG. 3 is a sectional view of a third embodiment of the invention including a bimetallic spring disk;
FIG. 4 is a sectional view of an assembly similar to that shown in FIG. 3, but also including a check valve; and
FIG. 5 is a sectional view of an assembly similar to those shown in FIGS. 3 and 4, and including a magnetic valve which is used in conjunction with a bimetallic spring disk.
DETAILED DESCRIPTION OF THE INVENTION
An assembly is provided for cutting off the water supply to a tap when the temperature exceeds a preselected level. Referring to the drawings herein, similar numerals are used throughout to indicate similar, but not necessarily identical structures, in the various embodiments of the invention shown in the figures.
Referring to FIG. 1, a water supply line to a shower head or the like is shown. The supply line comprises a housing 5 including an inlet 6 for receiving a mixture of hot and cold water, and an outlet 7. A valve disk 2 operates in conjunction with a valve seat 3 to control the flow of water between the inlet and the outlet The valve disk 2 is mounted to a supporting member 9 which is, in turn, mounted to the rear end of the housing 5 by a set screw 4. The set screw is positioned in a threaded opening within a closure plug 4A. The set screw bears against a connecting member 9A and is rotatable with respect thereto. An expandable element such as a longitudinally expanding wax-filled thermostatic element 1 or the like is mounted to and positioned between members 9 and 9A.
A coil spring 8 is supported by the disk 2 at one end thereof and an abutment member 8A near the outlet 7 The spring resiliently urges the valve disk 2 away from the valve seat 3 in order to allow the free flow of water between the inlet 6 and outlet 7 under normal conditions.
Should the temperature of the water entering the housing 5 exceed a preselected maximum, e.g., 113° F., the expandable element 1 will have expanded sufficiently so as to cause the valve disk 2 to enter into the opening within seat 3. A small radio clearance is defined between the valve disk 2 and seat 3 to allow the hot water to slowly leak therethrough. Such water will cool quickly, and the valve can be reopened at once upon the water temperature returning to acceptable levels In addition, the residual flow of water indicates to the user that the fixture is not shut off and that there is simply a water temperature problem in the supply line. The temperature at which the valve "closes" can be adjusted by means of the set screw 4 to move the valve disk 2 towards or away from the valve seat 3. If moved closer to the valve seat 3, the water supply will be cut off at a lower temperature as the expandable element 1 will not need to expand to as great an extent in order to move the valve disk 2 within the opening in valve seat 3.
The valve disk 2 may be provided with a rubber sleeve (not shown) to form a seal against the valve seat 3. The elasticity of the rubber should be sufficient to allow movement of the valve disk upon the expansion of the expandable element. A hole may be provided in the valve disk for allowing a residual flow of water when the valve disk is in the closed position.
FIG. 2 illustrates a second embodiment of the invention. As in the first embodiment, a housing 5 is provided which includes an inlet 6 and an outlet 7. The housing walls define an entrance chamber 13 and a control chamber 12 which are separated by a diaphragm 11. A cylindrical member defining a portion of an exit chamber 14 and the outlet 7 is mounted to the housing. The valve member itself comprises a disk 2 and a valve seat 3 which operate in a well known manner. A tube 17 having an outflow bore 15 establishes fluid communication between the exit chamber 14 and the control chamber 12. A sleeve 18 is positioned about the tube 17 along the portion in which it extends through the diaphragm 11. The sleeve has a greater diameter than the outside diameter of the tube 17, and terminates in the entrance chamber 13. The entrance chamber is accordingly in fluid communication with the control chamber 12. Water flows outside of tube 17 from the entrance chamber 13, through the annular space 16 within sleeve 18, into the control chamber 12, and through an outflow bore 15 into the exit chamber 14. When the valve is open, water can also flow past the valve disk 2 and seat 3 into the exit chamber 14.
A bimetallic strip 10 is mounted to one end of the cylinder 14A which defines the exit chamber 14 by a screw 20. If the water temperature within the exit chamber exceeds a preselected value, the strip moves to the position shown in solid lines in FIG. 2, thereby closing off the tube 17 and, as a result, closing the diaphragm valve 11. Since water can no longer drain out of the control chamber 12, the additional load on the diaphragm brings the valve disk 2 into closing contact with the valve seat 3. The temperature at which the valve is closed may be adjusted by displacement of the tube 17. The lower portion of the tube is accordingly threaded at 19 to allow such adjustment along its longitudinal axis with respect to housing 5.
FIG. 3 shows an embodiment of the invention similar to that shown in FIG. 2 Here again, water can enter through the entrance chamber 13 through the inflow bore 16 of sleeve 18 into the control chamber 12. In this case, however, the outflow bore 15 is located in the valve disk 2, through which the water can escape into the exit chamber 14. A bimetallic spring disk 21, otherwise known as a "click" disk, is mounted in opposing relation to the outflow bore 15. The disk is adjusted to a certain "pop" temperature, such that it will "pop" into a closed position at 45° C., for example, and "pop" back into the open position at, for example, 40° C. (104° F.). As discussed above, the pre-cambered disk 21 is directly opposed to the outflow bore 15, the latter being closed when the higher temperature is reached. The diaphragm valve will accordingly then close as well. To allow the limited flow of water, a notch (not shown) may be provided in the valve disk 2.
FIG. 4 illustrates a modification of the structure shown in FIG. 3, a check valve 22 here being positioned in the inflow bore 16 and including a seal 23. A coil spring 24 is positioned between the sleeve 18 and an abutment 18A. In this embodiment, water can flow from the entrance chamber 13 into the control chamber 12, but not in the other direction. This embodiment is particularly advantageous in combination with the bimetallic spring disk 21. Since the disk, even after it pops, will not seal the outflow bore 15 of the control chamber 12 completely, opening of the main valve in reverse flow is precluded because water can seep into the control chamber 12.
FIG. 5 illustrates an embodiment of the invention similar to those shown in FIGS. 3 and 4, except that a magnetic valve 25 is used in combination with the bimetallic spring disk 21. Most fixtures having contactless optical and/or electronic control open by means of a magnetic valve. Protection against scalding can therefore be obtained economically by installing a bimetallic spring disk 21. FIG. 5 shows the fixture in a position in which, according to the position of the magnet, the valve would be open, but it is instead kept closed by the release or pop of the bimetallic disk 21. The magnetic valve is not shown in detail as practically any type of magnetic valve may be employed herein. A slight residual flow of water can be provided when the valve is closed by providing a slit in the underside of the disk.
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An assembly is provided for the prevention of scalding in showers and other such installations. The assembly includes a valve assembly within a mixed water supply line and a temperature sensitive element for controlling the operation of the valve assembly. The valve assembly is preferably designed to allow some leakage when in the closed position.
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The present invention relates to new diphenylurea compounds.
The invention relates also to their use as mixed α 2 /5-HT 2c ligands.
DESCRIPTION OF THE PRIOR ART
Compounds having a diphenylurea structure have been described in the Application JP 11130750 for their serotonergic antagonistic properties, and in the Application WO 99 32436 for their use as raf kinase inhibitors.
BACKGROUND OF THE INVENTION
The frontal cortex plays an essential role in the processes that control the functions affected in psychiatric disorders. In particular, it is now accepted that the disturbance of monoaminergic transmission is strongly implicated in the etiology of those various disorders. For example, in the case of depression, monoaminergic activity is reduced in the corticolimbic regions.
Among the various monoamine auto- and hetero-receptors implicated in regulatory mechanisms, α 2 -A.R. (autoreceptors) and 5-HT 2c receptors have proved to be of major importance. Those two receptor sub-types act in the same way by inhibiting dopaminergic and adrenergic transmission. On the one hand a retrocontrol is exerted by α 2 -A.R. receptors on noradrenergic neurons (J. Pharmacol. Exp. Ther., 1994, 270, 958), and on the other hand 5-HT 2c receptors exert an inhibiting control on dopaminergic and noradrenergic transmission (Neuropharmacology, 1997, 36, 609).
In the past, compounds binding one or the other of those receptor sub-types have demonstrated their potential in the treatment of a plurality of pathologies.
For example, the beneficial role of α 2 antagonist compounds has been studied in the treatment of cognitive disorders (J. Pharmacol., 1992, 6, 376), Parkinson's disease (CNS Drugs, 1998, 10, 189), libido disorders and sexual dysfunction (J. Pharmacol., 1997, 11, 72). Similarly, 5HT 2c receptor antagonist compounds have demonstrated their usefulness in the treatment of sexual dysfunction (ref. J. Pharmacol., ibid.), Parkinson's disease (Drug News Perspect., 1999, 12, 477), and also anxiety (Br. J. Pharmacol., 1996, 117, 427) and schizophrenia (Neurosci. Lett., 1996, 181, 65).
Compounds having a dual α 2 -A.R. and 5-HT 2c antagonist character may be of significant use for clinicians for achieving, with the administration of a single compound, an appreciably enhanced action in the restoration of neurotransmission by means of a synergistic effect. That kind of compound furthermore presents a considerable advantage in comparison with the administration of two different products.
The compounds of the invention have a novel structure that confers on them such a dual α 2 /5-HT 2c antagonist character, and they are accordingly useful in the treatment of depression, anxiety, schizophrenia, Parkinson's disease, cognitive disorders, libido disorders and sexual dysfunction, sleep disorders, drug abuse, and impulsive behaviour disorders.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the compounds of formula (I):
wherein:
R 1 , R 2 , R 3 and R 4 independently represent a hydrogen atom, a halogen atom or an alkyl, alkoxy, hydroxy, alkylthio, mercapto, cyano, amino (optionally substituted by one or two alkyl groups), nitro, carboxy, alkoxycarbonyl, aminocarbonyl (optionally substituted by one or two alkyl groups) or carbamoyl group, or, taken in pairs, form together with the carbon atoms to which they are bonded a phenyl ring or an aromatic heterocycle having from 5 to 7 ring members and containing from 1 to 3 hetero atoms selected from nitrogen, oxygen and sulphur,
L 1 and L 2 each represents a hydrogen atom or together form a —CH 2 —CH 2 — group,
X 1 , attached at the 2 or 3 position of the aromatic ring, represents a bond, and in that case X 2 represents a hydrogen atom, a halogen atom, an alkyl, alkoxy, hydroxy, nitro or cyano group, or an amino group (optionally substituted by one or two alkyl groups),
or,
X 1 and X 2 , together with two adjacent carbon atoms to which they are bonded in the 2, 3 or 4 position of the aromatic ring, form a (C 4 -C 7 )cycloalkyl group wherein one or two —CH 2 — groups of the cycloalkyl ring are optionally replaced by an oxygen atom or an NH group (optionally substituted by an alkyl group), and wherein one carbon atom of the cycloalkyl ring is substituted by the group G,
X 3 represents a hydrogen atom, a halogen atom, an alkyl, alkoxy, hydroxy, nitro or cyano group, or an amino group (optionally substituted by one or two alkyl groups),
G represents a group selected from:
wherein:
the broken lines indicate the optional presence of a double bond,
Alk represents a linear or branched (C 1 -C 6 )alkylene group wherein, when G 1 or G 2 contains an imidazoline group, the group Alk- is attached at the 2 position of the ring,
n is 0 or 1,
T 3 represents an alkyl, optionally substituted aryl, optionally substituted arylalkyl, optionally substituted heteroaryl or optionally substituted heteroarylalkyl group,
T 4 represents an alkyl, optionally substituted aryl, optionally substituted arylalkyl, optionally substituted heteroaryl or optionally substituted heteroarylalkyl group,
wherein:
the term “alkyl” denotes a linear or branched group containing from 1 to 6 carbon atoms,
the term “alkoxy” denotes a linear or branched alkyl-oxy group containing from 1 to 6 carbon atoms,
the term “aryl” denotes a phenyl, naphthyl or biphenyl group,
the term “heteroaryl” denotes an aromatic monocyclic group, or a bicyclic group in which at least one of the rings is aromatic, each group containing from 5 to 11 ring members and from 1 to 5 hetero atoms selected from nitrogen, oxygen and sulphur,
the expression “optionally substituted” associated with the groups aryl, arylalkyl, heteroaryl and heteroarylalkyl denotes that those groups are unsubstituted or substituted on the cyclic moiety by one or more halogen atoms and/or alkyl, alkoxy, hydroxy, mercapto, alkylthio, cyano, amino (optionally substituted by one or two alkyl groups), nitro, carboxy, alkoxycarbonyl, aminocarbonyl (optionally substituted by one or two alkyl groups) or carbamoyl groups, wherein the heteroaryl and heteroarylalkyl groups may in addition be substituted by an oxo group,
to enantiomers and diastereoisomers thereof, and also to addition salts thereof with a pharmaceutically acceptable acid or base.
Among the pharmaceutically acceptable acids there may be mentioned hydrochloric acid, hydrobromic acid, sulphuric acid, phosphonic acid, acetic acid, trifluoroacetic acid, lactic acid, pyruvic acid, malonic acid, succinic acid, glutaric acid, fumaric acid, tartaric acid, maleic acid, citric acid, ascorbic acid, methanesulphonic acid, camphoric acid, etc.
Among the pharmaceutically acceptable bases there may be mentioned sodium hydroxide, potassium hydroxide, triethylamine, tert-butylamine, etc.
In preferred compounds of formula (I), R 1 and R 4 each represents a hydrogen atom.
In compounds of formula (I), R 2 and R 3 are advantageously selected from a halogen atom and an alkyl group.
An advantageous embodiment of the invention relates to compounds of formula (I) wherein X 1 is attached at the 2 position of the phenyl ring.
Another advantageous embodiment of the invention relates to compounds of formula (I) wherein, when L 1 and L 2 together form a —CH 2 —CH 2 — group, R 3 and R 4 , together with the carbon atoms to which they are bonded, form a phenyl ring.
Preferred compounds of the invention are those wherein X 1 represents a bond and X 2 represents a halogen atom or an alkyl or alkoxy group.
Another advantageous embodiment of the invention relates to compounds of formula (I) wherein X 3 represents a hydrogen atom.
In preferred compounds of formula (I), G will advantageously be selected from the groups
wherein T′3 will be more especially an optionally substituted heteroaryl group or optionally substituted heteroarylalkyl group.
Other preferred compounds of the invention are those wherein X 1 and X 2 , together with the two carbons in the 2 and 3 positions of the aromatic ring to which they are bonded, form a (C 4 -C 7 )cycloalkyl group, for example a cyclopentyl group.
The aryl group preferred according to the invention is the phenyl group.
Among the preferred compounds of the invention, the following, more especially, may be mentioned:
N-(3-chloro-4-methylphenyl)-N′-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]phenyl}urea,
N-[4-chloro-3-(4,5-dihydro-1H-imidazol-2-ylamino)phenyl]-N′-(3-chloro-4-methylphenyl)urea,
N-(3-chloro-4-methylphenyl)-N′-[2-(1H-imidazol-4-yl)-indan-5-yl]urea,
N-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]phenyl}-N′-(3,4-dimethylphenyl)urea,
The invention extends also to a process for the preparation of the compounds of formula (I).
One process for the preparation of the compounds of formula (I) is characterised in that there is used as starting material an aromatic amine of formula (II):
wherein X 1 , X 2 , X 3 and G are as defined for formula (I),
which is condensed by heating in basic medium with a compound of formula (III):
wherein R 1 , R 2 , R 3 and R 4 are as defined for formula (I),
to yield the compound of formula (I/a):
a particular case of the compounds of formula (I) wherein R 1 , R 2 , R 3 , R 4 , X 1 , X 2 , X 3 and G are as defined hereinbefore,
wherein the isocyanate of formula (III) is either commercially available or is prepared according to known procedures, for example from the corresponding carboxylic acid by reaction with sodium azide and rearrangement of the acyl azide obtained,
which compounds of formula (I/a)
may, if necessary, be purified according to a conventional purification technique,
are optionally separated into isomers according to a conventional separation technique,
are, if desired, converted into addition salts with a pharmaceutically acceptable acid or base.
Another process for the preparation of the compounds of formula (I) is characterised in that there is used as starting material an amine of formula (IV):
wherein L 1 , L 2 , R 1 , R 2 , R 3 and R 4 are as defined for formula (I),
which is condensed by heating in basic medium with a compound of formula (V):
wherein X 1 , X 2 , X 3 and G are as defined for formula (I),
to yield the compound of formula (I/b):
a particular case of the compounds of formula (I) wherein R 1 , R 2 , R 3 , R 4 , L 1 , L 2 , X 1 , X 2 , X 3 and G are as defined hereinbefore,
wherein the isocyanate of formula (V) is either commercially available or is prepared according to known procedures, for example from the corresponding carboxylic acid by reaction with sodium azide and rearrangement of the acyl azide obtained,
which compounds of formula (I/b)
may, if necessary, be purified according to a conventional purification technique,
are optionally separated into isomers according to a conventional separation technique,
are, if desired, converted into addition salts with a pharmaceutically acceptable acid or base.
Another process for the preparation of the compounds of formula (I) is characterised in that there is used as starting material an amine of formula (VI):
wherein X 1 , X 2 and X 3 are as defined for formula (I), G N34 represents an NH group or a 1-piperazinyl or 4-piperidinyl group, and P represents a hydrogen atom or a group protecting the amine function,
which is condensed by heating in basic medium with a compound of formula (III):
wherein R 1 , R 2 , R 3 and R 4 are as defined for formula (I),
to yield the compound of formula (VII):
wherein R 1 , R 2 , R 3 , R 4 , X 1 , X 2 , X 3 , G N34 and P are as defined hereinbefore,
which compound of formula (VII),
when G N34 represents a 1-piperazinyl or 4-piperidinyl group, after deprotection where necessary of the amine function, is subjected to a substitution reaction in basic medium to yield the compound of formula (I/c):
a particular case of the compounds of formula (I) wherein R 1 , R 2 , R 3 , R 4 , X 1 , X 2 and X 3 are as defined hereinbefore and G 34 represents a group G 3 or G 4 as defined for formula (I),
or
when G N34 represents an NH group, after deprotection where necessary, is condensed with thiophosgene to yield the compound of formula (VIII):
wherein R 1 , R 2 , R 3 , R 4 , X 1 , X 2 and X 3 are as defined hereinbefore,
which is subjected to the action of ethylenediamine to yield the compound of formula (IX):
wherein R 1 , R 2 , R 3 , R 4 , X 1 , X 2 and X 3 are as defined hereinbefore,
which compound of formula (IX) is subjected to an intramolecular cyclisation reaction catalysed by a palladium compound to yield the compound of formula (I/d):
a particular case of the compounds of formula (I) wherein R 1 , R 2 , R 3 , R 4 , X 1 , X 2 and X 3 are as defined hereinbefore,
which compounds of formulae (I/c) and (I/d),
may, if necessary, be purified according to a conventional purification technique,
are optionally separated into isomers according to a conventional separation technique,
are converted, if desired, into addition salts with a pharmaceutically acceptable acid or base.
The present invention relates also to pharmaceutical compositions comprising as active ingredient at least one compound of formula (I), alone or in combination with one or more pharmaceutically acceptable, inert, non-toxic excipients or carriers.
Among the pharmaceutical compositions according to the invention there may be mentioned more especially those which are suitable for oral, parenteral, nasal or transdermal administration, tablets or dragées, sublingual tablets, gelatine capsules, lozenges, suppositories, creams, ointments, dermal gels etc.
The useful dosage varies according to the age and weight of the patient, the nature and severity of the disorder and the administration route, which may be oral, nasal, rectal or parenteral. Generally, the unit dosage ranges from 0.05 mg to 500 mg for a treatment of from 1 to 3 administrations per 24 hours.
The following Examples illustrate the invention and do not limit it in any way. The structures of the compounds described were confirmed by customary spectroscopic techniques.
The starting materials used are known products or are prepared according to known procedures.
PREPARATION A
3-(4,5-Dihydro-1H-imidazol-2-ylmethyl)aniline
Step 1: 2-(3-Nitrobenzyl)-4,5-dihydro-1H-imidazole hydrochloride
A mixture of 30.7 mmol (5 g) of 3-nitrophenylacetonitrile and 30 mmol (7.2 g) of ethylenediamine para-toluenesulphonate is heated at 100° C. for 1 hour. After cooling to 20° C., the mixture is hydrolysed with 100 ml of a 5M aqueous solution of sodium hydroxide and then extracted with dichloromethane. The organic phases are dried over magnesium sulphate and concentrated. The residue obtained is converted into the hydrochloride by the action of an ethanolic HCl solution to yield the expected product.
Step 2: 3-(4,5-Dihydro-1H-imidazol-2-ylmethyl)aniline
A solution of 22.7 mmol (5.5 g) of the product described in the above Step in a mixture of 100 ml of ethanol and 10 ml of water is stirred under a hydrogen atmosphere in the presence of 0.5 g of 10% palladium-on-carbon. When the absorption of hydrogen has ceased, the reaction mixture is filtered and concentrated to yield the expected product.
PREPARATION B
3-[1-(4,5-Dihydro-1H-imidazol-2-yl)ethyl]aniline
Step 1: 2-(3-Nitrophenyl)propanenitrile
A mixture of 62 mmol (10 g) of 3-nitrophenylacetonitrile, 1.11 mol (100 g) of dimethyl carbonate and 3.1 mmol (0.43 g) of potassium carbonate is heated for 6 hours at 170° C. in an autoclave. After cooling, 200 ml of dichloromethane are added and the organic phase is washed with 100 ml of water and then with 100 ml of a saturated aqueous solution of sodium chloride. The organic phase is dried over magnesium sulphate and concentrated. The residue obtained is purified by chromatography on silica gel, using as eluant a 90/10 cyclohexane/ethyl acetate mixture, to yield the expected product.
Step 2: 2-[1-(3-Nitrophenyl)ethyl]-4,5-dihydro-1H-imidazole
The expected product is obtained in accordance with the procedure described in Preparation A, Step 1, using as starting material the compound described in the above Step.
Step 3: 3-[1-(4,5-Dihydro-1H-imidazol-2-yl)ethyl]aniline
The expected product is obtained in accordance with the procedure described in Preparation A, Step 2, using as starting material the compound described in the above Step.
PREPARATION C
3-[1-(4,5-Dihydro-1H-imidazol-2-yl)-1-methylethyl]aniline
Step 1: 2-Methyl-2-(3-nitrophenyl)propanenitrile
40 ml of 50% sodium hydroxide solution are added to a vigorously stirred solution of 123 mmol (20 g) of 3-nitrophenylacetonitrile and 369 mmol (46.5 g) of dimethyl sulphate in 200 ml of dimethyl sulphoxide. After stirring for one hour, the reaction mixture is diluted with 2 liters of water and extracted twice with 1 liter of diethyl ether. The organic phases are dried over sodium sulphate and concentrated to yield the expected product.
Step 2: 2-[1-Methyl-1-(3-nitrophenyl)ethyl]-4,5-dihydro-1H-imidazole
The expected product is obtained in accordance with the procedure described in Preparation A, Step 1, using as starting material the compound described in the above Step.
Step 3: 3-[1-(4,5-Dihydro-1H-imidazol-2-yl)-1-methylethyl]aniline
The expected product is obtained in accordance with the procedure described in Preparation A, Step 2, using as starting material the compound described in the above Step.
PREPARATION D
4-Methyl-3-(4-methyl-1-piperazinyl)aniline
Step 1: 4-(2-Methylphenyl)-1-piperazinecarbaldehyde
With vigorous stirring, 437 mmol (77 g) of 2-methylphenylpiperazine are added to a solution of 415 mmol (61.3 g) of trichloroacetaldehyde in 400 ml of dibutyl ether. The reaction mixture is heated at 80° C. for 1 hour and, after cooling, concentrated to yield the expected product.
Step 2: 1-Methyl-4-(2-methylphenyl)piperazine
A solution of 437 mmol (90 g) of the compound described in the above Step in 400 ml of tetrahydrofuran is added to a suspension of 568 mmol (21.6 g) of lithium tetrahydroaluminate in 300 ml of tetrahydrofuran. The reaction mixture is stirred for 12 hours at 50° C. After cooling, the reaction mixture is hydrolysed with 52.5 ml of water and then 48 ml of an aqueous 10% sodium hydroxide solution and finally with 88.5 ml of water. The precipitate formed is filtered off over Celite and the filtrate is concentrated. The residue obtained is taken up in 200 ml of water and extracted 3 times with 250 ml of dichloromethane. The organic phase is dried over magnesium sulphate and concentrated to yield the expected product.
Step 3: 1-Methyl-4-(2-methyl-5-nitrophenyl)piperazine hydrochloride
416 mmol (64 g) of potassium nitrate in powder form are added to a solution of 347 mmol (100 g) of the hydrogen sulphate of the compound described in the above Step in 500 ml of concentrated sulphuric acid. Stirring is carried out for 5 hours, and the reaction mixture is poured onto 1200 g of ice and then neutralised with solid potassium carbonate and extracted 3 times with 500 ml of ethyl acetate. The organic phases are dried and concentrated to yield the expected product. The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Step 4: 4-Methyl-3-(4-methyl-1-piperazinyl)aniline
The expected product is obtained in accordance with the procedure described in Preparation A, Step 2, using as starting material the compound described in the above Step.
PREPARATION E
3-[4-(2,3-Dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]aniline
Step 1: 1-(2,3-Dihydro-1,4-benzodioxin-2-ylmethyl)-4-(3-nitrophenyl) piperazine
A solution of 54.2 mmol (10 g) of 2-chloromethyl-2,3-dihydro-1,4-benzodioxin, 54.2 mmol (9.2 g) of 3-nitrophenylpiperazine and 6 g of potassium hydrogen carbonate in 100 ml of methyl-4-pentanone is heated at reflux for 72 hours. After cooling, the reaction mixture is concentrated. The residue is taken up in 200 ml of water and extracted with 200 ml of dichloromethane. The organic phase is dried over magnesium sulphate, concentrated and purified by chromatography on silica gel, using as eluant a 99/1/0.1 dichloromethane/methanol/ammonium hydroxide mixture, to yield the expected product.
Step 2: 3-[4-(2,3-Dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]aniline
The expected product is obtained in accordance with the procedure described in Preparation A, Step 2, using as starting material the compound described in the above Step.
PREPARATION F
N 3 -(4,5-Dihydro-1H-imidazol-2-yl)-4-methyl-1,3-benzenediamine
Step 1: 2-Methyl-5-nitrophenylcarbamothioic acid chloride
2.25 l of water are added to a solution of 130 mmol (20 g) of 2-methyl-5-nitroaniline in 375 ml of concentrated hydrochloric acid. At a temperature of 0° C., 162 mmol (19 g) of thiophosgene are poured in in one go. The reaction mixture is stirred vigorously for 24 hours at ambient temperature. The precipitate formed is filtered off and then taken up in diethyl ether. The organic phase is washed with water, dried over magnesium sulphate and concentrated to yield the expected product.
Step 2: N-(2-Aminoethyl)-N′-(2-methyl-5-nitrophenyl)thiourea
A solution of 123 mmol (24 g) of the compound described in the above Step in 1000 ml of toluene is heated to 60° C. 246 mmol (8.27 ml) of ethylenediamine are rapidly added and the mixture is heated at 100° C. for 3 hours. After cooling, the organic phase is washed with a 1M hydrochloric acid solution. The aqueous phase is rendered alkaline with concentrated sodium hydroxide solution and then extracted with dichloromethane. The organic phase is washed with water, dried over magnesium sulphate, concentrated and purified by chromatography on silica gel, using as eluant a 90/10/1 dichloromethane/methanol/ammonium hydroxide mixture, to yield the expected product.
Step 3: N-(2-Methyl-5-nitrophenyl)-4,5-dihydro-1H-imidazol-2-amine
A hot solution of 38.8 g of potassium hydroxide in 135 ml of water is added at 50° C. to a solution of 63 mmol (16.0 g) of the compound described in the above Step. With vigorous stirring, at 80° C., a hot solution of 72.5 mmol (27.2 g) of lead acetate in 135 ml of water is added. After 30 minutes, the reaction mixture is filtered over Celite and concentrated. The residue is taken up in 100 ml of water and the pH is adjusted to 10. Following extraction with dichloromethane, the organic phase is dried over magnesium sulphate and concentrated to yield the expected product.
Step 4: N 3 -(4,5-Dihydro-1H-imidazol-2-yl)-4-methyl-1,3-benzenediamine
The expected product is obtained in accordance with the procedure described in Preparation A, Step 2, using as starting material the compound described in the above Step.
PREPARATION G
N 1 -(4,5-Dihydro-1H-imidazol-2-yl)-1,3-benzenediamine
Step 1: N-(3-Nitrophenyl)-4,5-dihydro-1H-imidazol-2-amine
The expected product is obtained in accordance with the procedure described in Preparation F, Step 2, using as starting material 3-nitrophenyl isothiocyanate.
Step 2: N 1 -(4,5-Dihydro-1H-imidazol-2-yl)-1,3-benzenediamine
The expected product is obtained in accordance with the procedure described in Preparation A, Step 2, using as starting material the compound described in the above Step.
PREPARATION H
2-Methoxy-5-(4-methyl-1-piperazinyl)benzoyl azide
A solution of 25 mmol (5.3 g) of phenyl dichlorophosphate in 100 ml of dichloromethane is added to a solution of 20 mmol (5 g) of 4-methoxy-3-(4-methyl-1-piperazinyl)benzoic acid (described in J. Med. Chem., 1994, 37, p.2255) and 50 mmol (3.25 g) of sodium azide in 4.05 ml of pyridine. After stirring for 12 hours at ambient temperature, the organic phase is washed with 100 ml of water, dried over magnesium sulphate and concentrated to yield the expected product.
EXAMPLE 1
N-(3-Chloro-4-methylphenyl)-N′-[3-(4,5-dihydro-1H-imidazol-2-ylmethyl)phenyl]urea hydrochloride
A solution of 4.7 mmol (1 g) of the compound described in Preparation A and 4.7 mmol (0.79 g) of 3-chloro-4-methylphenyl isocyanate in 50 ml of dimethylformamide is heated for 2 hours at 100° C. After cooling, the reaction mixture is concentrated. The residue obtained is taken up in 200 ml of dichloromethane, and the precipitate obtained is filtered off and purified by chromatography on silica gel, using as eluant a 90/10/1 dichloromethane/methanol/ammonia mixture, to yield the expected product. The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: 227-229° C. Elemental microanalysis: C 18 H 19 ClN 4 O.HCl
C
H
N
Cl
% Calculated:
57.00
5.31
14.77
9.35
% Found:
56.56
5.41
14.32
9.59
EXAMPLE 2
N-(3-Chloro-4-methylphenyl)-N′-{3-[1-(4,5-dihydro-1H-imidazol-2-yl)ethyl]phenyl}urea hydrochloride
The expected product is obtained in accordance with the procedure described in Example 1, with replacement of the product described in Preparation A with the compound described in Preparation B.
Melting point: 100-102° C. Elemental microanalysis: C 19 H 21 ClN 4 O.HCl
C
H
N
Cl
% Calculated:
58.02
5.64
14.24
9.01
% Found:
58.07
5.95
13.55
8.91
EXAMPLE 3
N-(3-Chloro-4-methylphenyl)-N′-{3-[1-(4,5-dihydro-1H-imidazol-2-yl)-1-methylethyl]phenyl}urea hydrochloride
The expected product is obtained in accordance with the procedure described in Example 1, with replacement of the product described in Preparation A with the compound described in Preparation C.
Melting point: 232-233° C. Elemental microanalysis: C 20 H 23 ClN 4 O.HCl
C
H
N
Cl
% Calculated:
58.97
5.94
13.75
8.70
% Found:
58.32
6.11
13.13
9.11
EXAMPLE 4
N-(3-Chloro-4-methylphenyl)-N′-[4-methoxy-3-(4-methyl-1-piperazinyl)phenyl]urea hydrochloride
A mixture of 13.6 mmol (3 g) of 4-methoxy-3-(4-methyl-1-piperazinyl)phenylamine and 13.6 mmol (2.26 g) of 3-chloro-4-methylphenyl isocyanate in 100 ml of toluene is heated at reflux for 2 hours. After cooling, the precipitate obtained is filtered off, and rinsed twice with diethyl ether. The solid obtained is purified by chromatography on silica gel, using as eluant a 96/4/0.4 dichloromethane/methanol/ammonium hydroxide mixture, to yield the expected product. The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: 206-208° C. Elemental microanalysis: C 20 H 25 ClN 4 O 2 .HCl
C
H
N
Cl
% Calculated:
55.29
6.10
12.90
18.36
% Found:
55.59
6.14
12.70
18.31
EXAMPLE 5
N-(3-Chloro-4-methylphenyl)-N′-[4-methyl-3-(4-methyl-1-piperazinyl)phenyl]urea hydrochloride
The expected product is obtained using the procedure described in Example 4, with the replacement of 4-methoxy-3-(4-methyl-1-piperazinyl)phenylamine with the compound described in Preparation D.
Melting point : 229-231° C. Elemental microanalysis: C 20 H 25 ClN 4 O.HCl
C
H
N
Cl
% Calculated:
58.68
6.40
13.69
17.32
% Found:
58.16
6.37
13.20
17.16
EXAMPLE 6
N-(3-Chloro-4-methylphenyl)-N′-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]phenyl}urea hydrochloride
The expected product is obtained using the procedure described in Example 4, with the replacement of 4-methoxy-3-(4-methyl-1-piperazinyl)phenylamine with the compound described in Preparation E.
Melting point: 180-185° C. Elemental microanalysis: C 27 H 29 ClN 4 O 3 .HCl
C
H
N
Cl
% Calculated:
57.30
5.53
9.90
18.79
% Found:
57.36
5.55
9.63
18.85
EXAMPLE 7
N-(3-Chloro-4-methylphenyl)-N′-[3-(4,5-dihydro-1H-imidazol-2-ylamino)-4-methylphenyl]urea hydrochloride
The expected product is obtained in accordance with the procedure described in Example 1, with replacement of the product obtained in Preparation A with the compound described in Preparation F.
Melting point: 252-254° C. Elemental microanalysis: C 18 H 20 ClN 5 O.HCl
C
H
N
Cl
% Calculated:
54.83
5.37
17.76
8.99
% Found:
54.91
5.25
17.78
9.12
EXAMPLE 8
N-(3-Chloro-4-methylphenyl)-N′-[3-(4,5dihydro-1H-imidazol-2-ylamino)phenyl]urea hydrochloride
The expected product is obtained in accordance with the procedure described in Example 1, with replacement of the product described in Preparation A with the compound described in Preparation G.
Melting point: 180-185° C. Elemental microanalysis: C 17 H 18 ClN 5 O.HCl
C
H
N
Cl
% Calculated:
53.01
5.10
18.14
10.38
% Found:
53.18
5.02
18.25
10.16
EXAMPLE 9
N-[4-Chloro-3-(4,5-dihydro-1H-imidazol-2-ylamino)phenyl]-N′-(3-chloro-4-methylphenyl)urea hydrochloride
Step a: N-(3-Chloro-4-methylphenyl)-N′-(4-chloro-3-nitrophenyl)urea
A solution of 29.8 mmol (5 g) of 3-chloro-4-methylphenyl isocyanate in 90 ml of toluene is heated to 70° C., and 29.8 mmol (5.15 g) of 4-chloro-3-nitroaniline are poured in. The solution is heated at reflux for 24 hours. The reaction mixture is cooled using ice, and the precipitate formed is filtered off and then rinsed with diethyl ether to yield the expected product.
Step b: N-(3-Amino-4-chlorophenyl)-N′-(3-chloro-4-methylphenyl)urea
A solution of 22.2 mmol (7.5 g) of the compound described in the above Step in 80 ml of a methanol/tetrahydrofuran mixture is heated to 45° C. in the presence of Raney nickel. While controlling the temperature, 33.3 mmol (1.61 ml) of hydrazine hydrate are added. The temperature is maintained at 45° C. for 30 minutes and a further 33.3 mmol (1.61 ml) of hydrazine hydrate is added. The mixture is stirred at reflux for 30 minutes. After cooling, the catalyst is filtered off and the filtrate is concentrated. The residue obtained is taken up in diethyl ether and washed to yield the expected product.
Step c: 2-Chloro-5-{[(3-chloro-4-methylanilino)carbonyl]amino}phenylcarbamothioic acid chloride
3.2 mmol (0.25 ml) of thiophosgene are added at 5° C. to a suspension of 3.2 mmol (0.32 g) of calcium carbonate in a mixture of 15 ml of dichloromethane and 2.2 ml of water. At that temperature, 3.2 mmol (1 g) of the compound described in the above Step dissolved in dichloromethane are added. After the additon of 4.25 mmol (0.36 g) of sodium hydrogen carbonate, the reaction mixture is stirred for 15 minutes at ambient temperature. After filtration over Celite, the filtrate is decanted off and the organic phase is washed with water and then with a saturated aqueous solution of sodium chloride. After drying over magnesium sulphate and filtration, the filtrate is concentrated. The residue obtained is taken up in diethyl ether and washed to yield the expected product.
Step d: N-[3-({[(2-Aminoethyl)amino]carbothioyl}amino)-4-chlorophenyl]-N′-(3-chloro-4-methylphenyl)urea
4.4 mmol (0.27 ml) of ethylenediamine are rapidly added to a solution, heated to 60° C., of 2.2 mmol (0.78 g) of the compound described in the above Step in 35 ml of toluene. The reaction mixture is heated at 100° C. for 3 hours. After cooling, the organic phase is washed with a 1N hydrochloric acid solution (10 ml). The aqueous phase is rendered alkaline with concentrated sodium hydroxide solution and then extracted with dichloromethane. The organic phase is washed with water, dried over magnesium sulphate, filtered and concentrated. The residue obtained is purified by chromatography on silica gel, using as eluant a 90/10/1 dichloromethane/methanol/ammonium hydroxide mixture, to yield the expected product.
Step e: N-[4-Chloro-3-(4,5-dihydro-1H-imidazol-2-ylamino)phenyl]-N′-(3-chloro-4-methylphenyl)urea
A hot solution of 16.5 mmol (1.5 g) of potassium hydroxide in 5.5 ml of water is added to a solution of 1.5 mmol (0.63 g) of the compound described in the above Step in 10 ml of ethanol at 50° C. With vigorous stirring at 80° C., a hot solution of 1.72 mmol (1.1 g) of lead acetate in 5.5 ml of water is added. After 30 minutes, the mixture is filtered over Celite and the filtrate is concentrated. The residue is taken up in 5 ml of water, the pH is adjusted to 10 and extraction is carried out with dichloromethane. The organic phase is dried over magnesium sulphate, concentrated and purified by chromatography on silica gel, using as eluant a 90/10/1 dichloromethane/methanol/ammonium hydroxide mixture, to yield the expected product. The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: 255-257° C. Elemental microanalysis: C 17 H 17 Cl 2 N 5 O.HCl
C
H
N
Cl
% Calculated:
49.23
4.37
16.89
25.65
% Found:
48.82
4.47
16.62
25.44
EXAMPLE 10
N-(3-Chloro-4-methylphenyl)-N′-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]-4-methophenyl}urea hydrochloride
Step a: 4-(5-{[(3-Chloro-4-methylanilino)carbonyl]amino}-2-methoxyphenyl)-1-piperazinecarboxylic acid tert-butanolate
A solution of 34.4 mmol (10 g) of 4-(5-amino-2-methoxyphenyl)piperazine-1-carboxylic acid tert-butanolate (described in J. Med. Chem., 1999, p.202) and 37.8 mmol (5.9 g) of 3-chloro-4-methylphenyl isocyanate in 150 ml of toluene is heated at reflux for 2 hours. The reaction mixture is concentrated, and the residue is taken up in 200 ml of 4N hydrochloric acid and then heated at reflux for 4 hours. After cooling, the precipitate formed is filtered off and treated with a 2N sodium hydroxide solution in order to regenerate the corresponding base.
Step b: N-(3-Chloro-4-methylphenyl)-N′-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]-4-methoxyphenyl}urea
A solution of 12.3 mmol (5 g) of the product described in the above Step in a mixture of 100 ml of acetonitrile and 100 ml of diethyl ketone is heated at reflux for 48 hours in the presence of 12.3 mmol (2.3 g) of 2-chloromethyl-2,3-dihydro-1,4-benzodioxin, 1.3 g of potassium hydrogen carbonate and 100 mg of potassium iodide. After cooling, the mixture is concentrated and the residue obtained is extracted with dichloromethane. The organic phase is dried, concentrated and purified by chromatography on silica gel, using as eluant a 97/3/0.3 dichloromethane/methanol/ammonium hydroxide mixture, to yield the expected product. The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: 193-197° C. Elemental microanalysis: C 28 H 31 ClN 4 O 4 .HCl
C
H
N
Cl
% Calculated:
58.23
5.88
9.58
7.29
% Found:
58.95
5.72
9.82
8.08
EXAMPLE 11
6-Chloro-5-fluoro-N-[4-methoxy-3-(4-methyl-1-piperazinyl)phenyl]-1-indolinecarboxamide
A solution of 10.9 mmol (3 g) of the compound described in Preparation H in 100 ml of toluene is heated at reflux for 1 hour. After cooling to 20° C., a solution of 10.9 mmol (1.9 g) of 6-chloro-5-fluoroindoline in 200 ml of dichloromethane is added, and the reaction mixture is heated at reflux for one night. After returning to ambient temperature, the reaction mixture is concentrated and purified by chromatography on silica gel, using as eluant a 95/5/0.5 dichloromethane/methanol/ammonium hydroxide mixture, to yield the expected product.
Melting point: 177-180° C. Elemental microanalysis: C 21 H 24 ClFN 4 O 2
C
H
N
Cl
% Calculated:
60.21
5.77
13.37
8.46
% Found:
59.15
6.05
12.82
8.85
EXAMPLE 12
N-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]-phenyl}-1,2-dihydro-3H-benzo[e]indole-3-carboxamide dihydrochloride
20 ml of a solution of 20% by weight phosgene in toluene are added at 20° C. to a solution of 3.12 g of 1,2-dihydrobenzo[e]indole in 300 ml of toluene. After one hour at 50° C., the mixture is heated to 100° C. with bubbling with nitrogen. A solution in toluene of 6 g of the compound described in Preparation E is then added at 20° C., and the mixture is subsequently heated at 80° C. for 12 hours. Following treatment, the residue is purified by chromatography on silica gel, using as eluant a 99/1/0.1 dichloromethane/methanol/ammonium hydroxide mixture.
The corresponding dihydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: 194-196° C. Elemental microanalysis: C 32 H 32 N 4 O 3 .2HCl
C
H
N
Cl
% Calculated:
64.75
5.79
9.44
11.95
% Found:
65.17
5.75
9.46
10.88
EXAMPLE 13
6 Chloro-5-fluoro-N-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]-phenyl}-1-2,3-dihydroindolecarboxamide dihydrochloride
The expected product is obtained using the procedure described in Example 12, with the replacement of 1,2-dihydrobenzo[e]indole with 6-chloro-5-fluoro-2,3-dihydroindole.
Melting point: 202-204° C. Elemental microanalysis: C 28 H 28 ClFN 4 O 3 .2HCl
C
H
N
Cl
% Calculated:
56.43
5.07
9.40
17.85
% Found:
56.22
4.92
9.40
17.98
EXAMPLE 14
N-{3-[4-(2,3-Dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]-4-methoxyphenyl}-N′-(3,4-dimethylphenyl)urea dihydrochloride
Step 1: 1-(2,3-Dihydrobenzo[1,4]dioxin-2-ylmethyl)-4-(2-methoxy-5-nitrophenyl)piperazine
The expected product is obtained using the procedure described in Preparation E, with the replacement of 3-nitrophenylpiperazine with 2-methoxy-5-nitrophenylpiperazine.
Step 2: 3-[4-(2,3-Dihydrobenzo[1,4]dioxin-2-ylmethyl)-piperazin-1-yl]-4-methoxyphenylamine
The expected product is obtained using the procedure described in Preparation A, Step 2, using as starting material the compound described in the above Step.
Step 3: N-{3-[4-(2,3-Dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]-4-methoxyphenyl}-N′-(3,4-dimethylphenyl)urea dihydrochloride
The final product is then obtained using the procedure described in Example 4, with the replacement of 4-methoxy-3-(4-methyl-1-piperazinyl)phenylamine with the compound described in Step 2 of that Example and with the replacement of 3-chloro-4-methylphenyl isocyanate with 3,4-dimethylphenyl isocyanate.
Melting point: 234-236° C. Elemental microanalysis: C 29 H 34 N 4 O 4 .2HCl
C
H
N
Cl
% Calculated:
60.52
6.30
9.73
12.32
% Found:
60.50
6.23
9.79
12.12
EXAMPLE 15
N-(3-Chloro-4-fluorophenyl)-N′-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]-4-methoxyphenyl}urea hydrochloride
The expected product is obtained using the procedure described in Example 14, with the replacement of 3,4-dimethylphenyl isocyanate with 3-chloro-4-fluorophenyl isocyanate.
Melting point: 120-130° C. Elemental microanalysis: C 27 H 28 ClFN 4 O 4 .HCl
C
H
N
Cl
% Calculated:
57.56
5.19
9.94
12.58
% Found:
57.62
5.39
9.59
11.72
EXAMPLE 16
N-{3-[4-(2,3-Dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]phenyl}-N′-(3,4-dimethylphenyl)urea hydrochloride
The expected product is obtained using the procedure described in Example 4, with the replacement of 4-methoxy-3-(4-methyl-1-piperazinyl)phenylamine with the compound described in Preparation E and using 3,4-dimethylphenyl isocyanate instead of 3-chloro-4-methylphenyl isocyanate.
Melting point: 228-230° C. Elemental microanalysis: C 28 H 32 N 4 O 3 .HCl
C
H
N
Cl
% Calculated:
66.07
6.53
11.01
6.96
% Found:
65.80
6.50
10.96
7.37
EXAMPLE 17
N-(3-Chloro-4-fluorophenyl)-N′-{3-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]phenyl}urea hydrochloride
The expected product is obtained using the procedure described in Example 4, with the replacement of 4-methoxy-3-(4-methyl-1-piperazinyl)phenylamine with the compound described in Preparation E and using 3-chloro-4-fluorophenyl isocyanate instead of 3-chloro-4-methylphenyl isocyanate.
Melting point: 132-136° C. Elemental microanalysis: C 26 H 26 ClFN 4 O 3 .HCl
C
H
N
Cl
% Calculated:
58.54
5.10
10.50
13.29
% Found:
58.40
5.47
10.02
12.61
EXAMPLE 18
6-Chloro-5-methyl-N-{4-[4-(2,3-dihydro-1,4-benzodioxin-2-ylmethyl)-1-piperazinyl]phenyl}-1-2,3-dihydroindolecarboxamide dihydrochloride
The expected product is obtained using the procedure described in Example 12, with the replacement of 1,2-dihydrobenzo[e]indole with 6-chloro-5-methyl-2,3-dihydroindole.
Melting point: 174-176° C. Elemental microanalysis: C 29 H 31 ClN 4 O 3 .2HCl
C
H
N
Cl
% Calculated:
58.84
5.62
9.46
17.97
% Found:
58.77
5.46
9.16
18.82
EXAMPLE 19
N-(3-Chloro-4-methylphenyl)-N′-[2-(1H-imidazol-4-yl)-indan-5-yl]urea hydrochloride
Step 1: 2-Bromo-1-indan-2-ylethanone
10 g of pure bromine are rapidly added at 0° C. to a solution of 10 g of 2-acetylindane in 150 ml of anhydrous methanol. After one hour at ambient temperature, 100 ml of water are added and the whole is stirred for 12 hours. After extracting twice with 200 ml of diethyl ether each time, and washing the organic phase with a sodium hydrogen carbonate solution and then with water, the expected product is dried over magnesium sulphate and concentrated.
Step 2: 4-Indan-2-yl-1H-imidazole
A mixture of 5.2 g of 2-bromo-1-indan-2-ylethanone and 43.4 ml of formamide is heated at 160° C. for 30 minutes. At ambient temperature 40 ml of water and then 40 ml of 1N hydrochloric acid are added. The aqueous phase is washed with dichloromethane and then neutralised with ammonium hydroxide. Extraction with ethyl acetate yields the expected product after evaporation.
Step 3: 4-(5-Nitroindan-2-yl)-1H-imidazole
5 g of 4-indan-2-yl-1H-imidazole are dissolved at 0° C. in 140 ml of pure sulphuric acid, and then 1 equivalent of urea nitrate in powder form is added in small portions. The reaction mixture is poured onto ice, rendered alkaline using sodium hydroxide solution and extracted with ethyl acetate. The expected product is obtained after evaporation.
Step 4: 2-(1H-Imidazol-4-yl)-indan-5-ylamine
The hydrochloride of the product obtained in Step 3 is stirred under a hydrogen atmosphere in the presence of 10% palladium-on-carbon in ethanol. After filtration and concentration of the solvent, the product is used as it is in the following Step.
Step 5: N-(3-Chloro-4-methylphenyl)-N′-[2-(1H-imidazol-4-yl)-indan-5-yl]urea hydrochloride
A mixture of 5.3 g of the hydrochloride of the product obtained in Step 4, 3.8 g of 3-chloro-4-methylphenyl isocyanate and 150 ml of dimethylformamide is heated at 100° C. for 2 hours. After subsequent evaporation of the solvent, the residue is purified by chromatography on silica gel using as eluant a 97/3/0.3 dichloromethane/methanol/ammonium hydroxide mixture.
The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: 235-237° C. Elemental microanalysis: C 20 H 19 ClN 4 O.1HCl
C
H
N
Cl
% Calculated:
59.56
5.00
13.89
17.58
% Found:
58.95
5.17
13.36
17.01
EXAMPLE 20
N-[2-(1H-Imidazol-4-yl)indan-5-yl]-N′-(4-methylsulphanylphenyl) urea hydrochloride
The expected product is obtained using the procedure described in Example 19, with the replacement of 3-chloro-4-methylphenyl isocyanate with 4-methylthiophenyl isocyanate.
Melting point: 243-245° C. Elemental microanalysis: C 20 H 20 N 4 OS.HCl
C
H
N
Cl
S
% Calculated:
59.92
5.28
13.97
8.84
8.00
% Found:
59.72
5.32
13.26
8.56
7.73
EXAMPLE 21
N-(3,4-Dimethylphenyl)-N′-[2-(1H-imidazol-4-yl)indan-5-yl]urea hydrochloride
The expected product is obtained using the procedure described in Example 19, with the replacement of 3-chloro-4-methylphenyl isocyanate with 3,4-dimethylphenyl isocyanate.
Melting point: 232-234° C. Elemental microanalysis: C 21 H 22 N 4 O.HCl
C
H
N
Cl
% Calculated:
65.88
6.05
14.63
9.26
% Found:
65.47
6.30
14.29
9.29
EXAMPLE 22
N-(3-Chloro-4-methylphenyl)-N′-[2-(4,5-dihydro-1H-imidazol-2-yl)-1,2,3,4-tetrahydro-7-isoquinolinyl]urea hydrochloride
Step 1: 2-(4,5-Dihydro-1H-imidazol-2-yl)-7-nitro-1,2,3,4-tetrahydroisoquinoline
A mixture of 10 g of 7-nitro-1,2,3,4-tetrahydroisoquinoline, 13.7 g of 2-methylsulphanyl-4,5-dihydro-1H-imidazole hydriodide and 100 ml of methanol is heated at reflux for 12 hours. The addition of diethyl ether causes the separation of a precipitate, which is taken up in water, neutralised using sodium hydroxide and extracted with dichloromethane.
Step 2: 2-(4,5-Dihydro-1H-imidazol-2-yl)-1,2,3,4-tetrahydroisoquinolin-7-ylamine
2 ml of hydrazine hydrate are added at 40° C. to a suspension of 2 g of the hydrochloride of the product obtained in Step 1 and 2 g of Raney nickel in 50 ml of ethanol. After 2 hours at 50° C., the catalyst is filtered off and the solvent is evaporated off.
Step 3: N-(3-Chloro-4-methylphenyl)-N′-[2-(4,5-dihydro-1H-imidazol-2-yl)-1,2,3,4-tetrahydro-7-isoqinolinyl]urea hydrochloride
The expected product is obtained using the procedure described in Step 5 of Example 19.
Melting point: 237-239° C. Elemental microanalysis: C 20 H 22 ClN 5 O.HCl
C
H
N
Cl
% Calculated:
57.09
5.47
16.65
16.89
% Found:
57.41
5.51
16.32
16.74
EXAMPLE 23
N-(3-Chloro-4-methylphenyl)-N′-{3-[2-(1H-imidazol-4-yl)ethyl]-phenyl}urea hydrochloride
Step 1: (3-Nitrophenyl)acetaldehyde
A mixture of 10 g of 2-(3-nitrophenyl)ethanol, 25.1 g of 1-hydroxy-1,2-benziodoxol-3(1H)-one 1-oxide and 300 ml of tetrahydrofuran is heated at reflux for 6 hours. After filtration and concentration of the solvent, the product is used as it is in the following Step.
Step 2: 2-(3-Nitrophenyl)-1-(1-trityl-1H-imidazol-4-yl)-ethanol
At ambient temperature, 4.2 ml of 3M ethylmagnesium bromide are poured into 5.48 g of 4-iodo-1-trityl-1H-imidazole dissolved in 30 ml of dichloromethane. After 1 hour, 1 g of the product obtained in Step 1 is dissolved in 20 ml of dichloromethane. After hydrolysis with a saturated solution of ammonium chloride, extraction with dichloromethane, and then washing the organic phase with water, the solvent is evaporated off and the residue is purified by chromatography on silica gel, using as eluant a 98/2 dichloromethane/methanol mixture.
Step 3: 4-[2-(3-Nitrophenyl)vinyl]-1-trityl-1H-imidazole
A mixture of 12.25 g of the product obtained in Step 2, 1 g of para-toluenesulphonic acid and 200 ml of toluene is heated at reflux for 5 hours. After returning to ambient temperature, washing the toluene solution with a 0.1N solution of sodium hydroxide and then with water, drying over magnesium sulphate and concentration, the expected product is obtained.
Step 4: 4-[2-(3-Nitrophenyl)vinyl]-1H-imidazole
A mixture of 11 g of the product obtained in Step 3, 6 ml of concentrated hydrochloric acid and 150 ml of methanol is heated at reflux for 2 hours. The solvent is concentrated and the residue is taken up in an isopropanol/diethyl ether mixture. The expected product is obtained by filtering off the precipitate that has formed.
Step 5: 3-[2-(1H-Imidazol-4-yl)ethyl]phenylamine
The hydrochloride of the product obtained in Step 4 is stirred under a hydrogen atmosphere in the presence of a 90% solution of 10% palladium-on-carbon in ethanol. After filtration and concentration of the solvent, the product is used as it is in the following Step.
Step 6: N-(3-Chloro-4-methylphenyl)-N′-{3-[2-(1H-imidazol-4-yl)-ethyl]-phenyl}urea hydrochloride
The expected product is obtained using the procedure described in Step 5 of Example 19.
Melting point: 237-239° C. Elemental microanalysis: C 19 H 19 ClN 4 O.HCl
C
H
N
Cl
% Calculated:
58.32
5.15
14.32
18.12
% Found:
58.40
5.13
13.97
18.35
EXAMPLE 24
N-(3-Chloro-4-methylphenyl)-N′-{3-[2-(4,5-dihydro-1H-imidazol-2-yl)ethyl]phenyl}urea hydrochloride
Step 1: 3-(3-Nitrophenyl)acrylonitrile
At 0° C., 75.5 g of diethyl cyanomethylphosphonate dissolved in tetrahydrofuran are poured into a suspension of sodium hydride in tetrahydrofuran. After 30 minutes' contact at ambient temperature, 56 g of 3-nitrobenzaldehyde dissolved in tetrahydrofuran are poured in. After 1 hour, hydrolysis is carried out with 300 ml of water and then the solvent is concentrated. Following extraction with dichloromethane, washing the organic phase with water, drying over magnesium sulphate and concentration, the precipitate is taken up in diethyl ether and filtered off.
Step 2: 3-(3-Nitrophenyl)propionitrile
There are introduced into a cylinder 3 g of the product obtained in Step 1, 1.59 g of tris(triphenylphosphine)rhodium(I) chloride and 90 ml of benzene. The whole is heated for 5 hours at 40° C. under a hydrogen pressure of 5 bar. The solvent is evaporated off and the residue is purified by chromatography on silica gel using dichloromethane as eluant.
Step 3: 2-[2-(3-Nitrophenyl)ethyl]-4,5-dihydro-1H-imidazole
1 g of the product obtained in Step 2 is heated for 2 hours at 160° C. with 1.32 g of ethylenediamine para-toluenesulphonate. A 0.1N sodium hydroxide solution is then added and extraction is carried out with dichloromethane. The organic phase is washed with water, dried over magnesium sulphate and concentrated. The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Step 4: 3-[2-(4,5-Dihydro-1H-imidazol-2-yl)ethyl]phenylamine
The hydrochloride of the product obtained in Step 3 is stirred under a hydrogen atmosphere in the presence of a 90% solution of 10% palladium-on-carbon in ethanol. After filtration and concentration of the solvent, the product is used as it is in the following Step.
Step 5: N-(3-Chloro-4-methylphenyl)-N′-{3-[2-(4,5-dihydro-1H-imidazol-2-yl)ethyl]phenyl}urea hydrochloride
The expected product is obtained using the procedure described in Step 5 of Example 19.
Melting point: 212-214° C. Elemental microanalysis: C 19 H 21 ClN 4 O.HCl
C
H
N
Cl
% Calculated:
58.02
5.64
14.24
18.03
% Found:
57.88
5.69
13.98
17.93
EXAMPLE 25
N-(3-Chloro-4-methylphenyl)-N′-[8-(1H-imidazol-4-yl)-5,6,7,8-tetrahydro-2-naphthalenyl]urea hydrochloride
Step 1: Trifluoromethanesulphonic acid 7-nitro-3,4,4a,8a-tetrahydronaphthalen-1-yl ester
9.8 ml of trifluoromethanesulphonic anhydride are poured at 0° C. into a solution of 10 g of 7-nitrotetralone and 11.8 g of 2,6-di-tert-butyl-4-methylpyridine in 365 ml of dichloromethane. After 24 hours at ambient temperature, concentration to dryness and taking up the residue in 200 ml of pentane at reflux for 30 minutes, the precipitate formed is filtered off. The organic phase is washed with a 1N hydrochloric acid solution and then with water, dried over magnesium sulphate and concentrated.
Step 2: 4-(7-Nitro-3,4,4a,8a-tetrahydronaphthalen-1-yl)-1-trityl-1H-imidazole
At ambient temperature, 15.34 ml of 3M ethylmagnesium bromide are poured into 16.74 g of 4-iodo-1-trityl-1H-imidazole dissolved in 250 ml of tetrahydrofuran. After 1 hour, 76.6 ml of a 1N solution of zinc chloride in diethyl ether are poured in. After contact for 1 hour, 12.4 g of the product obtained in Step 1 dissolved in 100 ml of tetrahydrofuran and 2.22 g of tetrakis(triphenylphosphine)palladium(O) are added and the whole is heated at reflux. Following hydrolysis with a saturated solution of ammonium chloride and extraction with dichloromethane, the organic phase is washed with water. The solvent is then evaporated off and the residue is purified by chromatography on silica gel using as eluant an 80/20 cyclohexane/ethyl acetate mixture.
Step 3: 8-(1-Trityl-1H-imidazol-4-yl)-4a,5,6,7,8,8a-hexahydronaphthalen-2-ylamine
7.7 g of the product obtained in Step 2 are stirred under a hydrogen atmosphere in the presence of 10% palladium-on-carbon in a methanol/tetrahydrofuran mixture. After filtration and concentration of the solvent, the product is used as it is in the following Step.
Step 4: 8-(1H-Imidazol-4-yl)-4a,5,6,7,8,8a-hexahydronaphthalen-2-ylamine
A mixture of 7.7 g of the product obtained in Step 3, 4.2 ml of concentrated hydrochloric acid and 100 ml of methanol is heated at reflux for 2 hours. After concentration of the solvent, the residue is taken up in an isopropanol/diethyl ether mixture. The expected product is obtained by filtering off the precipitate.
Step 5: N-(3-Chloro-4-methylphenyl)-N′-[8-(1H-imidazol-4-yl)-5,6,7,8-tetrahydro-2-naphthalenyl]urea hydrochloride
A mixture of 0.7 g of the product obtained in Step 4, 0.55 g of 3-chloro-4-methylphenyl isocyanate and 50 ml of toluene is heated at reflux for 3 hours. The precipitate is then filtered off.
The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: 255-257° C. Elemental microanalysis: C 21 H 21 ClN 4 O.1HCl
C
H
N
Cl
% Calculated:
60.44
5.31
13.42
16.99
% Found:
60.28
5.41
13.02
17.20
EXAMPLE 26
N-(3-Chloro-4-methylphenyl)-N′-[7-(1H-imidazol-4yl)-5,6,7,8-tetrahydro-2-naphthalenyl]urea hydrochloride
Step 1: 7-Nitro-3,4-dihydro-1H-naphthalen-2-one
At 0° C., 100 g of 2-tetralone are dissolved in 460 ml of pure sulphuric acid and 84.6 g of potassium nitrate in powder form are added in small portions. The mixture is then poured onto ice and extracted using dichloromethane. Following evaporation of the solvent, the residue is purified by chromatography on silica gel using as eluant a 90/10 cyclohexane/tetrahydrofuran mixture.
Step 2: Trifluoromethanesulphonic acid 7-nitro-3,4-dihydronaphthalen-2-yl ester
The expected product is obtained using the procedure described in Step 1 of Example 25, with the replacement of 7-nitrotetralone with 14.3 g of the product obtained in Step 1.
Step 3: 4-(7-Nitro-3,4-dihydronaphthalen-2-yl)-1-trityl-1H-imidazole
The expected product is obtained using the procedure described in Step 2 of Example 25, with the replacement of trifluoromethanesulphonic acid 7-nitro-3,4,4a,8a-tetrahydronaphthalen-1-yl ester with 11.2 g of the product obtained in Step 2.
Step 4: 7-(1-Trityl-1H-imidazol-4-yl)-5,6,7,8-tetrahydronaphthalen-2-ylamine
5.5 g of the product obtained in Step 3 are stirred under a hydrogen atmosphere in a methanol/tetrahydrofuran mixture in the presence of 10% palladium-on-carbon,. After filtration and concentration of the solvent, the product is used as it is in the following Step.
Step 5: 7-(1H-Imidazol-4-yl)-5,6,7,8-tetrahydronaphthalen-2-ylamine
A mixture of 5.5 g of the product obtained in Step 4, 3.8 ml of concentrated hydrochloric acid and 100 ml of methanol is heated at reflux for 2 hours. Following concentration of the solvent, the residue is taken up in an acetone/diethyl ether mixture. The precipitate is filtered off and yields the expected product.
Step 6: N-(3-Chloro-4-methylphenyl)-N′-[7-(1H-imidazol-4-yl)-5,6,7,8-tetrahydro-2-naphthalenyl]urea hydrochloride
A mixture of 0.9 g of the product obtained in Step 4, 0.71 g of 3-chloro-4-methylphenyl isocyanate and 70 ml of toluene is heated at reflux for 3 hours. The precipitate is filtered off and then recrystallised from an ethanol/methanol mixture.
The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: 206-208° C. Elemental microanalysis: C 21 H 21 ClN 4 O.1HCl
C
H
N
Cl
% Calculated:
60.44
5.31
13.42
16.99
% Found:
59.84
5.17
13.06
16.88
EXAMPLE 27
N-(3-Chloro-4-methylphenyl)-N′-[4-(1H-imidazol4-yl)-chroman-6-yl]urea hydrochloride
Step 1: 6-Nitrochroman-4-one
At −35° C., 60 g of 4-chromanone are added in small portions to 385 ml of 90% nitric acid. The whole is poured onto ice and then extracted with dichloromethane. The organic phase is washed with a saturated solution of sodium hydrogen carbonate and dried over magnesium sulphate and then the solvent is evaporated off.
Step 2: Trifluoromethanesulphonic acid 6-nitro-2H-chromen-4-yl ester
The expected product is obtained using the procedure described in Step 1 of Example 25, with the replacement of 7-nitrotetralone with 20 g of the product obtained in Step 1.
Step 3: 4-(6-Nitro-2H-chromen-4-yl)-1-trityl-1H-imidazole
The expected product is obtained using the procedure described in Step 2 of Example 25, with the replacement of trifluoromethanesulphonic acid 7-nitro-3,4,4a,8a-tetrahydronaphthalen-1-yl ester with 11.1 g of the product obtained in Step 2.
Step 4: 4-(1H-Imidazol-4-yl)-chroman-6-ylamine
The hydrochloride of the product obtained in Step 3 is stirred under a hydrogen atmosphere in ethanol in the presence of 10% palladium-on-carbon. After filtration and concentration of the solvent, the product is used as it is in the following Step.
Step 5: N-(3-Chloro-4-methylphenyl)-N′-[4-(1H-imidazol-4-yl)-chroman-6-yl]urea hydrochloride
A mixture of 0.76 g of the product obtained in Step 4, 0.59 g of 3-chloro-4-methylphenyl isocyanate and 70 ml of toluene is heated at reflux for 2 hours. The precipitate is filtered off and then recrystallised from an ethanol/methanol mixture.
The corresponding hydrochloride is obtained by the action of an ethanolic HCl solution.
Melting point: >260° C. Elemental microanalysis: C 20 H 19 ClN 4 O 2 .1HCl
C
H
N
Cl
% Calculated:
57.29
4.81
13.36
16.91
% Found:
56.83
4.98
12.96
16.63
Examples 28 to 30 were prepared in accordance with the procedures described above.
EXAMPLE 28
N-[3-(1H-Imidazol-4-yl)-chroman-6-yl]-1,2-dihydro-3H-benzo[e]indole-3-carboxamide
EXAMPLE 29
N-(3-Chloro-4-methylphenyl)-N′-[3-(1H-imidazol-4-yl)-chroman-6-yl]urea
EXAMPLE 30
N-(3-Chloro-4-methylphenyl)-N′-[2-(1H-imidazol-4-yl)-1,2,3,4-tetrahydro-7-isoquinolinyl]urea
Pharmacological Study
EXAMPLE A
Penile Erection Test in the Rat
The test allows the evaluation of the capacity of pharmacological agents to inhibit penile erections caused by the administration of a 5-HT 2c selective agonist, RO 60-0175.
Male Wistar rats weighing from 120 to 140 g on the day of the experiment are placed individually into plexiglass observation boxes immediately after having been administered the test compound or the carrier. Thirty minutes later, the animals are administered RO 60-0175 (1.25 mg/kg, subcutaneous route) and the number of erections that occur during the 30 minutes that follow is counted.
Results: The compounds of the invention appear to be capable of inhibiting penile erections induced by the administration of the 5-HT 2c selective agonist. They accordingly have an antagonist character in respect of 5-HT 2c receptors. By way of example, the inhibitory concentration 50 (IC 50 ) of the compound of Example 6 is 0.7 mg/kg.
EXAMPLE B
Test in the Mouse of Aggressiveness Induced by Isolation
The animals used are male CD-1 mice. On arrival, the mice are isolated in individual cages with free access to food and drink. After a period of isolation of one month, pairs of mice that are constant in their aggressiveness are selected by observation of the latent period, the number and the duration of attacks when they are placed in each other's presence.
The test takes place once a week. On the day of the test, each mouse of the pair of mice (resident mouse and intruder mouse) is given a subcutaneous injection of carrier (control animals) or of test product (treated animals) in a volume of 10 ml/kg. After 30 minutes, the intruder mouse is introduced into the cage of the resident mouse. The latent period of the first attack and the number and duration of attacks are then measured for a period of three minutes.
A product is considered as specifically anti-aggressive when it reduces the number and the duration of attacks at non-sedative doses.
Results: The compounds of the invention appear to reduce significantly the number and duration of attacks. By way of example, the inhibitory dose 50 (ID 50 ) of the compound of Example 6 is 2.5 mg/kg (subcutaneous administration).
EXAMPLE C
Marble-Burying Test in the Mouse
This test allows evaluation of the capacity of pharmacological agents to inhibit the spontaneous marble-burying behaviour in mice, the inhibition being predictive of antidepressant and/or anti-impulsive action.
Male NMRI mice weighing from 20 to 25 g on the day of the experiment are placed individually in Macrolon boxes containing 5 cm of sawdust and covered with a perforated plexiglass plate. Twenty four “tiger's eye” glass marbles are evenly distributed on the sawdust at the periphery of the box. At the end of 30 minutes' free exploration, the animals are removed from the box and the number of buried marbles is counted.
Results: The compounds of the invention appear to inhibit spontaneous marble-burying behaviour in mice. By way of example, the effective dose 50 (ED 50 ) of the compound of Example 6 is 0.4 mg/kg.
EXAMPLE D
Determination of the Affinity for α 2 Adrenergic Receptors in the Rat
The affinity was determined by competition experiments with [ 3 H]-RX 821,002. Membranes are prepared from rat cerebral cortex and incubated in triplicate for 60 minutes at 22° C. with 0.4 nM [ 3 H]-RX 821,002 and the test compound in a final volume of 1.0 ml. The incubation buffer contains 50 nM Tris-HCl (pH 7.5), 1 mM EDTA and 100 μM GppNHp. Non-specific binding is determined using 10 μM phentolamine.
Data analysis: At the end of the incubation, the incubation medium is filtered across WHATMAN GF/B filters impregnated with 0.1% polyethylenimine and washed three times with 5 ml of cooled buffer. The radioactivity retained on the filters is determined by liquid scintillation counting. The binding isotherms are analysed by non-linear regression.
Results: The compounds of the invention exhibit an antagonist activity specific for α 2 -adrenergic receptors, for example a pKi of 6.7 for the compound of Example 6.
EXAMPLE E
Pharmaceutical Composition
Formulation for the preparation of 1000 tablets each containing 10 mg of active ingredient
compound of Example 6
10 g
hydroxypropyl cellulose
2 g
wheat starch
10 g
lactose
100 g
magnesium stearate
3 g
talc
3 g
|
Compounds of formula (I):
and medicinal products containing the same which are useful as dual α 2 /5-HT 2c antagonists.
| 2
|
TECHNICAL SCOPE
The present invention relates to a cassette made of thin sheet or a similar material which is intended to constitute a lost form when casting concrete framework while co-operating with the concrete in the finished framework in the absorption of forces.
BACKGROUND TECHNOLOGY
It has previously been known how to cast framework with the aid of an integral form consisting of cassettes arranged next to one another, whereby the underside of the form constitutes a complete ceiling in the room under the framework. Such a cassette consists of a U-shaped, longitudinal unit of thin steel sheet comprising a rectangular bottom with an edge beam section extending along its respective two parallel longitudinal sides, substantially at a right angle to the bottom on the side which is to be turned up. The said edge beam section comprises both a web rising at a right angle from the bottom and at its upper edge a flange extending at a right angle away from the web and towards the centre on one side of the cassette and away from the centre on its other side. This imparts to the cross-section of the edge beam section a shape enabling adjacent cassettes to be hooked into one another so as to form a continuous framework. The flanges are at their free edges provided with a support edge facing downward, which ensures additional stability and prevents two adjacent units from sliding apart during the casting process.
When casting a framework with the known cassettes by way of a form, their ends are made to rest on the shell of the building, which may consist of a steel shell, temporary support beams resting on temporary piles supporting it along its length. The cassettes in the form are hooked to one another in sequence until the entire area of the framework has been covered. Once the adjacent webs have been joined for instance with the aid of rivets the concrete is applied.
The webs of the edge beam section are provided with holes and aligned with one another in two adjacent edge beam sections, as a result of which the concrete forms a connection along the length of the beams.
The cassettes are subject to tensile forces acting in their plane both during casting and after hardening and loading of the concrete. It is therefore important that the cassettes should be joined with great accuracy. This has proved to be difficult with previously known designs. Apart from a reduced capacity to absorb such tensile stresses the cassettes had a tendency to separate owing to indentations about the rivet heads but also because the fasteners were located too far from the undersides of the cassettes. Furthermore, if a fire broke out, the edge beam sections used also to be in part directly exposed to heat, which is normally not permissible, unless special measures were taken.
Nor are these designs proof against the escape of unbound concrete water while the concrete is being cast, such water being able to flow down on the undersides of the cassettes causing such disfigurations that costly measures could not be avoided.
SUMMARY OF INVENTION
The present invention is intended to provide a framework cassette without any of the disadvantages of the known cassettes, which is easier to install and to join and can also be made sound absorbent instead of being a source for echos. The object has been achieved by the present invention relating to a framework cassette which comprises a preferably rectangular bottom, with an edge beam section extending along its respective two parallel sides, the web thereof being substantially perpendicular to the bottom and whereby the respective edge reinforcement has a cross-section substantially identical with that of a shelf at a slightly higher point on the web. The primary tensile reinforcement consists of the cassette but the invention is also characterised by the fact that an additional section can be provided capable of constituting a tensile reinforcement especially in the transverse direction or constituting an economy device with a view to reducing the amount of concrete, creating space for larger installations and having curves in the web projections, susequently referred to as bulges, so as to bring about a shear connection between the concrete and the sheet while acting as a reinforcement for flat surfaces of the web.
The invention is described in greater detail in the subsequent paragraphs, in the claims and in the attached figures.
DESCRIPTION OF THE DRAWINGS
FIG. 1 showing cassettes in accordance with the invention and resting on a shell,
FIG. 2 showing a cross-section of the cassettes casting concrete,
FIG. 3 showing a cross-section of the cassettes casting concrete and with an economy device inserted, and
FIG. 4 showing edge beam sections before and after joining.
DETAILED DESCRIPTION OF INVENTION
The said edge beam section, 2, comprises both a web, 3, and a flange, 5, at its upper edge as well as a shelf, 6, at a base point of the web, 3, whereby the flange, 5, and the shelf, 6, extend at right angles away from the web, 3, shelf 6 towards the centre, 10, of one side of the cassette, 1, and flange 5 away from the centre, 10, on its other side. The cross-section of the edge beam section, 2, makes it possible as a result for adjacent cassettes, 1, to be hooked to one another to bring about a cohesive and tight concrete form. At least the flange, 5, which is facing away from the centre, 10, of the cassette is at its free edge provided with an edge reinforcement, 7, facing towards the edge plane, whereby a reinforcement of the joints between two adjacent cassettes, 1, is achieved. The said web, 3, also comprises projections or bulges, 8, facing towards the centre, 10, of the cassette, 1, and constituting the main link between the cassette, 1, and the concrete cast in the cassette, 1. The bulges, 8, reinforce also the plane areas of the web, 3, so as to reduce any danger of buckling.
To the cassette may also be added a rectangular top section, 9, intended for placing between the shelves, 6, and covering the space between the webs, 3, of the cassette. One side thereof is curved downward and partly backward and up. The height of the curved part, 12, is prior to mounting somewhat larger than the distance between the underside of the shelf, 6, and the upper side of bottom, 11, of the cassette. For in the course of mounting the curved part, 12, has to be inserted under the shelf, 6, being resiliently pressed together to some extent so as to join tightly to the underside of the shelf, 6, the edge beam section, 2, and the bottom, 11, of the cassette. The opposite side of the top section, 9, is bent up at a right angle and should after mounting in the cassette, 1, follow the side of the web, 3, upward to the lower row of bulges, 8, terminating in an edge bent obliquely inward and upward, i.e. the snap edge, 13, which advantageously snaps fast under the undersides of the bulges, 8. The top section, 9, can be designed either with a substantially flat top surface, 17, which after assembly extends between both webs, 3, of the cassette, 1, or it may have an upward bulging top surface, 18. When casting the concrete it is intended for the top section, 9, to close off the web, 3, and the bottom, 11, of cassette, 1, so as to create a cavity below the top section, 9. The bottom, 11, of the cassette can for instance be perforated through the enclosure so as to achieve a sound-damping effect. The cavity between the bottom, 11, of the cassette and the top section, 9, is advantageously utilised for requisite sound-insulating mats, electricity and heat and ventilation lines etc. If the top section, 9, is made with a flat surface, 17, between the webs, 3, of the cassette, 1, the top section, 9, also acts as a tensile reinforcement in the direction transverse to the longitudinal direction of the cassette, 1. If the upper surface of the cassette, 1, is bent upward, 18, the top section's, 9, capacity to absorb tensile forces is lost but on the other hand space is gained for installations and a lot of concrete is saved, thus above all reducing its weight. The main function of the concrete consists after all in absorbing the pressure loads in the upper sections of the framework and in forming a surface.
When assembling framework cassettes, 1, in order to cast a framework the said cassette, 1, is hooked to the preceding one so that the edge reinforcement, 7, of the upper flange, 5, grips the free edge of the flange below, 5, as a result of which the respective positions of the cassettes, 1, are fixed. Any pipes and lines as well as sound-absorbent mats, 14, are now placed on the bottom, 11, of the cassette, whereupon the curved part, 12, of the top section, 9, is inserted into the recess below one shelf, 6, and fixed to shelf, 6, of the opposite web, 3. The top sections, 9, are secured on the one hand to the horizontal surfaces of the shelves, 6, and on the other hand to the top sections, 9, of adjacent cassettes by means of self-cutting and self-tapping screws or possibly rivets fitted vertically through the shelves, 6, of the said web and two top sections, 9, on the upper or lower side of the shelf, 6. When the top section, 9, is exposed to tensile stresses at a right angle to the longitudinal direction of the edge beam sections, 2, the joint absorbs this stress as a shear stress acting on the fastener. This inter alia means that no indentations are formed about the heads in the sheet. As a result of the arrangement where the webs, 3, and the flanges, 9, are facing the same direction, room is made for modern assembly tools required to bring about the vertical joints. It is advantageous to locate the shelves, 6, at as low a level as possible since, inter alia, projecting parts of the joint actively take part in the co-operation between the concrete and the cassettes, 1. A disadvantage of having the shelf, 6, and the flange, 5, facing in the same direction consists in the fact that the web, 3, tends to be deflected in that direction and subjected to loading. This can be avoided by inclining the web, 2, of the cassettes, 1, the shelf, 6, and flange, 5, of which are located uppermost during assembly, towards the centre, 10, of the cassette, so that the web, 3, forms an angle of 70°-89° with the bottom, 11, of the cassette, see left-hand illustrations in FIG. 4. When the adjacent webs, 3, are joined, see right-hand illustration in FIG. 4, the assembly is inclined. In the loaded state the assembly tends to turn in the opposite direction. As a result the bending resistance of the cassette increases when it is loaded during the casting process since the controlled bending axis coincides with the main axis of inertia of the edge beam section, 2.
As a result an otherwise accelerating stress characteristic is obviated when bending a cassette, 1.
When joining the webs, 3, the bottoms, 11, of the cassettes are bent slightly upward thus compensating any downward bend when they are loaded with concrete or if top sections, 9, are used for installations, etc. With a view to reducing the danger of the bottom, 11, of the cassette buckling, the latter can be provided with grooves, 19. If required the cassette can also be made sound-absorbent by providing its bottom with a dense pattern of holes, preferably also filling the space next to the bottom with an insulating material, 14, such as mineral wool. The insulation can be so selected as to ensure fire protection of the cast framework.
Having completed the assembly of the cassettes, 1, a layer of concrete is poured over the cassettes, 1. After hardening of the concrete a construction results, which is characterised by high carrying capacity. As a result of this design, which causes the joints between the cassettes to be tightly sealed, adjacent webs, 3, are pressed against one another when they are loaded by the flowing concrete, whereas with previous conventional designs where holes were provided to join the webs there was a tendency for the webs to be pressed apart owing to internal excess pressure on the part of the concrete water.
The cassette, 1, forms a tensile reinforcement in the construction as regards bending perpendicularly to the longitudinal direction of the cassette, 1. The top section, 9, constitutes a tensile reinforcement as regards bending parallel to the longitudinal direction of the cassette, 1, and this tensile reinforcement is largely retained even in case of a fire. The bulges, 8, engaging one another and acting as dowels bring about very good shear connection between the cassette, 1, and the concrete. With this design there is practically no danger of shear failure in the shear joint. With correct assembly the casting form will be completely tight. There are no holes in the web causing the concrete water to run out in the joints between the reinforcements, and the load exerted by the concrete compresses adjacent reinforcements, not as used to be the case with previous designs tending to separate them.
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A framework cassette of thin sheet intended to be joined to adjacent cassettes so as to constitute a lost form when casting concrete framework and co-operating with the concrete in the finished framework as regards the absorption of forces. It consists of a rectangular bottom (11) along the two longitudinal sides of which edge beam sections are bent up. These edge beam sections consist in part of an upper, horizontal flange (5), a vertical web (3) with bulges (8) and furthest down a sleeve (6). On the sleeves (6) and between them is located a top section (9) which is also secured to them. The space between the top section (9) and bottom (11) of the cassette can be filled with insulation or used for installation material (14). The concrete is cast over the top section (9) and between the webs (3).
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FIELD OF THE INVENTION
[0001] The present invention relates to frequency transposition, and more particularly, to reducing the second-order nonlinearity of a frequency transposition device or mixer. The present invention advantageously applies to wireless communication systems, and more particularly, to cellular mobile telephones.
BACKGROUND OF THE INVENTION
[0002] In a terminal of a wireless communication system, such as a cellular mobile telephone for example, direct conversion or zero intermediate frequency transposition is an alternative to a superheterodyne architecture. This is particularly well suited to allow very highly integrated architectural approaches for the terminal.
[0003] A direct conversion receiver or a zero intermediate frequency receiver (zero-IF receiver) converts the band of the useful signal directly around the zero frequency (baseband). This is done instead of converting it to an intermediate frequency on the order of a few hundred MHz.
[0004] Direct conversion radio frequency receivers have a drawback with respect to the second-order nonlinearity of the input stages. Specifically, since after the mixer the band of the useful signal is centered around zero, any undesired signal, whether continuous or low frequency, is therefore a glitch or spurious signal. These spurious signals may arise in particular from the DC offset (or from the modulation of the low-frequency spurious signals) generated by input blocking signals on account of the second-order nonlinearity of the upstream stages.
[0005] More precisely, this second-order nonlinearity may arise either from the low noise amplifier (LNA) generally connected after the antenna, or from the mixer. However, any undesired low frequency signal at the output of the low noise amplifier does not present a problem to a first approximation since the mixer will convert it to a high frequency signal. Consequently, the main problem arises from the second-order nonlinearity of the mixer itself.
[0006] Most contemporary circuits do not use a specific design for solving the problem of the second-order nonlinearity of the mixer. These circuits generally use algorithms for monitoring these DC spurious signals. However, such algorithms are not easy to develop, and moreover, they are ineffective when the blocking signals do not induce a purely DC spurious signal, as is the case in constant envelope modulation GSM systems. Instead a low-frequency modulated spurious signal is generated, as is the case for non-constant envelope modulation systems, such as WCDMA systems.
[0007] Designs have been proposed for addressing this problem of second-order nonlinearity of the mixer. Some of these approaches, developed in particular for constant envelope modulation systems, are based on setting the DC offset of the mixer during production using an adjustable output load. Such an approach is described for example in the article by Alyosha Molnar, titled “A Single Chip Quad Band (850, 900, 1800, 1900 MHz) Direct Conversion GSM/GPRS RF Transceiver With Integrated VCOs And Fractional-N Synthesizer,” ISSCC 2002, session 14.
[0008] Another approach referred to as dynamic matching includes switching dynamically the inputs and the outputs so as to have a symmetric mean operation of the mixer while the mixer is operating. Such an approach is described in the article by Edwin Bautista, et al., titled “Improved Mixer IIP2 Through Dynamic Matching,” ISSCC 2000, session 23, wireless building blocks paper WP 23.1.
[0009] However, while such an approach is beneficial since it does not require an adjustment during production, it nevertheless has the drawback of requiring very good synchronization of the switching of the inputs and the outputs. This is particularly difficult to achieve since the inputs and the outputs are spaced apart on the layout on account of isolation problems. Moreover, a specific switching clock is necessary with the risk of undesired aliasing within the band of the useful signal.
SUMMARY OF THE INVENTION
[0010] In view of the foregoing background, an object of the present invention is to address the second-order nonlinearity problem of the mixer without requiring an adjustment to the mixer during production.
[0011] Another object of the present invention is also to not require a specific algorithm for monitoring the DC offsets induced by the blocking signals.
[0012] Yet another object of the present invention is to provide a mixer that is not sensitive to modulated input blocking signals. This is particularly beneficial to receivers incorporated in third generation mobile telephones.
[0013] The present invention starts from the observation that the cause of the second-order nonlinearity of a frequency transmission device or mixer is mainly due to the electrical offset in the transistors of the current switching circuit of the mixer. Starting from this observation, the present invention proposes to calibrate this offset in the mixer itself. Stated otherwise, the present invention proposes a process for reducing the second-order nonlinearity of a frequency transposition device comprising a current switching circuit with two differential pairs of transistors controlled by a local oscillator signal.
[0014] According to a general characteristic of the invention, the two differential pairs are statically mutually disconnected and dynamically mutually connected. The process may comprises a current switching circuit calibration mode, in which the local oscillator is rendered inactive and each of the two pairs is calibrated in succession by zeroing the ground path current of the pair not undergoing calibration and by setting the voltage difference applied to the bases of the transistors of the pair undergoing calibration until the output voltage of the frequency transposition device (that is, the output voltage of the current switching circuit) is zeroed to within a predetermined accuracy. The base voltage difference thus obtained is stored.
[0015] The process furthermore comprises a normal operating mode of the mixer in which the local oscillator is rendered active and the two voltage differences stored respectively on completion of the calibration mode are applied to the bases of the transistors of the two pairs. According to one mode of implementation, in the calibration mode the phase of setting the base voltage difference comprises a detection of the changing of sign of the difference in output voltage.
[0016] The voltage difference applied to the bases of the two transistors of a pair is provided by a digital analog converter in response to a digital control word. The phase of setting the base voltage difference comprises, for example, modifying the digital control word and storing the base voltage difference obtained on completion of the calibration, and then storing the corresponding digital control word. Thus, in one mode of implementation of the invention, the digital control word will be modified, for example by a decrement from a maximum value, until the changing of the sign of the output voltage difference is detected.
[0017] Another aspect of the present invention is directed to a frequency transposition device comprising a current switching circuit with two differential pairs of transistors controlled by a local oscillator signal. The two differential pairs may be statically mutually disconnected and dynamically mutually connected, and the device may comprises a calibration loop activated on command. The calibration may calibrate each differential pair by setting the voltage difference applied to the bases of the transistors of the pair undergoing calibration until the output voltage of the frequency transposition device is zeroed to within a predetermined accuracy. Storage means may store for each pair the base voltage difference obtained after calibration. Control means may either render the local oscillator inactive and activate the calibration means by zeroing the ground path current of each pair in succession, or render the local oscillator active to deactivate the calibration loop and to apply the two voltage differences stored respectively in the storage means to the bases of the transistors of the two pairs.
[0018] According to one embodiment of the invention, the calibration loop may comprise detection means for detecting the changing of the sign of the output voltage difference. The detection means may comprise a comparator whose two inputs are linked to the two differential outputs of the device.
[0019] According to one embodiment of the invention, the calibration loop comprises two digital/analog converters respectively connected to the bases of the transistors of the two pairs. Each converter may apply a voltage difference to the bases of the transistors of the corresponding pair in response to a digital control word. Monitoring means may be connected to the output of the detection means for formulating successive control words until a stop signal delivered by the detection means is received.
[0020] Additionally, each converter preferably delivers a voltage difference proportional to the absolute temperature (PTAT voltage). The control means may deactivate the calibration loop by deactivating the detection means and the monitoring means. The device according to the invention is advantageously embodied in integrated form.
[0021] The invention is also directed to a component of a wireless communication system, for example a cellular mobile telephone, incorporating a frequency transposition device as defined hereinabove.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Other advantages and characteristics of the present invention will become apparent on examining the detailed description of nonlimiting embodiments and modes of implementation, and of the appended drawings in which:
[0023] [0023]FIG. 1 is a block diagram partially illustrating the internal architecture of a cellular mobile telephone according to the present invention;
[0024] [0024]FIG. 2 is a schematic diagram illustrating in greater detail an embodiment of a frequency transposition device according to the present invention; and
[0025] FIGS. 3 to 5 are flow charts illustrating a mode of implementation of the process according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] In FIG. 1, the reference TP denotes a cellular mobile telephone incorporating frequency transposition devices or mixers MXI or MXQ according to the present invention. More precisely, the mobile telephone comprises a radio frequency stage connected to a digital stage designed around a processor PBB and analog/digital converters ADC.
[0027] The radio frequency stage comprises at the front end an antenna ANT followed by a low noise amplifier LNA connected to the two mixers MXI and MXQ. The two mixers MXI and MXQ belong in a conventional manner to two phase quadrature processing channels, customarily referred to as the I channel and the Q channel by those skilled in the art.
[0028] Each mixer MXI and MXQ receives a frequency transposition signal from a local oscillator LO. A 0/90° phase shifter between the local oscillator and the mixers allows delivery to the mixer MXQ of a local oscillator signal phase-shifted by 90° with respect to the local oscillator signal delivered to the mixer MXI. Each of the mixers is followed by a controlled-gain amplifier, and by a low pass filtering stage.
[0029] One of the mixers, for example the mixer MXI, will now be described while referring more particularly to FIG. 2. The second mixer MXQ is similar to mixer MXI. The mixer MXI has a differential structure for example and comprises a current switching circuit with two differential pairs of transistors Q 10 , Q 11 and Q 20 , Q 21 . The outputs of these transistors are coupled in a crossed manner. More precisely, the collector of the transistor Q 10 and the collector of the transistor Q 20 are linked together to form a first output terminal BS 1 . The collector of the transistor Q 11 and the collector of the transistor Q 21 are linked together to form a second output terminal BS 2 . These two output terminals form the differential output of the mixer MXI. The resistors R 1 and R 2 represent the load resistances of the mixer MXI.
[0030] The base of the transistor Q 10 and the base of the transistor Q 21 are linked together by two capacitors C 10 and C 21 connected in series. Likewise, the base of the transistor Q 11 and the base of the transistor Q 20 are connected together by two capacitors C 11 and C 20 connected in series. The midpoint of the two capacitors C 10 and C 21 as well as the midpoint of two capacitors C 11 and C 20 are respectively connected to the two terminals of the differential output of the local oscillator LO.
[0031] The two bases of the transistors Q 11 and Q 20 are moreover linked together by two resistors R 11 and R 20 . The same holds for the bases of the transistors Q 10 and Q 21 which are linked together by way of two resistors R 10 and R 21 . Voltage sources Vmc 1 and Vmc 2 allow the common mode to be monitored.
[0032] Thus, with this arrangement, the two differential pairs are statically mutually disconnected but dynamically mutually connected. That is, they are mutually connected in the presence of a radio frequency signal at the differential input BE 1 -BE 2 of the mixer MXI. In this regard, an input transconductor block is connected between the terminals BE 1 and BE 2 and the collectors of the transistors of the two differential pairs.
[0033] In the described example, which is in no way limiting, the input transconductor block comprises two bipolar transistors T 1 and T 2 whose emitters are linked to ground and whose respective bases are linked to the terminals BE 1 and BE 2 . These two transistors T 1 and T 2 are linked to the collectors of the two transistors Q 10 -Q 11 and Q 20 -Q 21 by two cascode arrangements. A voltage source Vref applied to the gates of the transistors Q 1 and Q 2 sets the static ground path current Idc 1 and Idc 2 of each of the two differential pairs.
[0034] In the described example, a set of two times three breakers I 11 , I 21 , I 31 and I 12 , I 22 and I 32 associated with two capacitors CP 1 and CP 2 , as well as with two resistors RP 1 and RP 2 , make it possible to choose between a low-gain operation or a high-gain operation.
[0035] In addition to what has just been described, the mixer comprises a calibration loop formed of a comparator CMP whose two inputs are linked respectively to the two output terminals BS 1 and BS 2 . The output of the comparator CMP is linked to monitoring means CTL regulated by a clock signal CK, and delivers a digital control word MNC (on n bits for example) to two digital/analog converters DAC 1 and DAC 2 .
[0036] The differential outputs of the converter DAC 1 are linked to the bases of the transistors Q 10 and Q 11 of the first differential pair, while the differential outputs of the converter DAC 2 are linked to the bases of the transistors Q 1 and Q 21 of the second differential pair. Thus, each converter is capable of applying a voltage difference to the bases of the corresponding transistors as a function of the control word applied to it. This control word defines a code for the converter. Control means, which may be embodied in software within the processor PBB for example, will activate or deactivate the calibration loop and the local oscillator LO.
[0037] The manner of operation of the mixer according to the invention will now be described in greater detail while referring more particularly to FIG. 3. If we consider the static behavior of the mixer, and more particularly the static behavior of each of the differential pairs taken independently of one another, then the dynamic ground path currents are zero as is the voltage delivered by the local oscillator LO which is stopped. The static current Idc 1 of the pair Q 10 -Q 11 for example, is in theory halved by the pair Q 10 -Q 11 .
[0038] However, on account of the mismatch of the transistors, there is a voltage offset which is manifested at the terminals BS 1 and BS 2 by a non-zero output voltage Vout equal to (−1+2α); RIdc 1 if we assume R=R 1 =R 2 . Thus, the DC output voltage Vout is an image of the defective matching α of the transistors Q 10 -Q 11 . Likewise, if we consider the pair Q 20 -Q 21 taken in isolation, this voltage Vout is an image of the defective matching of the transistors Q 20 and Q 21 .
[0039] An objective of the calibration loop will then be to zero this voltage Vout for each of the differential pairs taken in isolation. More precisely, as illustrated in FIG. 3, we begin for example with the calibration 30 of the pair of transistors Q 10 -Q 11 . This calibration is more particularly illustrated in FIG. 4.
[0040] For this calibration, the local oscillator LO is stopped, and the comparator CMP and the monitoring means CTL are activated. The breakers I 11 , I 12 and I 22 are open and the other breakers I 21 , I 31 and I 32 are closed. The pair Q 10 and Q 11 is then calibrated, and the static ground path current Idc 2 of the pair of transistors Q 20 and Q 21 is zeroed. This is carried out through the configuration of the breakers.
[0041] In the described example, the converter DAC 1 is given its maximum code, for example by placing all the bits of the control word at 1. The changing of the output value of the comparator CMP will be detected (step 40 ). Specifically, as long as the voltage difference Vout is positive, the comparator CMP delivers the value 1 for example, whereas if this voltage difference is negative, the comparator CMP delivers the value 0.
[0042] The changing of the output value of the comparator CMP will therefore be characteristic of the zeroing of the voltage Vout to within the accuracy of the converter DAC 1 . As long as the output value of the comparator CMP is not modified, the monitoring means will decrement (step 41 ) the control word applied to the converter DAC 1 . This will have the consequence of modifying the base voltage difference applied to the differential pair of transistors Q 10 and Q 11 .
[0043] Upon the changing of the output value of the comparator CMP, the corresponding control word will be stored (step 42 ), for example in a register RG 1 . The phase of calibration of the pair of transistors Q 10 and Q 11 is then terminated.
[0044] Thereafter one proceeds as illustrated in step 31 of FIG. 3 to calibration of the pair of transistors Q 20 and Q 21 . This calibration is illustrated in greater detail in FIG. 5. Only the differences with FIG. 4 will now be described. For this calibration, the breaker 121 is kept open and the breaker 122 closed. Also, it is now the static ground path current Idc 1 which is zeroed. Steps 50 , 51 and 52 are similar to steps 40 , 41 and 42 .
[0045] Upon the detection of the changing of the output value of the comparator CMP, the corresponding control word of the converter DAC 2 is stored in a register RG 2 . This marks the end of the calibration phase of the pair Q 20 -Q 21 .
[0046] Once this calibration mode has been performed, we then go to a normal operating mode (step 32 ). In the normal operating mode, the converters DAC 1 and DAC 2 are continuously controlled by the control words obtained on completion of the calibration mode. Consequently, they apply respectively to the corresponding transistor pairs the base voltage differences allowing electrical correction of the defective matching of the transistors of the current switching circuit.
[0047] In this normal operating mode, the local oscillator LO is active. On the other hand, the comparator CMP is inactive, as are the monitoring means CTL (clock CK off). In the normal operating mode it is then possible to choose a low-gain mode (step 34 ) in which all the breakers I 11 , I 21 , I 31 , I 12 , I 22 and I 32 are closed, or else a high-gain mode in which all the aforesaid breakers are open.
[0048] The calibration will be performed, in the case of a cellular mobile telephone, preferably when the telephone is switched on, and at later instants which will be defined by the baseband processor PBB. This will make it possible in particular to take account of the changing of the temperature which is a parameter that influences the defective matching. In this regard, it will be advantageous to provide converters DAC 1 and DAC 2 incorporating a voltage source proportional to absolute temperature (PTAT source).
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A frequency transposition device includes a current switching circuit with two differential pairs of transistors being controlled by a local oscillator signal. In a current switching circuit calibration mode, the local oscillator is rendered inactive and the two pairs of transistors are calibrated in succession by zeroing the ground path current of one of the pairs of transistors not undergoing calibration, and by setting the voltage difference applied to the bases of the transistors of the pair of transistors undergoing calibration. This is done until the output voltage of the frequency transposition device is zeroed to within a predetermined accuracy. The base voltage difference obtained is stored after calibration. In a normal operating mode the local oscillator is rendered active, and the two stored voltage differences are applied to the respective bases of the two differential pairs of transistors.
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TECHNICAL FIELD
This invention relates to optical transmission receivers or transmitters and, in particular, to apparatus for aligning an optical fiber to an electrooptic device such as a light source or receptor.
BACKGROUND OF THE INVENTION
The increasing development of optical fibers for communications purposes has created a need for a quick and inexpensive means of precisely aligning and coupling an optical fiber to a light emitter or detector. While a variety of such emitters or detectors are employed, the method of aligning and coupling is similar.
Semiconductor lasers, because of their compact size and high light output, are particularly well suited for use as emitters. The higher light output attainable extends the transmission range and reduces the number of optical amplifiers in the transmission path. The peak light-emitting area of the semiconductor laser, however, is not uniform. This area, while within the laser-emitting stripe, significantly varies among devices. Therefore, individual alignment of each laser and fiber is required to achieve low optical coupling loss. For similar reasons, individual alignment is also required for light-emitting diodes and photodiodes.
It is known (Bell System Technical Journal, March 1972, pages 573-594) to mount both the laser and fiber on separate holders and use micromanipulators to move the holders and thereby attain the desired alignment of laser and fiber. The optimum positioning is then secured by epoxy. The technique is time consuming and requires the use of precision fixturing.
The use of V-grooves on the orthogonal faces of a coupler block is disclosed by G. D. Khoe et al in U.S. Pat. No. 4,030,811, issued on June 21, 1977. This procedure requires precise initial placement of the laser on a cylindrical mounting rod. The laser position is then adjusted by sliding the rod in a V-groove disposed in a coupler block. Fabrication of the block is expensive and the laser mounting arrangement provides marginal thermal dissipation capacity due to the limited contact area between mounting rod and V-groove. This exiguous dissipation capacity substantially increases the likelihood of premature laser failure.
In U.S. Pat. No. 4,065,203 to Goell et al, issued Dec. 27, 1977, the use of a stepped header or mounting apparatus for a laser and optical fiber is disclosed. Both of these elements are located on different levels and with the aid of epoxy are aligned. As epoxy deteriorates under varying temperature and humidity conditions, this technique does not possess long term stability required in telecommunications applications.
SUMMARY OF THE INVENTION
The above-described prior art problems are solved, in accordance with one aspect of the invention, by mounting the device and optical fiber on a precisely formed stepped header. The improvement over the prior art resides in that the difference between the device and fiber mounting levels is precisely fabricated so that when the device and the fiber are placed on their respective mounting levels, the misalignment is only along one dimension. As a result, precise alignment is more rapidly achieved and maintained. Specifically, the time necessary to precisely align the device and fiber is reduced at least 50 percent. Moreover, as an epoxy or other material is not required to bring the two elements into alignment along a second direction, the precision positioning is not affected by temperature or humidity.
According to another aspect of the invention, the header can be modified to provide a hermetic laser-optic fiber junction.
It is an advantage of the invention that both header configurations can be readily molded within an optical fiber connector assembly. As a smooth surface finish is required for engaging surfaces of such assemblies, an embodiment of the header is provided with an integral tube for entrapping gases during the molding process. This technique is set forth in detail in copending application of L. Curtis, Ser. No. 837,398, filed Sept. 28, 1977, assigned to applicants' assignee.
In another embodiment of the invention, the header is advantageously employed to provide mounting means for the optical connector containing a light emitter or receptor.
All of the above embodiments are, of course, equally applicable to use with a myriad of optical sources or receptors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an embodiment of a nonhermetic header with a semiconductor laser and attached electrical connections;
FIG. 2 illustrates the method of precisely aligning the optical fiber to the laser;
FIG. 3 shows an optical fiber precisely aligned and secured to the laser-header combination of FIG. 1;
FIG. 4 depicts a hermetic header in accordance with the present invention;
FIG. 5 shows the hermetic header and aligned laser and optical fiber;
FIG. 6 shows an embodiment of the non-hermetic header with provisions for fabricating an integral tube to facilitate the molding of the header and optical fiber within a plastic optical connector;
FIG. 7 illustrates the side view of FIG. 6 after forming the tube; and
FIG. 8 shows an embodiment of an optical connector containing the header of either FIG. 3 or FIG. 5.
DETAILED DESCRIPTION
Referring to the drawings, FIGS. 1, 2 and 3 show a nonhermetic metallic header for aligning and coupling an electrooptic device to an optical fiber in accordance with the present invention. The device 15, which can be either an optical source, such as a laser or an LED, or an optical detector, is permanently bonded on a plateau 11 by means such as soldering. Also provided on header 10 is a fiber receiving trough 12 disposed adjacent to the plateau 11. The trough has a flat bottom 13 and is configured to have a precise depth D to facilitate the alignment process to be discussed infra.
The header is also advantageously provided with mounting holes 16 as well as electrical feedthrough trough 18. Electrical feedthrough 14 is inserted into trough 18 and the inner wire 9 is permanently secured to device 15 by means of solder 17. The dimension or shape of electrical feedthrough trough need not be precise, as the function of the trough is merely to hold feedthrough 14 in an approximate position for soldering to device 15.
For purposes of illustration and discussion, the method of aligning and coupling a device such as a laser to the fiber is shown in detail in FIG. 2. The laser 15 with its inner wire 9 affixed, is activated. Optical fiber 19 is fully inserted until its mating end 20, or a portion thereof, is in contact with output face 21 of laser 15. To achieve optimum coupling, fiber 19 is moved transversely, as indicated by arrows L-L', across the output face 21 of laser 15 until maximum light output is measured at the opposite end 23 of fiber 15. While fiber 15 is in this optimum position, bonding agent 25, such as epoxy is dispensed over laser 15 and fiber 19 to retain the two in optimum alignment. After the bonding agent sets, fiber 19 can be cut to any desired length. It should be noted that if epoxy is used here it is only to hold the fiber in a position of optimum coupling, rather than as in the prior art to achieve optimum alignment itself. Therefore, temperature and humidity variations, which adversely affect the epoxy, will not affect the precision alignment.
As shown in FIG. 2, the depth D of fiber receiving trough 12 is precisely formed so that when fiber 19 is fully inserted the center of fiber 19, immediately adjacent to laser 15, lies in a plane of maximum light output from laser 15. This plane, (A-A'), parallel to the trough bottom, intersects the point of maximum light emission from laser 15. As a result, the alignment process is limited to adjustment of the fiber 19 in only one dimension (L-L'). Of course, the above-described alignment procedure could be performed by fixing the fiber in the trough and moving the laser across plateau 11. As noted above, the use of epoxy in this instance is only to hold the fiber in optimum position, rather than as in the prior art to achieve the optimum alignment itself.
It should also be understood that a further advantage of the present invention is that by providing a trough width W that is many times the width X of laser 15, the laser may be positioned over a range of locations along plateau 11 without adversely affecting coupling efficiency.
A metallic hermetic header 30 having all advantages of the nonhermetic header 10 is shown in FIGS. 4 and 5. The hermetic header embodiment is provided with a well portion which includes a plateau 31 on which a laser 32 is mounted and a fiber receiving trough 33 with a flat bottom 34. In similar fashion, header 30 is also advantageously provided with both an electrical feedthrough trough 35, for electrical lead 36, and mounting holes 37. The dimensional requirements of fiber receiving trough 33 is identical to that of trough 12 described above.
Alignment of the fiber to the laser with the hermetic header is identical to the procedure described with regard to the nonhermetic embodiment. As the fiber 43 is flexible, the length of fiber within the well portion 39 of header 30 can be moved laterally to attain optimum coupling. A bonding agent is again used to permanently secure the fiber relative to the laser.
Access to the well portion of the header is provided by holes 41 and 40, dimensioned so as to accommodate an optical fiber and an electrical lead, respectively. Sealing of the holes can be accomplished by several techniques. As illustrated in FIG. 5, solder preform 44 is disposed between optical fiber 43 and the periphery of hole 41. With the application of heat, the preform will melt and seal the annulus surrounding fiber 43. In similar fashion, preform 42 seals hole 40 containing electrical lead 36. Another sealing technique is to coat both the insulation 45 of lead 36 and the circumference of fiber 43 with solder in the region adjacent to raised periphery 38. After fiber 43 and lead 36 are inserted through holes 41 and 40, respectively, the deposition of additional solder seals both openings.
Completion of the hermetic seal is accomplished by soldering or welding a metal plate, not shown, to each side of the raised periphery. This operation may be facilitated by the use of another solder preform 46 as shown in FIG. 5.
Both the hermetic and nonhermetic header may be molded within an optical connector plug, as for example the type disclosed in the copending application of P. K. Runge, Ser. No. 630,930, filed Nov. 11, 1975, assigned to the applicants' assignee, to provide an optical receiver or transmitter. During molding, entrapped gases tend to produce voids in the mating surfaces of the connector shell. These voids can cause misalignment of the connector halves and result in optical losses. To avoid this both headers can advantageously be provided with an integral tube which extends from the header and surrounds the optical fiber. During the molding operation, the tube retains entrapped gases in the mold, thereby eliminating the problem of voids on the mating surfaces of the finished connector.
FIG. 6 illustrates the nonhermetic header provided with provisions for fabricating an integral tube. The header 55 of the type described above is formed with a T-shaped extension 50 having ends 51. After inserting the fiber 59 within a plastic tubular mandrel 52, the ends 51 are rolled around the mandrel as shown in FIG. 6 to form a metal tube 53. FIG. 7 depicts a side view of the finished tube and header.
FIG. 8 illustrates an optical connector plug 60 containing either of the above-described headers. The ends of the header containing mounting holes 61 protrude through the connector shell 60, thereby providing convenient mounting means. The optical fiber 62 also protrudes from the connector shell 60. The mating end of the fiber is embedded within a flexible contact dome 63. To provide an optical connection, the flexible dome 63 is compressed against a corresponding dome on a mating connector half (not shown) containing only an optical fiber.
Satisfactory models of the nonhermetic header have been fabricated from copper by a coining process. The process can be used as well for the hermetic header. The copper is then advantageously gold plated to provide a good surface for bonding of the laser. While the header can be manufactured from a choice of ductile metals, it is preferable to use a metal with high thermal conductivity to facilitate the transfer of heat from the semiconductor laser.
While the above descriptions refer to the alignment of a semiconductor laser to an optical fiber, it is to be understood that the present invention is equally applicable for the alignment and coupling of optical fibers to other devices, such as light-emitting diodes and photodiodes.
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The invention relates to apparatus for precisely aligning an optical device, i.e., a light source or receptor, to an optical fiber. In one embodiment, the apparatus comprises a header (10) having a plateau (11) for mounting the device (15) and a trough (12) for positioning of the optical fiber (19). The depth (D) of the trough is precisely configured so that the alignment process is limited to adjustment in only one direction (L-L'). A second embodiment (30) allows for the hermetic enclosure of the optical device and adjacent section of optical fiber while providing the same alignment advantage.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. national phase patent application under 35 U.S.C. §371 of International Patent Application Serial No. PCT/DE2015/200353, having an international filing date of 9 Jun. 2015, and designating the United States, which claims priority based upon German Patent Application No. DE 10 2014 212 421.2, filed on 27 Jun. 2014, the entire contents of each of which applications are hereby incorporated by reference herein to the same extent as if fully rewritten.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present invention relates to a dual clutch, in particular a multi-plate dual clutch for coupling a drive shaft of a motor vehicle engine to a transmission shaft of a motor vehicle transmission and/or an auxiliary output shaft of an auxiliary power take-off of the motor vehicle, in particular a power take-off shaft. The dual clutch includes a drive clutch for coupling the motor vehicle engine with the transmission shaft and an auxiliary power take-off clutch for coupling the motor vehicle engine with the auxiliary output shaft. The drive clutch and the auxiliary power take-off clutch are each to be actuated independently of one another by means of a separate lever mechanism.
[0004] Description of the Related Art
[0005] Dry dual clutches that are installed outside of the transmission on the vehicle and are actuated mechanically are known from the prior art. Such conventional dual clutches have a first clutch for driving operation, the so-called drive clutch or drive shaft clutch, and a second clutch for an auxiliary drive, for example a power take-off drive, the so-called auxiliary drive clutch or power take-off drive clutch. A distinction is made between conventional dual clutches, in which the drive shaft clutch and the power take-off shaft clutch are engaged in the deactivated state, and safety clutches (so-called safety PTO dual clutches), in which the drive shaft clutch is engaged in the deactivated state and the power take-off shaft clutch is disengaged in the deactivated state.
[0006] It is disadvantageous that in such known dry dual clutches the maximum thermal absorptive capacity of the clutches and the maximum thermal capacity of the clutch linings as a rule is quickly reachable, in particular when transmitting high torques. Increasing the transmissible torque while keeping the construction size the same is therefore limited. In the critical load range, high wear of the friction linings and a resulting change of the operating points and clamping forces is therefore the negative consequence.
[0007] Added to the problem situation described above is the fact that the average power of motor vehicles using dual clutches, for example tractors, and thus the demands on the clutches, are constantly growing. Present-day tractor dual clutches have reached their performance limits in some cases, especially with regard to thermal demands.
[0008] In WO 2006/084435 A1 a clutch unit is disclosed having a housing that is attachable to a flywheel. To make a first and a second clutch in that clutch unit two contact plates are contained which are non-rotating relative to the housing but are axially movable, and to each of which a clutch disk is assigned. The clutches are actuatable independently of one another by means of lever arrangements that are swivel-mounted on the housing, wherein one lever arrangement is coupled with each contact plate to disengage and engage the corresponding clutch The first clutch facing the flywheel is engaged in the non-actuated state by means of a diaphragm spring clamped between its contact plate and the housing, the diaphragm spring being positioned axially between the adjacent contact plates. The second clutch, provided on the side of the first clutch facing away from the flywheel, is disengaged in the non-actuated stage and is forced closed by a force exerted on its lever arrangement, the lever arrangement of the second clutch being coupled with the assigned contact plate by means of axially operative tensile elements. There is at least one spring element clamped between the tensile elements and the contact plate, which has a predetermined pre-tensioning when the second friction clutch is disengaged and undergoes an additional elastic deformation as the second clutch is engaged.
[0009] In DE 10 2012 207 244 A1 a clutch arrangement is disclosed for use in the drive train of a tractor, including a drive clutch and an auxiliary drive clutch, wherein the drive clutch is positioned between an internal combustion engine and a transmission input shaft, and the auxiliary drive clutch is positioned between the internal combustion engine and an auxiliary drive, wherein the clutch arrangement includes a clutch housing having a formed sheet metal part.
[0010] In DE 10 2013 214 966 A1 a dual clutch is disclosed for coupling a drive shaft of a motor vehicle engine with a transmission shaft of a motor vehicle transmission, and/or an auxiliary power take-off of the motor vehicle, in particular a power take-off shaft. The dual clutch includes a first friction clutch for frictionally pressing a first clutch disk that is couplable with the transmission shaft between a first contact plate and a first counter plate, wherein the first contact plate is movable in an axial direction to engage the first friction clutch. A second friction clutch is included for frictionally pressing a second clutch disk that is couplable with the auxiliary power take-off between a second contact plate and a second counter plate, wherein the second contact plate is movable in the axial direction to engage the second friction clutch. A first actuating element is provided to move the first contact plate and a second actuating element is provided to move the second contact plate, wherein the second contact plate is connected to a thrust ring that is operationally connected to the second actuating element to transmit the displacing movement. A pre-stressed pressure storage element is positioned between the second actuating element and the thrust ring. In DE 10 2013 215 079 A1 a dual clutch is disclosed for coupling a drive shaft of a motor vehicle engine with a transmission shaft of a motor vehicle transmission and/or to an auxiliary power take-off of the motor vehicle, in particular a power take-off shaft. The dual clutch includes a first friction clutch for frictionally pressing a first clutch disk that is couplable with the transmission shaft between a first contact plate and a first counter plate, wherein the first contact plate is movable in an axial direction to engage the first friction clutch. A second friction clutch is provided for frictionally pressing a second clutch disk that is couplable with the auxiliary power take-off between a second contact plate and a second counter plate, wherein the second contact plate is movable in the axial direction to engage the second friction clutch. The dual clutch includes a first actuating element to move the first contact plate and a second actuating element to move the second contact plate. The second contact plate is connected to a thrust ring that is operationally connected to the second actuating element to transmit the displacing movement. The second actuating element has at least one spring element for pre-biasing, wherein the at least one spring element is positioned between the second actuating element and the thrust ring.
[0011] Starting from the above-identified prior art, an object of the present invention is to develop a dual clutch that can absorb and remove more frictional heat with the same or only slightly greater construction space, and, in addition, offers easy increase of the maximum torque. The dual clutch in accordance with the present invention should be capable of replacing known dual clutches with minimal modification effort and expense for the customer (a plug-in solution).
SUMMARY OF THE INVENTION
[0012] The object noted above is achieved by the present invention in the case of a clutch conforming to the genre, the dual clutch having a wet chamber housing in which the drive clutch and the power take-off clutch are accommodated fluid-tight, while the respective lever mechanisms for the drive clutch and for the auxiliary power take-off clutch are located outside the wet chamber housing. The dual clutch according to the present invention is preferably designed as a multi-plate clutch. A wet chamber housing is understood to mean a housing that is capable, inherently or through the use of seals, of creating a space that contains lubricant and is sealed/delimited against the outside.
[0013] A particular advantage of the present invention is that a conventional, existing dual clutch, for example a dry dual clutch, can be exchanged for a wet dual clutch according to the present invention with only a little modification effort and expense for the customer. The dual clutch according to the present invention is actuated by means of a lever mechanism that is outside the wet chamber housing. The clutch friction devices of both a drive clutch and an auxiliary power take-off clutch are located in a sealed area known as the wet chamber, which is enclosed by the wet chamber housing and is sealed fluid-tight. The dual clutch can therefore be designed and used advantageously as a wet clutch, so that with the same or only slightly greater construction space compared to known dual clutches according to the genre, a large volume of frictional heat can be absorbed and removed. In addition, the dual clutch according to the present invention is especially well suited for transmitting high maximum torques.
[0014] The drive clutch and the auxiliary power take-off clutch are actuatable independently of one another; in particular they are engageable simultaneously.
[0015] The dual clutch according to the present invention is thus especially well suited for use in agricultural machinery such as tractors.
[0016] Advantageous embodiments of the invention will be explained in greater detail below.
[0017] According to one embodiment of the present invention, the dual clutch can have a clutch housing that supports the lever mechanisms. A drive clutch friction lining that is coupled with the drive shaft can be positioned compressably between a first clamping plate and the clutch housing. An auxiliary output friction lining that is coupled with the auxiliary output shaft can be positioned compressably between a second clamping plate and the clutch housing. The first contact plate and the second contact plate can each be indirectly or directly operationally connected and movable, in particular movable independently of one another, to engage the drive clutch and the auxiliary power take-off clutch by means of the applicable lever mechanism. The friction linings can be designed in particular as disk packs.
[0018] The wet chamber housing preferably rests against the clutch housing through a seal, preferably a labyrinth seal, and is sealed in relation to the clutch housing.
[0019] In one embodiment, the wet chamber housing can have a first wet chamber housing half with a first housing part and a second housing part. The housing parts are joined with one another fluid-tight in an advantageous manner, in particular welded to one another, for example by means of a laser-welded seam. Housing sealing can be located between the two housing halves. In one form of the invention, the first wet chamber housing half rests against the clutch housing through the seal or labyrinth seal and is sealed in relation to the clutch housing. It is of particular advantage if one housing part or a plurality of housing parts or all housing parts are formed sheet metal parts, in particular deep drawn parts.
[0020] In one embodiment, the wet chamber housing has a second wet chamber housing half that can be securely connected to the clutch housing, in particular by welding. It can also rest closely against the drive shaft and/or the output shaft, providing a seal, in particular by means of an oil seal.
[0021] It is of particular advantage if the wet chamber housing or the first wet chamber housing half has a flange for connection to the motor vehicle structure, preferably on a transmission housing, in particular for connecting it in a non-rotatable condition. That enables the clutch to be positioned especially easily on the vehicle, and is well suited for exchanging an already existing clutch.
[0022] In another embodiment of the present invention, the wet chamber housing or the first wet chamber housing half can form a bearing seat, in particular for a roller bearing that supports the clutch housing so that it can rotate relative to the wet chamber housing. Such an arrangement is easy to assemble. The roller bearing is preferably a sealed bearing, so that no additional measures are necessary to seal the wet chamber at that location.
[0023] The wet chamber housing preferably has a coolant inlet, in particular a cooling oil inlet, and additionally, or alternatively, a coolant outlet (cooling oil outlet) on its underside. In that way, the interior space or wet chamber surrounded by the wet chamber housing, in which the drive clutch and the auxiliary power take-off clutch with the respective corresponding actuating mechanisms are accommodated, can be flushed with coolant especially simply. Through the connections, for example, cooling oil from an oil reservoir, or transmission oil from the transmission, can be introduced into the wet chamber and returned from it back into the oil sump of the transmission through the outlet. For the most effective possible return of oil from the wet chamber housing, it is beneficial if a coolant channel is provided to collect the coolant. Instead of a coolant inlet in the wet chamber housing, coolant can be introduced into the wet chamber housing via the drive shaft, and/or the auxiliary output shaft, and/or a gap between them.
[0024] In another embodiment, the wet chamber housing has a feed-through that accommodates the first contact plate or the second contact plate, or a transmission element connected to the first or second contact plate, so that it is positionable between the lever mechanism and the respective contact plate in the axial direction. The feed-through is preferably sealed by means of an O-ring seal.
[0025] Alternatively, or additionally, the wet chamber housing can have a feed-through through which an additional drive clutch housing or an additional auxiliary power take-off clutch housing is carried out from the wet chamber housing. That acts as a contact plate and in addition carries a friction lining or friction lining pack in the radial direction. The feed-through is preferably sealed by means of O-ring seals.
[0026] In another form of the present invention, the wet chamber housing or the second wet chamber housing half can be sealed in relation to the drive shaft and/or the auxiliary output shaft by means of an oil seal. That brings about an especially effective and reasonably-priced sealing of the wet chamber enclosed by the wet chamber housing.
[0027] In another embodiment of the present invention, the drive clutch can have a disk carrier that is non-rotatably connected to the drive shaft, and the auxiliary power take-off clutch can have a disk carrier that is non-rotatably connected to the auxiliary output shaft.
[0028] The drive clutch can have a disk carrier. The latter is non-rotatably positioned on the drive shaft, for example by means of a toothed connection. The auxiliary power take-off clutch can likewise have a disk carrier. The latter is non-rotatably positioned on the auxiliary output shaft, for example by means of a toothed connection. The disk carrier or carriers may can be a formed sheet metal part, for example a deep drawn part, and can carry the friction lining, for example on an outer edge segment.
[0029] The clutch housing of the dual clutch can be formed essentially of a clutch base plate, also referred to as the clutch housing, and a base plate carrier, which are designed as an essentially bell-shaped, formed sheet metal part, for example as a deep drawn part. The clutch base plate and base plate carrier can be welded together. A plurality of lever holders, also referred to as lever bearing blocks, can be positioned on the clutch base plate, for example by means of rivets. Each lever holder serves as a pivot support for an actuating lever for one of the clutches.
[0030] The clutch housing, for example in particular the base plate carrier, can be connected to an arc-shaped spring damper unit by means of a toothed connection, and can be coupled with it rotationally. The latter can be connected to a flywheel, which in turn can be connected to the drive unit. It is particularly advantageous if the clutch housing, in particular the base plate carrier, is supported in the axial direction by means of a journal bearing unit or similar bearing unit, in particular on the flywheel. In that way, relative movements between the flywheel and the clutch housing or base plate carrier can be absorbed. One of the shafts, the auxiliary output shaft or the drive shaft, can be supported on the flywheel by means of a roller bearing.
[0031] The friction lining of the auxiliary power take-off clutch can be positioned between the clutch housing, in particular the clutch base plate, and the disk carrier.
[0032] Its disks are arranged in the axial direction and can be pressed together in the axial direction by means of the contact plate between the latter and the clutch housing, in particular the base plate carrier. The friction lining of the drive clutch can be located radially inside the plate carrier between the latter and a drive clutch housing. Its disks are arranged in the axial direction and can be pressed together in the axial direction by means of the contact plate between the latter and the drive clutch housing.
[0033] The lever mechanism for the auxiliary power take-off clutch can include an actuating lever that is pivotable about a pivot axis and is biased by means of a spring. It can carry a peg on which an actuating means, for example an eye bolt, is positioned so that it can pivot. The actuating means is operationally connected to the contact plate in the axial direction. The contact plate and actuating means are preferably fixed in positions that are adjustable relative to one another. The actuating lever can be in contact with an adjuster ring. The latter is preferably supported relative to a locating pin by means of a roller bearing system, so that relative rotation between adjuster ring and locating pin is possible and position changes of the locating pin in the axial direction are transmitted to the adjuster ring.
[0034] Alternatively, the actuating lever can be provided with a threaded through hole running in the axial direction, into which an adjusting screw is screwed. The latter can extend through the actuating lever in the axial direction and be in contact with a drive clutch housing. The clutch can be adjusted by repositioning the adjusting screw relative to the actuating lever. The drive clutch housing can function as a contact plate, and in particular can have a collar that is located on the side of the disk pack facing away from the actuating lever in the axial direction, and that presses the disk pack in the axial direction against the clutch housing or t he clutch base plate when actuated by the actuating lever.
[0035] Between the drive clutch housing and the contact plate (a part of the contact plate or a clutch base plate) of the auxiliary power take-off clutch, a power storage unit, for example a diaphragm spring, is advantageously positioned. It can also be said that the contact plate and the drive clutch housing are under tension with one another in the axial direction by means of the diaphragm spring.
[0036] Expressed differently and in summary, the dual clutch according to the present invention, which can, for example, be a tractor dual clutch, that has two clutches—one for the propulsion drive and one for the auxiliary power take-off (power take-off shaft). Each of the two clutches is actuated by means of a disengaging system present on the vehicle. This system sets the lever mechanism of the relevant clutch in motion, which results in disengaging or engaging the friction device. In particular, the clutches can be actuated simultaneously and engaged simultaneously. An increase in the torque can be enabled by adding additional frictional and steel disks. The construction space remains nearly the same when that is carried out. Parts of the dual clutch are located in a sealed waste housing that is non-rotatably connected to a transmission bell housing of the motor vehicle. Attached thereto is a connection that serves as an outlet and is located on the bottom of the waste housing to carry oil back to the oil sump of the transmission. The input of the cooling oil can occur through a separate connection in the waste housing, or through a transmission input shaft in the form of a hollow shaft, or through a gap between a solid shaft and a hollow shaft as transmission input shafts. The drive clutch and power take-off shaft clutch can be damped by using an arc-shaped spring damper. The friction system can be subjected beneficially to an oil volume flow whose task is to remove frictional heat that has developed in the clutch. Increased service life of the friction system also results. According to the invention, the lever mechanism is located outside the wet chamber capsule. The friction linings or disk packs with disk carriers are located within the wet chamber. In that case, the clutch housing, in particular the clutch base plate, contributes fundamentally to the sealing of the wet chamber. Between the clutch base plate and the wet chamber waste housing is a large seal, in particular a labyrinth seal, which seals the wet chamber off from the surroundings.
[0037] The wet dual clutch according to the present invention, which can be realized in particular as a tractor dual clutch, offers several advantages in comparison to known dry systems. Heat can be removed effectively through oil cooling, which guarantees operation with a long service life, even under heavy loads. Because of low friction on the friction surfaces, there is little wear on the friction linings. It is easy to adapt to increases in torque with very little effect on construction space by the number of friction linings. A disengaging system previously used or installed on the motor vehicle can be taken over unchanged to actuate the clutch. All-in-all, only slight changes need to be made to the vehicle. Multiple embodiments of the invention will be explained in greater detail below on the basis of drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The drawing figures show the following:
[0039] FIG. 1 is a schematic sectional view of a dual clutch according to the present invention and having a drive shaft clutch and a power take-off shaft clutch,
[0040] FIG. 2 is an enlarged detail of the power take-off clutch of FIG. 1 ,
[0041] FIG. 3 shows the flow of torque in the power take-off shaft clutch of the dual clutch of FIG. 1 ,
[0042] FIG. 4 shows the flow of torque in the drive shaft clutch of the dual clutch of FIG. 1 ,
[0043] FIG. 5 shows a basic layout diagram of clutch forces in the deactivated state,
[0044] FIG. 6 shows a basic layout diagram of the actuation of the power take-off shaft clutch,
[0045] FIG. 7 shows a basic layout diagram of the actuation of the drive shaft clutch,
[0046] FIGS. 8A and 8B show basic layout diagrams of the cooling oil flow directions within the clutch,
[0047] FIG. 9 shows an enlarged detail of the axial support of the dual clutch of FIG. 1 ,
[0048] FIG. 10 is a schematic view showing the installation of the dual clutch of FIG. 1 on a vehicle,
[0049] FIG. 11 shows a perspective partial sectional view of a housing seal, and
[0050] FIG. 12 shows basic layout diagrams of the components of the housing seal of FIG. 11 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] The figures are merely schematic in nature, and serve only to aid in understanding the present invention. The same elements are identified by the same reference numerals. Details of the different embodiments can be combined with one another.
[0052] FIG. 1 shows a dual clutch 1 according to the present invention. It includes a first, radially inner clutch unit 2 , in the present exemplary embodiment a drive shaft clutch 2 , and a second, radially outer clutch unit 3 , in the present exemplary embodiment a power take-off shaft clutch 3 . The dual clutch 1 is designed as a wet clutch.
[0053] Referring to FIG. 2 , power take-off shaft clutch 3 has a disk carrier 4 , that is non-rotatably positioned on a power take-off shaft 6 by means of power take-off shaft toothed connection 5 . The disk carrier 4 is an essentially bell-shaped formed sheet metal part, for example a deep drawn part, and carries a disk pack 8 on the outer side of its radially outer edge segment 7 .
[0054] The drive shaft clutch 2 has a disk carrier 9 , that is non-rotatably positioned on a drive shaft 11 by means of drive shaft toothed connection 10 . The disk carrier 9 is an essentially bell-shaped formed sheet metal part, for example a deep drawn part, and carries a disk pack 13 on the inner side of its radially outer edge segment 12 .
[0055] Furthermore, the dual clutch 1 has a clutch housing 14 . The latter is formed essentially of a clutch base plate 15 , also referred to as the power take-off clutch housing 14 , and a base plate carrier 16 , that are each designed as an essentially bell-shaped formed sheet metal part, for example as a deep drawn part. The clutch base plate 15 and the base plate carrier 16 are welded together by means of a welded seam 17 running in the circumferential direction. Positioned on the clutch base plate 15 are a plurality of lever holders 18 , also referred to as lever bearing blocks 18 , by means of rivets 19 . Each lever holder 18 serves as a pivot support for an actuating lever 20 for the power take-off shaft clutch 3 or for an actuating lever 21 (see FIG. 1 ) for the drive shaft clutch 2 , in each case about a respective pivot axis 22 located in a respective lever holder 18 .
[0056] The base plate carrier 16 is connected to an arc-shaped spring damper unit 24 through a toothed connection 23 , and is thereby coupled rotationally with the arc-shaped spring damper unit 24 . The latter has a flange by means of threaded connections 25 and is connected to a flywheel 26 , which in turn is connected by means of threaded connections 27 to a drive (not shown), for example an internal combustion engine.
[0057] As shown in particular in FIG. 9 , the base plate carrier 16 is supported on the flywheel 26 in the axial direction by means of a journal bearing unit 28 . The journal bearing unit 28 serves to enable relative movements between the flywheel 26 and the base plate carrier 16 , which is non-rotatably positioned in contact with the arc-shaped spring damper unit 24 . Furthermore, the power take-off shaft 6 is supported in the flywheel 26 by means of a roller bearing 29 . The result is that the base plate carrier 16 rotates at the drive speed N an , and with it also the clutch base plate 15 , as shown in FIG. 1 , aside from rotation speed fluctuations due to a damping effect brought about by means of the arc-shaped spring damper unit 24 .
[0058] As best seen in FIG. 2 , the disk pack 8 of the power take-off shaft clutch 3 is positioned between the clutch base plate 15 and the disk carrier 4 . Its disks are arranged in the axial direction, and can be pressed together in the axial direction by means of a contact plate 30 between the latter and the base plate carrier 16 , so that torque is transmitted from the flywheel 26 through the arc-shaped spring damper unit 24 , the toothed connection 23 , the base plate carrier 16 , the clutch base plate 15 , the disk pack 8 , the disk carrier 4 and the power take-off shaft toothed connection 5 to the power take-off shaft 6 .
[0059] The disk pack 13 of the drive shaft clutch 2 is located radially inside the disk carrier 9 between the latter and a drive clutch housing 46 . Its disks are arranged in the axial direction, and can be pressed together by means of the drive clutch housing 46 between the latter and the clutch base plate 15 , so that torque is transmitted from the flywheel 26 through the arc-shaped spring damper unit 24 , the toothed connection 23 , the base plate carrier 16 , the clutch base plate 15 , the disk pack 13 , the disk carrier 9 , and the drive shaft toothed connection 10 to the drive shaft 11 .
[0060] As shown in FIG. 1 , contact plate 30 consists essentially of an inner contact plate part 36 and an outer contact plate part 37 . The inner contact plate part 36 is positioned on the side of the clutch base plate 15 facing toward the disk pack 8 (the inner side or wet side of the clutch). The outer contact plate part 37 is positioned on the side of the clutch base plate 15 facing away from the disk pack 8 (toward the outer side or dry side of the clutch). The inner contact plate part 36 and the outer contact plate part 37 are connected to one another by means of a thrust cylinder 38 , which extends through an opening formed in the axial direction in the clutch base plate 15 . The thrust cylinder 38 is sealed in relation to the clutch base plate 15 by means of an O-ring seal, and is movable in the axial direction in the opening in the clutch base plate 15 , relative to the latter.
[0061] The actuating lever 20 for the power take-off shaft clutch 3 has an outer lever end 31 formed radially outside the pivot axis 22 , and an inner lever end 32 formed radially inside the pivot axis 22 , and is pre-biased by means of a torsion spring 65 . The outer lever end 31 includes a peg 33 on which an eye bolt 34 is carried by means of its eye so that it can pivot around the peg 33 . The end of the eye bolt 34 opposite the eye is provided with threads and extends through an opening provided in the outer contact plate part 37 in the axial direction. The outer contact plate part 37 and the eye bolt 34 are fixed in the axial direction in positions that are adjustable relative to one another by means of a threaded connection with lock nut 35 . The radially inner lever end 32 works together with a conventional release unit which is not shown in the drawings, and by means of the latter is able to be moved in the axial direction.
[0062] As shown in FIG. 1 , actuating lever 21 for the drive shaft clutch 2 has a radially inner lever end 39 formed radially inside the pivot axis 22 , and is pre-biased by means of a torsion spring 66 . The radially outer lever end 40 of the actuating lever 21 is provided with an opening through which the pivot axis 22 extends. The inner lever end 39 works together with a release unit (not shown) and by means of the latter is able to be actuated in the axial direction. Radially inside the pivot axis 22 , the actuating lever 21 is provided with a threaded through opening 44 running in the axial direction. An adjusting screw 45 is screwed into the latter, which extends through the actuating lever 21 in the axial direction and is in contact with the drive clutch housing 46 . The drive clutch 2 can be adjusted by repositioning the adjusting screw 45 relative to the actuating lever 21 . The drive clutch housing 46 has a collar 47 that is located on the side of the disk pack 13 facing away from the actuating lever 21 in the axial direction, and presses the disk pack in the axial direction against the clutch base plate 16 by actuation of the actuating lever 21 .
[0063] Positioned between the drive clutch housing 46 and the outer contact plate part 37 is a diaphragm spring 48 (see FIG. 4 ). The radially inner side of the diaphragm spring 48 rests against the drive clutch housing 46 , with a metal ring 49 inserted in between. The radially outer side of the diaphragm spring 48 is in contact with the contact plate part 37 . It can also be noted that the outer contact plate part 37 and the drive clutch housing 46 are under tension with one another in the axial direction by means of the diaphragm spring 48 .
[0064] The drive shaft clutch 2 and the power take-off shaft clutch 3 are actuatable independently of one another. In the non-actuated state, both the power take-off shaft clutch 3 and the drive shaft clutch 2 are engaged (normally closed). The pressure force necessary to engage the clutches 2 , 3 and press the disk packs 8 , 13 together is produced by the diaphragm spring 48 . The non-actuated state is shown in FIG. 5 .
[0065] The description of the actuation of the power take-off shaft clutch 3 is provided with reference to FIG. 6 . Relative to the non-actuated state, the actuating lever 20 is pivoted clockwise about the pivot axis 22 by means of the release unit, which is not shown in the drawings. The outer lever end 31 moves in the axial direction away from the flywheel 26 , taking the eye bolt 34 with it. The outer contact plate part 37 together with the thrust cylinder 38 and the inner contact plate part 36 is moved away from the disk pack 13 toward the diaphragm spring 48 , so that the latter is no longer clamped between the contact plate 30 and the base plate carrier 16 and the power take-off shaft clutch 3 disengages.
[0066] The description of the actuation of the drive shaft clutch 2 is provided with reference to FIG. 7 . Relative to the non-actuated state, the actuating lever 21 is pivoted clockwise about the pivot axis 22 by means of the release unit (not shown).
[0067] The pivoting of the actuating lever 21 causes a shift of the adjusting screw 45 in the direction of the flywheel 26 . The drive clutch housing 46 with the collar 47 is moved toward the diaphragm spring 48 in the direction of the flywheel and away from the disk pack 13 , so that the latter is no longer clamped between the collar 47 and the clutch base plate 15 and the drive shaft clutch 2 disengages.
[0068] As best seen in FIG. 2 , dual clutch 1 according to the present invention is designed as a wet clutch, and is therefore sealed against the environment by means of a housing 50 . The housing 50 has a first housing part 51 , also referred to as the engine-side wet chamber cover, a second housing part 52 , also referred to as the outer wet chamber cover, a third housing part 58 , also referred to as the transmission-side wet chamber cover, and a fourth housing part 43 in the form of a housing ring. All four housing parts 51 , 52 , 58 , 43 are formed sheet metal parts. The first housing part 51 and the second housing part 52 are tightly connected to one another by means of a flange 53 , with a housing seal 54 interposed. The flange 53 has a passage opening 55 or a plurality of passage openings 55 , with which the housing 50 and thus the dual clutch 1 is mounted on a structure of a vehicle as shown in FIG. 10 , for example on a transmission housing 56 of a tractor. The base plate carrier 16 is supported opposite the first housing part 51 by means of a roller bearing 57 . The second housing part 52 is sealed in relation to the clutch base plate 15 by means of a seal 59 , for example a labyrinth seal.
[0069] As shown in FIG. 6 , the third housing part 58 is welded to the clutch base plate 15 by means of a welded seam 41 , and is sealed in relation to the drive clutch housing 46 by means of an O-ring seal 42 . The fourth housing part 43 is likewise welded to the clutch base plate 15 by means of a welded seam 62 , and is sealed in relation to the drive clutch housing 46 by means of a and O-ring seal 67 . Stated differently, the drive clutch housing 46 is accommodated radially between the third housing part 58 and the fourth housing part 43 so that it is movable in the axial direction. To further seal off the interior of the dual clutch 1 enclosed by the housing 50 , the roller bearing 57 is designed as a sealed bearing. The base plate carrier 16 is sealed in relation to the power take-off shaft 6 by means of an oil seal 60 . Finally, the third housing part 58 is sealed in relation to the driveshaft 11 by means of an oil seal 61 . In the illustrated embodiment, cooling oil is introduced into the interior of the housing 50 through a gap 68 between the power take-off shaft 6 and the drive shaft 11 (see for example FIG. 8A ) and oil holes bored in the driveshaft. The second housing part 52 has a feed-through for an oil drain 63 (see, for example, FIG. 8B ). Cooling oil (at approx. 80° C.) introduced into the housing 50 through the gap 68 and the oil bores 69 in drive shaft 11 , for example from the oil sump of the transmission, is distributed in the interior of the housing 50 , for example flung radially outward, due to the rotation of the clutch components accommodated in the housing 50 , for example the power take-off shaft 6 , the drive shaft 11 , the disk carriers 4 and 9 , and the parts moved thereby. The oil wets the disk packs 8 and 13 that are heating up during operation of the clutch and cools them down. The oil drain 63 is provided at the radially lowest point of the housing 50 , so that oil that collects in a channel 64 and has been heated by operation of the clutch can be removed easily from the housing 50 , for example to the oil sump of the transmission. The oil flow through the dual clutch is represented by the dashed lines in FIGS. 8A and 8B .
[0070] The principle of installation of the dual clutch 1 on the vehicle is shown in FIG. 10 . First, the dual clutch 1 accommodated and installed in the housing 50 is mounted on the transmission housing 56 of the vehicle, by being screwed to the latter by means of the flange 53 . As the mounting step is carried out, the outer ends of the actuating levers 20 , 21 , designed in the form of corresponding interfaces, are connected to conventional throw-out bearings (not shown) provided on the vehicle. Next, the arc-shaped spring damper unit 24 is joined with the dual clutch 1 by means of the toothed connection 23 , designed for example as a splined shaft profile.
[0071] The labyrinth seal 59 is shown in detail in FIGS. 11 and 12 . It has an outer ring 70 and an inner ring 71 . The outer ring 70 is accommodated in the second housing part 52 and sealed in relation thereto, with a seal 72 interposed. The inner ring 71 is positioned on the clutch base plate 15 , and rotates together with it. The outer ring 70 has, in its upper half, webs 73 running in the radial direction, which are formed into U-shaped catch troughs 74 at their inner ends. The lower half of the outer ring 70 is flattened out into an inclined plane 76 . The inner ring 71 has continuous annular webs 75 that extend between the webs 73 of the outer ring 70 .
[0072] The outside diameter of the inner ring 71 on the inner side of the clutch is greater than its outside diameter on the outer side of the clutch. The inside diameter of the outer ring 70 on the inner side of the clutch is greater than its inside diameter on the outer side of the clutch. In that way, a gap running obliquely radially inward from the inner side of the clutch to the outer side of the clutch is formed between the outer ring 70 and the inner ring 71 . Because of the rotation of the latter together with the clutch base plate 15 , cooling oil that gets onto the inner ring is flung outward into the spaces between the webs 73 of the outer ring 70 , runs down on these into the catch troughs 74 , and is guided along the inclined plane in the lower half of the outer ring 70 back into the clutch housing.
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A multi-plate dual clutch for coupling a motor vehicle engine to a drive shaft of a motor vehicle transmission and to an auxiliary power take-off output shaft of the motor vehicle. The dual clutch includes a drive clutch for coupling the motor vehicle engine with the drive shaft, and an auxiliary power take-off clutch for coupling the motor vehicle engine with the auxiliary output shaft. The drive clutch and the auxiliary power take-off clutch can each to be operated independently of one another by a separate lever mechanism. The dual clutch includes a wet chamber housing in which the drive clutch and the auxiliary power take-off clutch are accommodated in fluid-tight relationship, while the respective lever mechanisms for the drive clutch and the auxiliary power take-off clutch are located outside the wet chamber housing.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority to Korean Patent Application No. 10-2011-0128323, filed on Dec. 2, 2011 in the Korean Intellectual Property Office, the entire contents of which is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to an air cleaner for a vehicle, and more particularly, to an air cleaner for a vehicle, which makes it possible to easily replace a filter of the air cleaner and secures strong airtightness of the filter.
2. Description of Related Art
In general, an air cleaner provided in an engine room of a vehicle purifies intake air that is necessary in a combustion process of an engine to obtain high output of the engine.
An air cleaner in the related art, as disclosed in Korean Unexamined Patent Publication No. 10-2005-0104070 entitled “Gasket Assembly Structure of Air Cleaner Filter”, published on Dec. 2, 2005, 2-3 p, FIG. 4 , includes a case and a cover, and a filter is installed in an inner space that is formed through engagement of the case with the cover. On the case of the air cleaner, an air inlet for making air flow into the case and an outlet for exhausting the inflow air from the case are formed.
Accordingly, outer air flows into the inside of the air cleaner 1 through an intake duct that is connected to the air inlet of the air cleaner, and the inflow air passes through the filter of the air cleaner, which filters foreign substances such as dust, to be supplied to the engine.
However, according to the above-described air cleaner in the related art, due to the design-related cause of the currently developed vehicles, a front pillar (A-Pillar) is formed long (deep) to the inside of the engine room in the front portion of the vehicle, and thus a cowl is also installed in the deep interior of the engine room. Further, a brake reserve tank is arranged on the front side of the engine room to keep away from the cowl and is positioned at an upper end portion of the air cleaner.
Accordingly, as illustrated in FIG. 1 , due to a narrow gap between the air cleaner 1 and peripheral components, it is not easy to rotate (open) the cover 3 from the case 2 that forms the air cleaner 1 , and this causes inconvenience and trouble in replacing the filter of the air cleaner 1 .
That is, in order to replace the filter of the air cleaner 1 in the related art as illustrated in FIG. 2 , a clamp 3 a is removed, the cover 3 is opened from the case 2 through the rotation thereof, and then a filter assembly 4 is extracted from the case 2 . However, as described above, due to the narrow layout of the engine room, the opening and closing structure of the air cleaner 1 , and the characteristic of the intake duct that is connected to the air cleaner 1 (in the case of the duct having a short length or the hose having no flexibility), the filter replacement is hampered by a lot of obstacles.
In particular, if a sufficient space between the open cover 3 and the case 2 is not secured, a rubber gasket 5 that is installed on the filter assembly 4 may be pressed (chewed) between the cover 3 and the case 2 during the replacement of the filter, and this may cause the airtightness of the filter to deteriorate.
The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY
Various aspects of the present invention are directed to providing an air cleaner for a vehicle, which makes it possible to easily replace a filter assembly of the air cleaner without being interfered by peripheral components provided in an engine room and secures strong airtightness of the filter assembly.
In one aspect of the present invention, the air cleaner apparatus for a vehicle, may include a filter assembly, a case that accommodates the filter assembly therein, a door rotatably installed on the case to open/close the case, and a link unit having both end portions rotatably installed on the inside of the case and the door respectively, for making the filter assembly adhere closely to or release from the case while interlocking with the rotating door.
The link unit may include a vertical link having one end portion that is rotatably coupled to the inside of the case, and a horizontal link having both end portions that are rotatably coupled on the other end portion of the vertical link and the door to make the filter assembly adhere closely to an inner surface of the case when the door is closed.
The horizontal link pushes the filter assembly upwards in the case when the door is closed while the vertical link rotates in the same direction as the door.
The filter assembly may include a filter frame accommodating a filter therein, a coupling projection formed to project from an outer surface of the filter frame, and a gasket installed to surround the coupling projection to be selectively in contact with the inner surface of the case and the horizontal link.
The horizontal and vertical links are installed on one side of the case, and an extension portion to which the gasket of the filter assembly adheres closely is provided on the inner surface of the case.
there is provided an air cleaner for a vehicle having a case that accommodates a filter assembly therein, which includes a door rotatably installed on the case to open/close the case; and a link means, having both end portions rotatably installed on the inside of the case and the door, for making the filter assembly adhere closely to or release from the case while interlocking with the rotating door.
The link means may include a vertical link having one end portion that is rotatably installed in the inside of the case; and a horizontal link having both end portions that are rotatably installed on the vertical link and the door to make the filter assembly adhere closely to an inner surface of the case when the door is closed.
Further, the filter assembly may include a filter frame accommodating the filter; a coupling projection formed to project from an outer surface of the filter frame; and a gasket installed to surround the coupling projection to be in contact with the inner surface of the case and the horizontal link. The horizontal and vertical links may be installed on one side of the case, and an extension portion to which the gasket of the filter assembly adheres closely may be provided on the inner surface of the case.
The air cleaner for a vehicle according to the present invention has the following effects.
First, since the filter replacement work of the air cleaner can be easily done, the repair performance and workability are improved.
In comparison to the air cleaner in the related art, in which the intake duct is connected to the air cleaner and it is not easy to open the cover due to the interference with the peripheral components in the engine room, the air cleaner according to the present invention facilitates the replacement work since the filter is replaced after the filter assembly is extracted in a sliding manner in a state where the door of the air cleaner is opened regardless of the peripheral components.
Second, the space around the air cleaner and the engine room layout setting can be efficiently used.
According to the present invention, since the filter is replaced through opening of the compact door rotatably installed on the case and extraction of the filter assembly in a sliding manner from the case through the open door, it is not required to fully open the case as in the related art, and thus the space around the air cleaner and the engine room layout setting can be efficiently used.
Third, the merchantability and customer satisfaction can be improved according to the improvement of the repair performance.
As described above, since the replacement work of the air cleaner is conveniently done, a driver can directly repair the filter without the necessity of visiting a repair shop, and thus the repair cost can be saved with the improvement of the customer satisfaction and merchantability.
The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view illustrating an installation state of a general air cleaner.
FIG. 2 is a view illustrating a filter replacement process in an air cleaner in the related art.
FIG. 3 is a view illustrating an air cleaner according to an exemplary embodiment of the present invention.
FIGS. 4A to 4C are views sequentially illustrating a filter replacement process in an air cleaner according to an exemplary embodiment of the present invention.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various 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.
DETAILED DESCRIPTION
Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that the present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.
FIGS. 3 and 4A to 4 C are views illustrating an air cleaner and a filter replacement process according to an exemplary embodiment of the present invention.
As illustrated in FIG. 3 , an air cleaner 100 according to an exemplary embodiment of the present invention includes a case 110 accommodating a filter assembly 130 , and a door 120 rotatably installed on one side of the case 110 to open and close an accommodation portion 111 of the case 110 in which the filter assembly 130 is inserted.
In the case 110 , as illustrated in FIGS. 4A to 4C , the accommodation portion 111 for accommodating the filter assembly 130 , that is, a filter frame 131 having a filter therein, in a sliding manner is formed, and on both sides of the accommodation portion 111 , an outwardly projecting extension portion 112 is formed so that a link means to be described later and a gasket 133 of the filter frame 131 can be arranged thereon.
The door 120 is installed on the front surface of the accommodation portion 111 of the case 110 to open/close the accommodation portion 111 . That is, a lower end portion of the door 120 is rotatably coupled to an outer surface of the case 110 , and a hook-shaped clamp 121 that is hooked on and fixed to the case is formed on an upper end portion of the door 120 .
A link means that interlocks when the door 120 is rotated is provided between the inner surface of the door 120 and the accommodation portion 111 . The link means includes a plurality of vertical links 123 having lower end portions that are rotatably installed on the accommodation portion 111 of the case 110 , and a horizontal link 122 having both end portions that are rotatably installed on the upper end portions of the vertical links 123 and the inner surface of the door 120 , respectively. Accordingly, when the door 120 is rotated, the horizontal link 122 and the vertical links 123 simultaneously interlock with each other. In particular, when the door 120 is closed, the horizontal link 122 pushes up the filter frame 131 , and the filter frame 131 adheres closely to the inner upper surface of the extension portion 112 of the case 110 to secure the airtightness of the filter assembly 130 .
On the other hand, the filter assembly 130 includes the filter frame that accommodates the filter therein, and the filter frame 131 is inserted and accommodated in the accommodation portion 111 of the case 110 in a sliding manner. A coupling projection 132 that projects outwardly is formed along an outer periphery of the filter frame 131 , and a rubber gasket 133 is installed to surround the coupling projection 132 . In particular, the front end portion of the coupling projection 132 has an extended diameter to be hooked on an open end portion of the gasket 133 , and thus the secession of the gasket 133 can be prevented. The coupling projection of the filter frame 131 and the gasket 133 are positioned in the extension portion 112 of the case 110 , and the horizontal link 122 that interlocks when the door 120 is opened/closed becomes in contact with the lower surface of the gasket 133 to make the filter frame 131 ascend or descend.
A filter replacement process of the air cleaner according to an exemplary embodiment of the present invention as described above will be described.
First, as shown in FIG. 4C , the clamp 121 of the door 120 that closes the accommodation portion 111 of the case 110 is pressed to release the lock on the case 110 , and then the door 120 is rotated to open the accommodation portion 111 of the case 110 .
When the door 120 is rotated, the horizontal link 122 and the vertical links 123 , which are provided in the accommodation portion 111 of the case 110 , are rotated and moved to the inner lower portion of the accommodation portion 111 as shown in FIG. 4B .
In an exemplary embodiment of the present invention, the vertical link 123 rotates in the same direction as the door 120 .
Due to the descending movement of the horizontal link 122 , the filter frame 131 that is pressed and supported upwardly by the horizontal link 122 becomes free in the accommodation unit 111 of the case, and then the filter can be replaced through extraction of the filter frame 131 from the accommodation portion 111 in a sliding manner.
After the filter is replaced, the filter frame 131 is again inserted into the accommodation portion 111 of the case 110 that is empty as shown in FIG. 4A in a sliding manner, and then the accommodation portion 111 is closed through reverse rotation of the door 120 to be locked in the case through the clamp 121 .
Then, by the rotation of the door 120 , the horizontal link 122 and the vertical links 123 , which are provided in the accommodation portion 111 of the case 110 , are rotated reversely and are moved again to the inner upper portion of the accommodation portion 111 . At the same time, the horizontal link 122 pushes up and supports the gasket 133 that surrounds the coupling projection 132 of the filter frame 131 onto the inner upper surface of the extension portion 112 of the case 110 , as shown in the enlarged view of FIG. 4C , to secure the strong airtightness of the filter.
As described above, since the filter replacement from the case 110 is performed in a sliding manner, the repair performance and workability are improved.
For convenience in explanation and accurate definition in the appended claims, the terms “upper”, “lower”, “inner” and “outer” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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An air cleaner apparatus for a vehicle may include a filter assembly a case that accommodates the filter assembly therein, a door rotatably installed on the case to open/close the case, and a link unit having both end portions rotatably installed on the inside of the case and the door respectively, for making the filter assembly adhere closely to or release from the case while interlocking with the rotating door.
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TECHNICAL FIELD
[0001] The present invention relates to cable assemblies composed of a conduit and a cable slidably disposed therewithin, wherein the cable is slidable with respect to the conduit for the purpose of operably connecting mutually separated devices connected with the ends thereof. More particularly, the present invention relates to a condensation drain located at the conduit for allowing escape of moisture from within the conduit.
BACKGROUND OF THE INVENTION
[0002] Cable assemblies are generally composed of an outer conduit and an inner cable which is sheathed by the conduit. The cable is able to slide axially within the conduit such that at the ends of the cable assembly there is relative movement as between the end of the conduit and the end of the cable whereby various devices are operably linked for providing a useful result, such as for example the actuation of a lock member at one end of the cable assembly in response to movement of a handle at the other end of the cable assembly.
[0003] In the automotive arts, a cable assembly is used to mechanically connect a door handle to a latch mechanism of the door, wherein these components are separated by a distance bridged by the cable assembly. An example of such a cable assembly used in an automotive door is depicted at FIG. 1 and is described in U.S. Pat. No. 6,050,619 to Arabia, Jr., et al. issued on Apr. 18, 2000 and assigned to the assignee hereof, the disclosure of which is hereby herein incorporated by reference.
[0004] A cable assembly 10 spans between a latch mechanism 12 and a door handle 14 . The cable assembly 10 is composed, as shown at FIG. 1A , of a conduit (or sheath) 16 and a cable (or core) 18 , wherein the cable is axially slidable in the cable passage 16 a of the conduit without binding. The conduit 16 has conduit connectors 16 a , 16 b at each end which interface with the latch mechanism 12 and the door handle 14 , respectively; and the cable 18 has cable connectors 18 a , 18 b at each end which also interface with the latch mechanism and the door handle, respectively. The cable assembly 10 is such that the conduit and the cable are both capable of acting in tension and in compression. In operation, when the door handle is pulled, the cable slides in relation to the conduit which effects actuation of the latch mechanism, whereby the door 20 is unlocked and unlatched in sequence.
[0005] Problematically, moisture can accumulate, as for non-limiting example by a condensation process, within the conduit of the cable assembly, whereby the cable can be subjected to possible corrosion and the moisture may be subject to possible freezing. Therefore, it would be beneficial if somehow moisture could escape the conduit, while yet the operative interaction between the cable and the conduit is unaffected.
SUMMARY OF THE INVENTION
[0006] The present invention is a cable assembly having a condensation drain provided for the conduit, wherein moisture is enabled to escape the conduit, yet the operative interaction between the cable and the conduit is unaffected by the presence of the condensation drain.
[0007] The condensation drain is, in one form of the present invention, a condensation drain body connected to one end of the conduit, wherein the cable passes therethrough. The condensation drain body has a top and oppositely disposed bottom, wherein a drainage opening is formed in the condensation drain body at the bottom thereof. The drainage opening is sized to allow moisture exiting therethrough, whereby the drainage opening is disposed at the gravitationally lowest location of the cable assembly such that moisture in the conduit gravitationally migrates to the drainage opening where it is able to exit the conduit to the external environment. The cable operationally remains disposed within the conduit adjacent the drainage opening. In another form of the present invention, the condensation drain is located anywhere along the conduit, wherein a drainage opening is provided in the bottom of the condensation drain body, which is disposed at the gravitationally lowest location of the cable assembly.
[0008] In either form, the drainage opening may be provided with a drip initiator which facilitates thereat the formation of droplets, and wherein the drip initiator may be mechanically robust sufficient to provide an abutment to the cable as an aid to retain the cable within the conduit at the drainage opening.
[0009] Accordingly, it is an object of the present invention to provide a cable assembly having a condensation drain provided for the conduit, wherein moisture is enabled to escape the conduit, yet the operative interaction between the cable and the conduit is unaffected by the presence of the condensation drain.
[0010] This and additional objects, features and advantages of the present invention will become clearer from the following specification of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an elevational view of a vehicle door having a latch mechanism and door handle which are operatively connected by a prior art cable assembly.
[0012] FIG. 1A is a cross-sectional view, seen along line 1 A- 1 A of FIG. 1 .
[0013] FIG. 2 is an elevational view of a vehicle door having a latch mechanism and door handle which are operatively connected by a cable assembly, wherein the conduit of the cable assembly is equipped with a condensation drain according to a first form of the present invention.
[0014] FIG. 2A is a cross-sectional view, seen along line 2 A- 2 A of FIG. 2 .
[0015] FIG. 3 is a side view of a portion of the cable assembly showing in particular the condensation drain of FIG. 2 .
[0016] FIG. 4 is a sectional view, seen along line 4 - 4 in FIG. 3 .
[0017] FIG. 4A is a view similar to FIG. 4 , wherein now a drip initiator according to the present invention is included.
[0018] FIG. 5 is a bottom view of a portion of the cable assembly showing in particular the condensation drain of FIG. 2 .
[0019] FIG. 6 is an elevational view of a cable assembly, wherein the conduit of the cable assembly is connected with a condensation drain according to a second form of the present invention.
[0020] FIG. 6A is a cross-sectional view seen along line 6 A- 6 A in FIG. 6 .
[0021] FIG. 7 is a partly sectional, perspective view of the condensation drain of FIG. 6 .
[0022] FIG. 8 is a sectional view seen along line 8 - 8 of FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring now to the Drawing, FIGS. 2 through 8 depict various aspects of a condensation drain for a cable assembly according to the present invention.
[0024] FIG. 2 is an exemplar environment of use (wherein other environments of use are contemplated) of a cable assembly 100 according to a first form of the present invention, wherein in a car door, the cable assembly mechanically links a door handle 102 to a latch mechanism 104 generally in the manner indicated with respect to FIG. 1 .
[0025] As can be discerned additionally from FIG. 2A , the cable assembly 100 includes a conduit (or sheath) 106 which receives therein a cable (or core) 108 , each of which being conventional as for example described with respect to FIGS. 1 and 1A , wherein now a condensation drain 110 is connected to one end of the conduit. The condensation drain 110 has a condensation drain body 110 a having a top T and an oppositely disposed bottom B, wherein a drainage opening 114 is formed in the condensation drain body at the bottom thereof.
[0026] The conduit 106 may be, for example, a cylindrically shaped, transversely flexible plastic which serves to confine and guide the cable slidably therewithin. The cable 108 may be, for example, a stranded metallic cable which is also transversely flexible which is sized to slidably move without binding in the cable passage 106 a of the conduit 106 . The cable assembly 100 is such that the conduit 106 and the cable 108 are both capable of acting in tension and in compression, wherein by way of example, when the door handle 102 is pulled, the cable slides in relation to the conduit which effects actuation of the latch mechanism 104 , whereby the door is unlocked and unlatched in sequence. A lubricant may be provided along the cable as an aid to the sliding of the cable with respect to the conduit.
[0027] Turning attention now additionally to FIGS. 3 , 4 and 5 , the condensation drain 110 is interfaced with the conduit 106 at a conduit connector 106 b whereat the end of the conduit is anchored to the condensation drain body 110 a , as for nonlimiting example by interference fit, adhesive or sonic weld. The condensation drain body 110 a is affixed to the door handle 102 at a condensation drain connector 112 , which may be, for example, a snap fit interface therebetween. The cable 108 extends through the condensation drain body 110 a via a cable passageway 110 b formed therein which communicates with the cable passage 106 a of the conduit 106 , whereby the cable interconnects with the door handle 102 in a conventional manner, as for example as generally described hereinabove with respect to FIG. 1 .
[0028] The moisture drainage feature of the condensation drain 110 is provided by the above mentioned drainage opening 114 formed in the bottom B of the condensation drain body 110 a which fluidically communicates with the cable passageway 110 b (and, therefore, also with the cable passage 106 a ), wherein the drainage opening is disposed at the gravitationally lowest location of the cable assembly 100 , as indicated by plane G in FIG. 2 . Accordingly, gravity will naturally pull any moisture (i.e., condensate), M, downwardly in the space S within the conduit between the cable and conduit toward the drainage opening so as to exit thereout to the external environment. Preferably, the drainage opening 114 is in the form of an elongated drainage slot 114 a , as is shown best at FIG. 5 .
[0029] It will be seen at FIG. 4 that for purposes of molding tooling the width W of the drainage opening 114 , 114 a exceeds the diameter D of the cable 108 , however, the cable is operatively retained in the cable passageway 110 b because it is kept under tension, and thereby biased away from the drainage opening. However, in the event that the cable is also to be used under compression, then either the width of the drainage opening may be made smaller than the diameter of the cable, or an abutment may be provided (see FIG. 4A discussed hereinbelow).
[0030] Turning attention now to FIGS. 6 through 8 , a second form of the cable assembly 100 ′ is depicted, wherein now the condensation drain 110 ′ is configured so as to be located anywhere along the cable assembly; that is, anywhere between the first and second conduit connectors (as for example the conduit connectors 16 a , 16 b respectively connecting to first and second devices (i.e., a door latch 14 and a latch mechanism 12 ), as shown at FIG. 1 ), wherein the cable 108 passes through the condensation drain via a cable passageway 110 b ′ formed therein (as for example connecting to cable connectors 18 a , 18 b at the respective first and second devices as shown at FIG. 1 ). Thus, it is understood that the conduit 106 ′ is interrupted at the condensation drain 110 ′, but the cable 108 is continuous therethrough. The cable passage 106 a ′ of the conduit 106 ′ (see FIG. 6A ) communicates with the cable passageway 110 b′.
[0031] The cable assembly 100 ′ is generally as described hereinabove, being composed of a conduit (or sheath) 106 ′ which receives therein a cable (or core) 108 , both, as previously mentioned, being capable of acting in tension and in compression. Alluding to the prior example of operation, when a door handle is pulled, the cable slides in relation to the conduit which effects actuation of a latch mechanism, whereby the door is unlocked and unlatched in sequence. The condensation drain 110 ′ is interfaced with the conduit 106 ′ at third and fourth conduit connectors 106 b ′, 106 c ′ whereat ends of the conduit are respectively anchored to respectively opposing sides of the condensation drain body 110 a ′, as for nonlimiting example by interference fit, adhesive or sonic weld.
[0032] The condensation drain body 110 a ′ has a top T′ and an oppositely disposed bottom B′, wherein the moisture drainage feature of the condensation drain 110 ′ is a drainage opening 114 ′ formed at the bottom of the condensation drain body 110 a ′ which fluidically communicates with the cable passageway 10 b ′ (and, therefore, also with the cable passage 106 a ′ of the conduit 106 ′). The drainage opening 114 ′ is disposed at the gravitationally lowest location of the cable assembly 100 ′, as indicated by plane G′ of FIG. 6 . Accordingly, gravity will naturally pull any moisture (i.e., condensate) M to run downwardly in the space S′ between the cable 108 and the conduit 106 ′ toward the drainage opening and exit thereout to the external environment. Preferably, the drainage opening 114 ′ is in the form of an elongated drainage slot 114 a′.
[0033] It will be seen at FIG. 8 , in the sense discussed hereinabove with respect to FIG. 4 , that for purposes of molding tooling the width of the drainage opening 114 ′ (or drainage slot 114 a ′) exceeds the diameter of the cable 108 , however, the cable is retained in the cable passageway 10 b ′ because it is kept under tension, and thereby biased away from the drainage opening. However, in the event that the cable is also to be used under compression, then either the width of the drainage opening may be made smaller than the diameter of the cable, or an abutment may be provided, as for example shown at FIG. 8 in the form of a drip initiator 116 .
[0034] An optional drip initiator 116 is shown in FIGS. 7 and 8 located at the bottom B′ of the condensation drain body 110 ′ adjoining the drainage opening 114 ′ (or drainage slot 114 a ′). The drip initiator 116 is preferably in the form of a lip 116 a spanning the drainage opening on either side of the lip, wherein an upstanding cut-out 116 b is formed of the conduit in generally normal relation to the drainage opening and generally co-terminal with the lip. The drip initiator 116 provides a feature at which drop formation is encouraged with respect to the exiting moisture, whereby the drops MD drip therefrom. The lip 116 a of drip initiator 116 may further serve, as mentioned above, as an abutment to assist retention of the cable within the cable passageway 110 b′.
[0035] In this regard, for the moment returning to the first form of the cable assembly 100 , FIG. 4A depicts a modification of FIG. 4 which now includes a drip initiator 116 ′ formed in the bottom B″ of the conduit body 110 a ″ of the conduit 110 ″ and adjoining the drainage opening 114 ″ (or drainage slot 114 a ″) in the manner as generally described with respect to FIG. 8 , having a lip 116 a ′ and a co-terminal upstanding cut-out 116 b ′. The drip initiator 116 ′ provides a feature at which drop formation is encouraged with respect to the exiting moisture, whereby the drops MD drip therefrom. The lip 116 a ′ of drip initiator 116 ′ may further serve, as mentioned above, as an abutment to assist retention of the cable 108 within the cable passageway 110 b″.
[0036] Optionally, the condensation drain body 110 a ′ is affixed to an article, as for example a door at its trim or interior panels, via for example, a snap fit interface therebetween snap features 118 located on a projection member 110 c integral to the condensation drain body. This affixment ensures that the drainage opening 114 ′ of the condensation drain 110 ′ will remain at the gravitationally lowest location of the cable assembly 100 ′.
[0037] In operation, the cable assembly 100 , 100 ′ with condensation drain 110 , 110 ′, 110 ″ is connected between selected devices, as for example a latch mechanism and a door handle, wherein the drainage opening 114 , 114 ′, 114 ″ of the condensation drain is disposed at a gravitationally lowest location of the cable assembly. Should any moisture get into the cable passage 106 a of the conduit 106 , 106 ′, as for example by condensation or otherwise, this moisture will be gravitationally pulled to the drainage opening where it will exit the conduit of the cable assembly.
[0038] To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims.
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A cable assembly having a condensation drain provided for the conduit thereof, wherein moisture is enabled to escape the conduit through a drainage opening of the condensation drain, yet the operative interaction between the cable and the conduit of the cable assembly is unaffected by the presence of the condensation drain. The condensation drain may be provided with a drip initiator which assists removal of the moisture from the conduit.
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FIELD OF THE INVENTION
The present invention pertains to an elastic sliding bearing for vehicle parts in motor vehicles in which a rigid inner bushing is rotatably arranged in an outer bushing and the outer bushing is arranged in an elastomeric body firmly adhering to the outer bushing and both bushings, at an axially outer end, axial bearing surfaces each at one radially directed flange projection.
BACKGROUND OF THE INVENTION
Such a bearing has been known from DE 38,00,314 - A1 and DE 38,04,886 - C2. It is used mainly to mount guide rails and has an outer bushing made of a rubberized metal, whose inner metal sleeve is in direct contact with the sliding surface of the inner bushing, and whose outer rubber body (elastomer) can be inserted into a bearing eye of a vehicle part. The flange projection extending on one side at the axial end of the inner bushing is made in one piece with the inner bushing. The radial flange projection at the axial end of the outer bushing is formed by a ring permanently connected to the outer bushing. Such bearings are designed as one-sided bearings per se and are mounted in a mutually mirror-inverted arrangement and tensioned relative to one another with an axial clearance, which is actually undesirable, in order to keep the torque low. To reduce the inherently high wear of such sliding bearings, the sealing lip made in one piece with the rubber body surrounds, in the prior-art design, the profile of the two flange projections of the inner bushing and outer bushing which are in contact with one another, and it touches, on the axially outer side, the flange projection at the inner bushing with a pre-tension. In addition, a coating consisting of a plastic possessing good sliding properties is provided between the radially expanding flange projections at the inner bushing and the outer bushing.
DE 36,13,123 - C2 discloses a sliding bearing, in which a plastic layer (polytetrafluoroethylene layer), is permanently provided on the inner bushing. The layer provides good sliding properties and is located between an inner bushing and an outer bushing. The inner gushing is surrounded by an elastomeric body (rubber body) that is connected to the outer bushing. The elastomeric body is surrounded by a rigid mounting bushing. Such sliding bearings cannot be used in the prior-art design for taking up axial loads.
A rubberized metal bearing for taking up axial and radial loads has been known from DE 23,42,990 - B2. This bearing is a molecular bearing which compensates for axial movements of the internal bearing parts in relation to the external bearing part only in the range of a permissible material deformation. Rotary sliding movements of the two parts in relation to one another do not take place in this prior-art bearing.
SUMMARY AND OBJECTS OF THE INVENTION
The task of the present invention is to provide an axially pre-tensioned sliding bearing of the design described in the introduction with a low friction torque and good antifrictional qualities, with axial spring characteristics that are independent of the radial spring characteristics, and at the lowest possible manufacturing cost.
According to the invention, an elastic sliding bearing is provided for vehicle parts in motor vehicles. The bearing comprises an inner bushing rotatably arranged in an outer bushing. The outer bushing is arranged in an elastomeric body which firmly adheres to the outer bushing. Each of the inner bushing and the outer bushing have bearing surfaces at one radially directed flange projection, the flange projection being arranged at an axially outer end. The elastomeric body is non-rotatably inserted into a mounting bushing. The mounting bushing is axially movably connected to the flange projection associated with the outer bushing by an elastomeric intermediate member. The elastomeric intermediate member includes means providing a cross section, in an axial direction, by which restoring forces, increasing with increasing axial displacement of the inner bushing in relation to the outer bushing, are built up on the elastomeric material of the intermediate member.
In a sliding bearing possessing these design characteristics, the radial loads and the axial loads are elastically absorbed by separate components in the known manner, so that the elastomeric body surrounding the outer bushing takes up only radial loads, and its spring characteristic can be optimally adjusted to these radial loads. In contrast, axial loads are compensated by the intermediate member arranged between the outer bushing and the radial flange projection associated with the outer bushing. The axial spring characteristic of this intermediate member can be optimally adapted to the axial movements in order to achieve a low friction torque. Correspondingly, the characteristics of the elastomeric materials for the elastomeric body taking up the radial loads and for the intermediate member may also be selected to be different. Further, the geometries of the elastomeric body and the intermediate member may be made different. A trapezoidal cross section is particularly suited for the intermediate member. By this structure restoring forces, which increase with increasing axial displacement of the inner bushing in relation to the outer bushing, are built up in the elastomeric material of the intermediate member. This can also be achieved with a cross section tapering toward the tip of the cone and other corresponding profilings of the intermediate member, and it can be supported by variations in the degree of hardness of the intermediate member over the cross section.
In a preferred embodiment, the intermediate member associated with the outer bushing is designed as a rubberized metal part which has, at its axial ends, metal rings of angular cross section, one of which forms the flange projection associated with the outer bushing, and the other can be permanently connected to a mounting bushing that can be inserted into a bearing eye of a vehicle part. On its sliding surface, which forms the axial bearing surface and cooperates with the sliding surface on the flange projection of the inner bushing, the metal ring acts as a radial flange projection possesses good sliding properties, which can be improved by coating with PTFE, by an inserted sliding ring, e.g., one made of the same material, or by other measures.
One particular embodiment of the arrangement according to the present invention provides for a one-piece bearing design. In this design, two inner bushings, are arranged mirror-inverted in relation to a common center plane. Further a common outer bushing, a common elastomeric body for taking up radial loads, and a common mounting bushing are provided. The axial ends of the mounting bushing are connected to an axially elastic intermediate member each. Each one of the intermediate members is connected to one of two flange projections associated with the outer bushing. Each of these flange projections cooperate with a flange projection at one of the two inner bushings. In the case of such a bearing design, the two inner bushings, arranged in a mirror-inverted manner in relation to one another, can be conventionally anchored in the vehicle part by a bolt extending through the inner bushings, and can be tensioned in the axial direction relative to another such that clearance- free mounting with minimal friction torque is possible. Axial loads in both directions are now compensated for by one of the two intermediate members, and the build-up of restoring forces which now takes place in the intermediate members, can be determined by the geometric shape, by material properties, and other parameters.
The intermediate member is preferably trapezoidal in section as noted above. The trapezoidal intermediate member consisting of an elastomeric material and the elastomeric body surrounding the outer bushing are preferably arranged in a firmly adhering manner on a mounting bushing that surrounds the elastomeric body and can be inserted into a bearing eye of a vehicle part. As a result of this construction, the intermediate member and elastomeric body are connected to one another. Two inner bushings may be arranged in a mirror-inverted manner in relation to a common center plane and may be provided with a common outer bushing, a common elastomeric body, a common mounting bushing and may be inserted into a bearing eye of a vehicle part. The common mounting bushing may be provided with axial ends which are connected to an axially elastic intermediate member which is connected to one of the two flange projections associated with the outer bushing. The flange projections cooperate with a flange projection, each at one of the two inner bushings. The two intermediate members are also arranged in a mutually mirror-inverted position in relation to a common center plane.
The intermediate member may be designed as a rubberized metal part with metal rings of angular cross-section at the axial ends. One of the metal rings may form a flange projection of the outer bushing and the other metal ring may be connected to a mounting bushing surrounding the elastomeric body.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
Embodiments of a divided bearing design and a one-piece bearing design with the characteristics of the present invention are represented in the drawing.
FIG. 1 is a sectional view taken in an axial plane through a two-piece bearing design; and
FIG. 2 is a sectional view corresponding to FIG. 1 in an axial plane through a one-piece bearing design.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A sliding bearing shown in Figure is inserted, in a mutually mirror-inverted arrangement, into one bearing eye in pairs or individually into two bearing eyes of a guide rail or the like, (not shown). This provides a connection of the sliding bearing to the longitudinal beams (not shown) of a motor vehicle by means of a bolt, also not shown in the drawing. The Figure of the drawing shows only one of the two bearings that form a pair. The sliding bearing consists of a rigid inner bushing 1, an essentially also rigid outer bushing 2, an elastomeric body 3 surrounding the outer bushing 2, and a mounting bushing 4, into which the elastomeric body 3, which is connected to the outer bushing 2 in a firmly adhering manner, is also inserted in a firmly adhering manner. To improve the sliding properties, a sliding layer consisting of a material with good sliding properties, e.g., a sliding bushing 5 made of PTFE is located between the inner bushing 1 and the outer bushing 2. At the end that is the axially inner end after mounting, the elastomeric body 3 is extended with an apron-like projection 6, whose edge lies sealingly around the inner bushing 1. At the end that is the axially outer end after mounting, the inner bushing is provided with a radially extending flange projection 7, which forms, in a radial plane, an axial bearing surface 8 which cooperates with a radial bearing surface 9 that is provided at a radial flange projection 10 which is in connection with the outer bushing 2. To improve the antifrictional properties, a layer consisting of a material with good sliding properties, e.g., a disk made of such a material, may also be inserted between the axial bearing surfaces 8 and 9. The flange projection 10, which is associated with the external bearing part, i.e., the outer bushing 2, has a radial bearing surface 15 which cooperates with a radial bearing surface 16 of the inner bushing 1 and is connected, via an intermediate member 11 made of an elastomeric material, to the mounting bushing 4 and consequently--via the elastomeric body 3--also to the outer bushing 2. The embodiment shows the intermediate member 11, designed as a rubberized metal part whose axial ends are formed by metal rings of angular cross section, of which the metal ring which is the axially outer metal ring after mounting, forms the radial flange projection 10 which is associated with the outer bushing 2, and the metal ring 12 that is the axially inner metal ring after mounting has a connection to the mounting bushing 4. The intermediate member 11 made of elastomeric material is designed in this embodiment as an intermediate member of trapezoidal shape in sections passing through the axial plane, wherein the cross section decreases from the inside to the outside in the axial direction. As a result, it can be achieved, assuming appropriate design, that small axial displacements of the inner bushing 1 in relation to the outer bushing 2 will build up in the intermediate member 11, restoring forces adapted to the torque, so that the friction torque of the bearing is not yet noticeably increased by this. Increasing axial displacements beyond the free path S cause an increase in the free path on the mirror-inverted side. When the free path S is reduced to nearly zero, the axial pre-tension on the part opposite the load is nearly eliminated. A further reduction of the free path is not possible, and neither is a further reduction of the pre-tension, so that no clearance can develop between 10 and 7 and 8 and 9. To improve the sealing of the bearing, the elastomeric material of the intermediate member 11 is made in one piece with a support edge 13 surrounding the axial bearing surfaces 8 and 9 on the outside, and the lip-like edge 14 of the support edge is in contact with the flange projection 7 at the inner bushing 1 axially on the outside and, after assembly, also with a vehicle part receiving the bearing.
The embodiment according to FIG. 2 shows the application of the design characteristics described with reference to a one-piece bearing design. In this arrangement, two inner bushings 1 are arranged in a bearing in mirror-inverted positions in relation to a radial center plane and can be connected to a vehicle part by a bolt (not shown) that passes through the inner bushings 1 and can be tensioned relative to one another. The radial flange projections 7 of the two inner bushings 1 are consequently located at the axially outer ends of the bearing. Their axial bearing surfaces 8 cooperate with an axial bearing surface 9 each at a flange projection 10, both of which are associated with a common outer bushing 2. The two inner bushings 1 partially engage the common outer bushing 2 with their axially inner ends that are directed toward one another. The antifrictional properties of the bearing are improved by a sliding bushing 5 in this case as well. The outer bushing 2 is surrounded on the outside by an elastomeric body 3 which is arranged on the outer bushing 2 in a firmly adhering manner and extends into a likewise common mounting bushing 4 in a firmly adhering manner. The metal rings 12 with angular cross section, which are part of the intermediate member 11 designed as a rubberized metal part, as was explained in connection with FIG. 1, are connected to the axial ends of the common mounting bushing 4. A collar edge 13 with a lip-like edge 14 surrounding the axial bearing surfaces 8 and 9 to ensure sealing between the bearing and the adjacent vehicle part is shown in this arrangement as well.
The radial bearing surfaces 15 and 16 in both embodiments may also enclose a sliding bushing between them or may be coated with a material possessing good sliding properties.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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An elastic sliding bearing for vehicle parts in motor vehicles, a rigid inner bushing (1) rotatably arranged in an outer bushing (2), and this is arranged in an elastomeric body (3) firmly adhering to the outer bushing. Both bushings have, at least at an axially outer end, axial bearing surfaces (8, 9) at one radially directed flange projection (7, 10) each. The flange projection (10) associated with the outer bushing is axially movably arranged in relation to this outer bushing (2) while an elastomeric intermediate member (11) undergoes elastic deformation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention generally pertains to a heat exchanger and more specifically to a mounting structure that provides the heat exchanger with double vibration isolation.
2. Description of Related Art
A typical water-source heat pump includes a compressor that compresses and circulates refrigerant in series-flow through two heat exchangers and a flow restriction (e.g., an expansion valve). One heat exchanger transfers heat between the refrigerant and an external source of water (e.g., ground water). The other heat exchanger transfers heat between the refrigerant and a comfort zone, such as a room or other area within a building. Often a four-way valve determines whether the heat pump heats or cools the comfort zone by selectively directing the refrigerant flow in a forward or reverse direction.
Heat pumps are often, but not always, installed as a system of several heat pumps, where each individual heat pump serves its own particular zone within a building, such as an apartment unit, hotel room, dormitory room, or classroom. A network of pipes interconnecting the heat pumps typically conveys water to and from each individual unit. Each heat pump unit often has its own supply and return air duct for its particular comfort zone.
When heat pumps are installed as a system of several units, often the most convenient location to install the units, the water piping, and the air ducts is overhead, or above the ceiling of each comfort zone. With the heat pumps in such proximity with the comfort zones, it becomes important to minimize any noise generated by the heat pumps. Noise is primarily created by the components that have moving parts, such as the compressor and a blower that forces the conditioned air through the room.
To provide a cushioned mounting for blowers or to minimize noise created by a compressor, such components can be mounted using vibration isolators, such as rubber grommets. Examples of such isolators are shown in U.S. Pat. Nos. 2,711,285; 4,984,971; 5,839,295; and 5,306,121. Further isolation can be achieved by installing an intermediate mounting plate between the compressor and a stationary base, as shown in the '971, '295, and '121 patents.
However, in conventional heat pumps, the effectiveness of a high performance compressor isolation system can be compromised by vibration and/or pressure pulsations transmitted to auxiliary components in direct contact with the compressor. One such component is the water-to-refrigerant heat exchanger. Typically, these components are not isolation mounted. Vibration transmission from the compressor to the unit structure via these components can become the controlling factor in heat pump noise.
SUMMARY OF THE INVENTION
To minimize noise that could be created by a heat exchanger vibrating its surrounding enclosure or ductwork, it is an object of the invention to provide the heat exchanger with double vibration isolation.
Another object of the invention is to provide a heat exchanger with double vibration isolation using an intermediate vibration isolation plate that is of sufficient mass to isolate the heat exchanger more effectively than would be possible with a single layer of isolation.
A further object is to provide a heat exchanger with double vibration isolation using an intermediate vibration isolation plate that is thicker than the sheet metal of an enclosure in which the heat exchanger is installed.
A still further object of the invention is to provide double vibration isolation for a compressor and heat exchanger combination.
Yet another object is to provide a heat pump having two heat exchangers coupled to a compressor, wherein the heat exchanger closest to the compressor is provided with double vibration isolation to reduce noise, while the other heat exchanger is more firmly mounted to add rigidity to an enclosure that surrounds the heat pump.
Another object of the invention is to install a network of heat pumps and its associated piping and ductwork above several comfort zones, while providing each heat pump with double vibration isolation that includes an intermediate vibration isolation plate interposed between the comfort zone and a heat exchanger of the heat pump.
These and other objects of the invention are provided by a heat exchanger that is coupled to a vibration isolation plate by way of a first resilient member, while a second resilient member couples the plate to an enclosure that contains the heat exchanger.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a heat pump incorporating the subject invention with some portions of the heat pump being schematically illustrated.
FIG. 2 is a cross-sectional view of a building with a heat exchange system that includes several interconnected heat pumps, each of which incorporate the subject invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a heat exchanger 10 is installed with double vibration isolation within a sheet metal enclosure 12 . Although heat exchanger 10 is readily applied to a variety of heating, ventilating, and air conditioning systems, it is preferably incorporated within a heat pump 14 . Thus, a preferred embodiment of the invention will be described with reference to heat pump 14 .
In this example, heat pump 14 includes sheet metal enclosure 12 , a refrigerant compressor 16 , a solenoid actuated directional valve 18 , heat exchanger 10 , a flow restriction 20 (e.g., an expansion valve), a second heat exchanger 22 , and a blower 24 . Valve 18 determines the direction of refrigerant flow to render heat pump 14 selectively operable in a heating or cooling mode.
In the cooling mode, valve 18 is positioned as shown to direct relatively hot, pressurized refrigerant from a discharge port 26 of compressor 16 into a port 28 of heat exchanger 10 . The refrigerant passes through heat exchanger 10 before discharging through a second port 30 of heat exchanger 10 . Heat exchanger 10 places the refrigerant in heat transfer relationship with a second fluid, such as ground water, well water, municipal water, etc. A liquid supply line 32 and a liquid return line 34 respectively convey the water to and from ports 36 and 38 of heat exchanger 10 . In this example, refrigerant-to-liquid heat transfer within heat exchanger 10 is provided by conveying the water through an inner tube 40 of heat exchanger 10 and conveying the refrigerant between the exterior of inner tube 40 and an outer tube 42 of heat exchanger 10 . Tubes 40 and 42 are both helically coiled with inner tube 40 being disposed within outer tube 42 . In the cooling mode, the water cools the pressurized refrigerant in heat exchanger 10 . The still pressurized, but cooler refrigerant discharging from port 36 passes through flow restriction 20 . Upon passing through restriction 20 , the refrigerant's pressure and temperature decreases. The refrigerant downstream of restriction 20 then passes through heat exchanger 22 to place the relatively cool refrigerant in heat transfer relationship with a current of air 44 created by blower 24 . The current of air 44 generally moves from a return air chamber 46 to a supply air duct 48 . The refrigerant in refrigerant-to-air heat exchanger 22 cools air 44 , which in turn is conveyed onto a comfort zone 50 (FIG. 2) by way of air duct 48 . Refrigerant having been warmed by air 44 is returned to a suction port 52 of compressor 16 to repeat the refrigerant cycle.
In the heating mode, valve 18 shifts so that a port 54 within valve 18 directs pressurized refrigerant from compressor 16 into heat exchanger 22 , where the relatively hot refrigerant now warms, rather than cools air 44 . From heat exchanger 22 , the refrigerant passes through restriction 20 to provide relatively cool, lower pressure refrigerant to heat exchanger 10 . In heat exchanger 10 , the refrigerant absorbs heat from the water passing through inner tube 40 . Another port 56 of valve 18 then directs the warmer refrigerant back to suction port 52 to repeat the refrigerant cycle in the heating mode.
Heat pumps, such as heat pump 14 , lend themselves well to a heat exchange system 58 where several heat pumps 14 interconnected by liquid lines 32 and 34 independently serve several comfort zones 60 within a building 62 , as shown in FIG. 2 . In the illustrated example, each heat pump 14 is in fluid communication with a comfort zone 60 by way of supply air duct 48 downstream of blower 24 and a return air duct 64 feeding chamber 46 . In such a system, the most convenient location for installing the heat pumps is often overhead, above the comfort zone they serve. When installed at such a location, it becomes very important to minimize any noise caused by heat pumps 14 .
Typically, noise originates at the compressor, which tends to vibrate due to its moving parts. However, compressor 16 being rather rigidly piped a relatively short distance to heat exchanger 10 causes heat exchanger 10 to vibrate as well. If not dealt with, the vibration of heat exchanger 10 can transfer to a sheet metal wall 66 along a top, bottom, and/or side of enclosure 12 . Vibration of sheet metal often produces objectionable noise, due to the relatively large surface area of the sheet metal and its other physical characteristics.
To minimize the noise, a vibration isolation plate 68 is interposed between heat exchanger 10 and wall 66 , i.e., plate 68 couples heat exchanger 10 to wall 66 , but is not necessarily physically “between” heat exchanger 10 and any particular wall 66 . For example, plate 68 should be considered as being interposed between heat exchanger 10 and an upper sheet metal wall 66 of enclosure 12 . A first resilient member 70 or isolator, such a rubber or polymeric grommet or spring provides a vibration-absorbing connection between plate 68 and a bracket 72 of heat exchanger 10 . A bolt 74 fastens isolator 70 to plate 68 . A second resilient member 76 (one or more) similar to isolator 70 provides a vibration-absorbing connection between plate 68 and enclosure 12 . Another bolt 78 fastens isolator 76 to enclosure 12 .
Together, the mass of heat exchanger 10 , the mass of plate 68 , and isolators 70 and 76 emulate a dual mass/spring system having two degrees of freedom. Ideally, the resulting vibration or noise transmitted to enclosure 12 has two high-response frequencies, rather than one as found in a simple mass/spring system having one degree of freedom. As a result, the amplitude of vibration drops off significantly at frequencies above the two high-response frequencies to provide a quieter system overall. To achieve such results, it has been found that vibration isolation plate 68 should have an appreciable amount of mass. More specifically, the thickness of plate 68 is preferably thicker than the sheet metal thickness of enclosure wall 66 (along the top, bottom, and/or side of the enclosure). In one embodiment, plate 68 is made of 10-gage sheet metal, while a significant portion of enclosure wall 66 is made of 18-gage sheet metal.
Although isolator 70 is the primary “spring” between heat exchanger 10 and plate 68 , some additional spring-effect is provided by the resilience of bracket 72 itself. It would also be well within the scope of the invention for the resilience of bracket 72 alone to provide all the spring effect. In such a case, bracket 72 would then be considered as a first resilient member coupling heat exchanger 10 to plate 68 .
In some embodiments, as shown in FIG. 1, a third resilient member 80 , plus a bolt 82 , couples compressor 16 to plate 68 . This helps isolate vibration of compressor 16 relative to plate 68 .
It should be appreciated by those skilled in the art that the actual structure of isolators 70 , 76 and 80 can vary and yet still remain within the scope of the invention. Isolator 84 , for example, basically combines isolator 76 and 80 as a single unitary piece. In other words, rather than discrete individual elements, isolators 76 and 80 basically become an integral extension of each other. An example of isolators 70 , 76 and 80 includes, but is not limited to, a model J4624 manufactured by Lord Corporation of Erie, Pa.
In some embodiments, heat exchanger 10 is substantially fixed relative to enclosure 12 , which is readily done, since heat exchanger 22 is farther from compressor 16 than is heat exchanger 10 . The extra length of pipe or tubing results in less compressor vibration transferred to heat exchanger 22 . In some cases, heat exchanger 22 being fixed to enclosure 12 adds to the enclosure's overall rigidity, and thus reduces the enclosure's tendency to vibrate and emit noise.
Although the invention is described with respect to a preferred embodiment, various modifications thereto will be apparent to those skilled in the art. For example, in some embodiments, a solenoid-actuated valve is connected to supply line 32 or return line 34 to control the flow of water through heat exchanger 10 . The actual direction of airflow 14 in and out of enclosure 12 can be from any side, top or bottom of enclosure 12 . Other variations are also well within the scope of the invention. Therefore, the scope of the invention is to be determined by reference to the claims, which follow.
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A heat exchanger within a sheet metal enclosure includes mounting structure that provides double vibration isolation to minimize noise. The mounting structure includes at least one resilient vibration isolator that couples the heat exchanger to a vibration isolation plate, and includes other similar isolators that couple the plate to the enclosure. The mass of the plate is sufficient to somewhat emulate a dual mass/spring system having two degrees of freedom. To this end, the plate is preferably thicker than the sheet metal walls of the enclosure. The double vibration isolated heat exchanger is especially applicable to systems having several heat pumps that are mounted overhead. In some embodiments, the heat pump's refrigerant compressor is also resiliently mounted to the vibration isolation plate.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of calendaring and scheduling and more particularly to calendar entry management in a calendaring and scheduling (C&S) system.
[0003] 2. Description of the Related Art
[0004] Calendaring systems have formed the core component of personal information management software and firmware applications for decades. Initially, a mere calendar display, modern calendaring systems provide scheduling and alarm functions in addition to full integration with contact management, time entry, billing and project management applications. The typical calendaring application minimally provides a mechanism for scheduling an event to occur on a certain date at a certain time. Generally, the event can be associated with a textual description of the event. More advanced implementations also permit the association of the scheduled event with a particular contact, a particular project, or both. Furthermore, most calendar applications provide functionality for setting an alarm prior to the occurrence of the event, as well as archival features.
[0005] Several software products include support for Calendaring & Scheduling (C&S). Known C&S products include Lotus(™) Notes(™), Microsoft(™) Outlook(™), and web-based products like Yahoo!(™) Calendar(™). These products allow one to manage personal events including appointments and anniversaries. C&S products also typically allow one to manage shared events, referred to generally as meetings. Electronic C&S software allows a group of people to negotiate around the scheduling of a proposed event such as a meeting, with the goal of selecting a time that allows most of the group to attend.
[0006] Specifically, collaborators who participate in e-meetings often maintain a personal schedule managed by a scheduling system. Collaborators can schedule e-meetings within the personal schedule sua sponte, or the collaborators can schedule e-meetings responsive to the receipt of an invitation. An invitation typically contains data regarding the e-meeting such as a topic, list of invitees, and most importantly, a date, time and location for the e-meeting. Using this data, the invitee can be prompted either to accept or decline the invitation. Oftentimes, the acceptance or declination of an invitation can be accomplished with a single user action such as a mouse click.
[0007] The typical C&S system provides a thirty (30 ) day calendar view for all events scheduled during the thirty days reflected in the calendar view. Each day in the thirty day calendar view can display twenty-four hours of time slots for the day. Notably, while the thirty day calendar view can be a very helpful tool for the average C&S system user, limitations subsist in the thirty day calendar view which makes it difficult for some C&S system users to readily identify important calendar data for a scheduled calendar event in the C&S system.
[0008] In this regard, in a C&S system, a meeting chairperson can schedule a calendar event involving a multiplicity of C&S users—sometimes dozens, hundreds or even thousands of C&S system users. For the meeting chairperson, it can be important to know how many of the invited C&S system users have agreed to participate in the scheduled calendar event. It further can be important to know from where the invited C&S system users will participate in the scheduled calendar event. For a scheduled calendar event of only a few invitees, it is a trivial exercise to open the scheduled calendar event into a single day view, and then a single time slot view to identify the requisite calendar data. For a scheduled calendar event of many invitees, however, such an exercise can be exhausting and error prone.
BRIEF SUMMARY OF THE INVENTION
[0009] Embodiments of the present invention address deficiencies of the art in respect to calendaring and scheduling and provide a novel and non-obvious method, system and computer program product for providing a unified view of aggregated calendar data in a C&S system. In one embodiment of the invention, a method for providing a unified view of aggregated calendar data for an event in a calendar view can be provided. The method can include selecting an event in the calendar view, aggregating calendar data for the event relating to all invitees for the event, computing statistics for the aggregated calendar data, and rendering a display of the computed statistics proximate to the selected event in the calendar view.
[0010] In one aspect of the embodiment, aggregating calendar data for the event relating to all invitees for the event can include aggregating a list of invitees for the event and grouping the invitees in the list according to which invitees have accepted an invitation to the event, which invitees have declined an invitation to the event, and which invitees have not yet responded to an invitation to the event. In another aspect of the embodiment, aggregating calendar data for the event relating to all invitees for the event can include aggregating a list of anticipated locations from which accepting ones of the invitees are to participate in the event, and grouping the list according to different locations.
[0011] In another aspect of the embodiment, computing statistics for the aggregated calendar data can include computing percentages of those invitees who have accepted an invitation to the event, those invitees who have declined the invitation, and those invitees who have not yet responded to the invitation. In yet another aspect of the embodiment, computing statistics for the aggregated calendar data can include computing percentages for different locations for those invitees who have accepted an invitation to the event and who have indicated a particular location from which to participate in the event.
[0012] Finally, rendering a display of the computed statistics proximate to the selected event in the calendar view further can include rendering a display of those invitees who have not yet responded to the invitation. In this regard, presence awareness can be applied to the display of invitees who have not yet responded to the invitation. Additionally, an invitee in the display of invitees can be linked to launch a corresponding message directed to the linked invitee.
[0013] In another embodiment of the invention, a C&S data processing system configured for providing a unified view of aggregated calendar data for an event in a calendar view can be provided. The system can include a C&S system disposed in a host computing platform, a data store of calendar events coupled to the C&S system, a calendar view provided by the C&S system, and calendar data aggregation logic. The logic can include program code enabled to select an event in the calendar view, to aggregate calendar data for the event relating to all invitees for the event, to compute statistics for the aggregated calendar data, and to render a display of the computed statistics proximate to the selected event in the calendar view. Notably, the calendar view can include a daily view, a weekly view or a monthly view.
[0014] Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
[0016] FIGS. 1A and 1B , taken together, are a pictorial illustration of an exemplary C&S system thirty day view configured for providing a unified view of aggregated calendar data;
[0017] FIG. 2 is a schematic illustration of a C&S system for providing a unified view of aggregated calendar data; and,
[0018] FIG. 3 is a flow chart illustrating a process for providing a unified view of aggregated calendar data in a C&S system.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Embodiments of the present invention provide a method, system and computer program product for providing a unified view of aggregated calendar data in a C&S system. In accordance with an embodiment of the present invention, an event in a calendar view can be activated to trigger an aggregation of calendar data for the event and a corresponding rendering of a unified view of the aggregated calendar data for the event. The aggregation of calendar data can include statistical data for the acceptance and declination of the event by the invitees for the event, or the anticipated locations of attendance indicated by the invitees in respective acceptances to an invitation for the event. Optionally, the unified view further can provide indicate with presence awareness those invitees to the event whom have not yet accepted or declined an invitation for the event.
[0020] In illustration, FIGS. 1A and 1B , taken together, are a pictorial illustration of an exemplary C&S system thirty day view configured for providing a unified view of aggregated calendar data. The thirty day view 110 shown in FIG. 1A and FIG. 1B can include a monthly calendar view 120 into which different events 130 can be scheduled. Different events 130 can be enabled for providing a unified view of corresponding aggregated calendar data. In this regard, an activatable icon 140 can be provided in proximity to the event 130 which, when activated, can trigger the aggregation of calendar data for the event 130 .
[0021] The aggregation of calendar data for the event 130 can include statistical data for the acceptance and declination of the event by the invitees for the event. Additionally, the aggregation of calendar data for the event 130 can include the anticipated locations of attendance indicated by the invitees in respective acceptances to an invitation for the event. Once the activatable icon 140 has been activated, a view selection pop-up menu 150 can be provided allowing the selection of a view 160 to the invitees associated with the event 130 , or a selection of a view 180 to the anticipated locations of attendance indicated by the invitees in respective acceptances to an invitation for the event 130 .
[0022] The view 160 to the invitees associated with the event 130 can include a view to statistical data indicating a percentage of invitees for the event 130 that have accepted an invitation to the event 130 , a percentage of invitees for the event 130 that have declined the invitation to the event 130 , and a percentage of invitees yet to respond to the invitation to the event 130 . By comparison, the view 180 to the anticipated locations of attendance indicated by the invitees in respective acceptances to an invitation for the event 130 can include a view to statistical data indicating different percentages of the invitees to the event 130 that have accepted an invitation to the event 130 that further have indicated a preference to participate at a particular location.
[0023] As before, the view 180 also can include a percentage of invitees yet to respond to an invitation to the event 130 . In both views 160 , 180 , however, the indication of the percentage of invitees yet to respond can be configured for activation. In response to activation of the indication of the percentage of invitees yet to respond, a list of invitees view 170 can be provided. The list of invitees view 170 can include a listing of those invitees that have yet to respond to an invitation for the event 130 . Each name in the listing can be activated to initiate communication with a corresponding one of the invitees, for instance by instant messaging. Additionally, each name in the listing can include presence awareness.
[0024] In further illustration, FIG. 2 is a schematic illustration of a C&S system configured for providing a unified view of aggregated calendar data. The system can include a host computing platform 210 supporting the operation of a C&S system 240 . A data store of calendar events 250 can be coupled to the host computing platform 210 and configured to store calendar events for the C&S system 240 . The host computing platform 210 can be communicatively coupled to one or more collaborative computing clients 220 over computer communications network 230 so as to permit the collaborative computing clients 220 to access the C&S system concurrently.
[0025] The C&S system 240 can be configured to produce a calendar view 260 . The calendar view 260 can include a thirty day calendar view, a weekly calendar view, or a daily calendar view, by way of example. The calendar view 260 can be coupled to calendar aggregation logic 300 . The calendar aggregation logic 300 can include program code enabled to aggregate calendar data for a selected event and to present the aggregated calendar data in a unified view in association with the selected event in the calendar view 260 . For example, the aggregated calendar data can include can include statistical data for the acceptance and declination of the selected event by the invitees for the selected event, or the anticipated locations of attendance indicated by the invitees in respective acceptances to an invitation for the selected event.
[0026] In yet further illustration of the operation of the calendar data aggregation logic 300 , FIG. 3 is a flow chart illustrating a process for providing a unified view of aggregated calendar data in a C&S system. Beginning in block 310 , a view command can be received in association with a selected event such as by mouse clicking an icon associated with the selected event. In block 315 , an aggregate menu can be rendered providing a choice of providing an invitee list view or a location list view. In decision block 320 , a selection can be received through the aggregate menu. If the selection is to provide an invitee list view, the process can continue through block 325 . Otherwise, the process can continue through block 340 .
[0027] In block 325 , an invitee list can be retrieved for the selected event and it can be determined whether each invitee in the list has accepted or declined an invitation to participate in the selected event. Additionally, invitees in the list that have not yet responded to the invitation for the selected event can be noted. Thereafter, in block 330 , statistics for the different groups of invitees in the list can be accumulated, for instance a percentage of the invitees that have accepted the invitation, a percentage of the invitees that have declined the invitation, and a percentage of invitees in the list that have not yet responded to the invitation.
[0028] In block 340 , a location list can be retrieved for the selected event. In this regard, for each invitee accepting an invitation for the selected event, it can be determined from where the invitee intends upon participating in the selected event. Additionally, invitees in the list that have not yet responded to the invitation for the selected event can be noted. Thereafter, in block 345 , statistics for the different groups of locations can be accumulated, for instance a percentage of accepting invitees choosing to participate from each location, and a percentage of invitees that have not yet responded to the invitation.
[0029] In either circumstance, in block 335 a view can be rendered to include the accumulated statistics. Thereafter, in block 350 it can be determined if a request has been received to identify those invitees that have not yet responded to the invitation. If not, the process can end in block 360 . Otherwise, in block 355 , a listing of the non-responsive invitees can be rendered in a separate view of non-responsive invitees. As part of the separate view, presence awareness for each of the non-responsive invitees. Furthermore, the individual names in the list of non-responsive invitees can be enabled for activation such that the selection of any one of individual names can launch a message for the corresponding invitee.
[0030] Embodiments of the invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the invention is implemented in software, which includes but is not limited to firmware, resident software, microcode, and the like. Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system.
[0031] For the purposes of this description, a computer-usable or computer readable medium can be any apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk—read only memory (CD-ROM), compact disk—read/write (CD-R/W) and DVD.
[0032] A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution. Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers. Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
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Embodiments of the present invention address deficiencies of the art in respect to calendaring and scheduling and provide a novel and non-obvious method, system and computer program product for providing a unified view of aggregated calendar data in a C&S system. In one embodiment of the invention, a method for providing a unified view of aggregated calendar data for an event in a calendar view can be provided. The method can include selecting an event in the calendar view, aggregating calendar data for the event relating to all invitees for the event, computing statistics for the aggregated calendar data, and rendering a display of the computed statistics proximate to the selected event in the calendar view.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is based upon, claims the benefit of priority of, and incorporates by reference Japanese Patent Application No. 2003-44205 filed Feb. 21, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vehicle regenerative braking apparatus.
2. Description of the Related Art
In recent years, a method for reclaiming or regenerating the deceleration energy of a vehicle by means of an electric machine has come into the stage of practical application with the goal of improving vehicle fuel efficiency. It is normal with vehicle regeneration methods to generate a braking force equivalent to the regenerative power (also called electrical braking force), and to make up the remaining required braking force with frictional force of the mechanical brake.
However, during regeneration, if operation of a large power-consuming load (e.g., a PTC heater) is stopped during regeneration, the share of regenerative power generated by the electric machine directed to battery charging increases. Therefore, the amount of power that can be accepted by the battery (maximum charge amount) is exceeded, and there is the possibility of detrimental effects to the battery. Further, the maximum charge amount is a function of multiple variables including the state of charge of the battery (SOC) and battery temperature. In instances such as when the SOC is near a state of full charge and the battery temperature is extremely high, the charge amount should be decreased, as compared to other instances.
As a solution to the aforementioned regenerative braking problem of regenerative power exceeding the maximum charge amount, it is conceivable to reduce the amount of regenerative energy at the point when the battery can no longer accept power, that is, at the point where regenerative power exceeds the maximum charge amount, in other words, when excess power (regenerative power−maximum charge amount) has been generated. However, if regenerative power is suddenly reduced then vehicle braking force (electrical braking force+frictional braking force) is lost and degrades the smoothness of driving as perceived and felt by the driver.
Even when compensation of the lost portion of electrical braking force by an increase in the frictional braking force of the hydraulic brake mechanism is attempted, it is difficult to make the speed of increase of frictional braking force from the hydraulic brake system match the dramatic speed of loss of regenerative power (several milliseconds). The following alternatives were thus conceived in the related art.
According to the related art disclosed in Japanese Patent No. 3,232,823, the efficiency of a generator is degraded when excess power is generated, and the excess power is converted to heat within the generator. The heat is then removed by generator absorption technology. However, when excess power is large it is very difficult to completely consume with this generator absorption technology, depending on how much the efficiency of the generator has been degraded. When using a component dedicated to power generation as an electric machine, adoption is physically impossible.
Japanese Patent Laid-Open Publication No. Hei 8-154304 discloses a switch-controlled discharge resistor which absorbs the excess power. However, with this discharge resistor technology, not only is a costly power resistor necessary, but a switching control device to set the power to be consumed by the discharge resistor to a value corresponding to the amount of excess power is also necessary. This requires increased production cost and increased installation space.
According to the related art disclosed in Japanese Patent Laid-Open Publication No. Hei 5-276686, excess power is directed into a catalytic heater or similar component. However, this entails only adapting the aforementioned PTC heater used as a load for consuming excess power for use as a catalytic heater, and when power is supplied to the catalytic heater at the point when excess power is generated, further consumption of excess power is difficult.
SUMMARY OF THE INVENTION
The present invention was devised to solve the above-mentioned problems, and it is therefore an object to provide a vehicle regenerative braking apparatus simple in structure that prevents adverse effects on a battery while appropriately handling excess power.
A first aspect of the present invention resides in a vehicle regenerative braking apparatus having a generator driven by an engine. The generator performs vehicle braking by generation of regenerative power during vehicle braking. A battery is charged by the regenerative power. A plurality of electrical loads are supplied by the generator and the battery, and a load control apparatus controls the electrical loads. The load control apparatus performs one of calculation, detection, and anticipation of a generation of excess power, which is the regenerative power that exceeds a battery-absorbable maximum charge amount. The load control apparatus also determines an excess power consumption load from the plurality of electrical loads to have excess power absorbed according to one of a calculated value, a detected value, and an anticipated value of the excess power and the excess power absorption capability of the electrical loads before or after generation of the excess power. Finally, the load control apparatus activates the excess power consumption load corresponding to the size of the excess power when generation of the excess power has been one of calculated, detected, and anticipated.
According to the present invention, to cope with the amount of the excess power that has occurred or has been predicted, electrical loads are appropriately selected as excess power consumption loads from a plurality of electrical loads, such that the excess power consumption loads can be made to consume the excess power. Accordingly, differing from the related art where excess power is disposed of by previously determined and fixed electrical loads, excess power can be consumed without incurring the problem of an inability to dispose of excess power owing to electrical loads intended for disposal of excess power already being in operation, nor the problem of needing to increase electrical loads dedicated to excess power consumption apart from pre-existing electrical loads. Thus a vehicle regenerative braking apparatus of simple structure which prevents adverse effects on a battery is possible.
Further, when power to be consumed by excess power consumption loads is adjustable, it is preferable to adjust the power to be consumed by the excess power consumption loads to match the excess power.
According to a preferred embodiment, the load control apparatus completes determination of the excess power consumption load per each calculated value of the excess power or for a predicted value of the excess power before actual generation thereof. Thus, the excess power consumption loads can be activated to effect the consumption of excess power before or as soon as excess power has actually been generated, and delivery of excess current to a battery can be avoided.
According to a preferred embodiment, with respect to a combination of the plurality of excess power consumption loads selected from the plurality of electrical loads, the load control apparatus determines the combination of excess power consumption loads to absorb the excess power corresponding to one of the calculated value, the detected value, and the anticipated value of the excess power and the total of excess power absorbability of the combination, and activates the combination corresponding to the size of the excess power when generation of excess power has been one of calculated, detected, and anticipated. Thus, it is possible to cope with the consumption of excess power, which exceeds the amount of power, that is further consumable by a single selectable excess power consumption load.
According to a preferred embodiment, the load control apparatus stores in memory groups of the electrical loads, which are selectable from the total vehicle electrical loads as the excess power consumption loads, as selectable loads. A single or combination of the excess power consumption loads is selected and decided upon from the selectable loads.
Thus, since selection of non-preferable excess power consumption loads for use as excess power consumption loads is not attempted but instead a pool of selectable excess power consumption loads is pre-formed, the selection of excess power consumption loads is simplified and there is no activation of non-preferable electrical loads for excess power consumption.
According to a preferred embodiment, the load control apparatus delays shutoff of electrical loads among the electrical loads which are presently in activation and can continue to be in activation, when generation of the excess power is one of calculated, detected, and anticipated. Thus, during the generation of excess power, the problem of adverse effects to a battery due to a sudden increase of excess power created by the shutoff of an electrical load in activation can be eliminated.
According to a preferred embodiment of the load control apparatus, when the electrical loads in activation as excess power consumption loads are shut off by manual operation, priority is given to these electrical loads at the next determination event of excess power consumption loads. For example, suppose that the load control apparatus may have already decided to activate the heater as an excess power consumption load despite an already high cabin temperature and thereby a passenger feels discomfort. Even in this case, if there was action by the passenger to shut the heater off, the heater would not be selected as an excess power consumption load at the next determination event by the load control apparatus. In this example, the comfort and other requests of the passenger can be given priority.
Regarding this embodiment, as selection (determination) criteria of electrical loads as excess power consumption loads, it is preferable to take into consideration any adverse effects from activation of each electrical load on passengers and the vehicle. When activation of electrical loads is predicted to have beneficial effects on passengers and the vehicle, it is preferable to elevate the priority in selection of the electrical loads as excess power consumption loads.
According to a preferred embodiment, the load control apparatus performs the determination of the excess power consumption loads so that the total of the increase amounts of power to be consumed by one or a combination of the electrical loads are more than the excess power and below the value of a predetermined margin added to the excess power. Thus, the flow of excessive charge current to a battery can be prevented, and regeneration can be performed within a preferable range.
According to a preferred embodiment, the load control apparatus excludes the electrical loads which are presently in activation from consideration when determining the excess power consumption loads. Thus, inadequate consumption of excess power can be prevented.
A second aspect of the present invention resides in a vehicle regenerative braking apparatus having a generator driven by an engine, the braking apparatus performing vehicle braking by generation of regenerative power during vehicle braking. A battery is charged by the regenerative power and a plurality of electrical loads are supplied by the generator and the battery. A load control apparatus controls the electrical loads. The load control apparatus performs one of calculation, detection, and anticipation of a generation of excess power being the regenerative power exceeding a battery-absorbable maximum charge amount. The load control apparatus delays shutoff of electrical loads maintainable in activation from among the electrical loads presently in activation when performing one of calculation, detection, and anticipation of the generation of the excess power. Thus, the shutoff of electrical loads in activation during generation of excess power, which creates a sudden increase in excess power and adversely affects a battery, can be eliminated.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a block diagram of an electrical system of a vehicle having a vehicle electrical load driving control apparatus according to an embodiment of the present invention;
FIG. 2 is a flow chart of an example of control when a driver depresses the brake pedal according to an embodiment of the present invention;
FIG. 3 is a block diagram of an electrical system showing an example of handling excess power according to an embodiment of the present invention;
FIG. 4 is a flow chart of a control process of a power supply control means for controlling consumption of excess power according to an embodiment of the present invention; and
FIG. 5 is a flow chart showing a modification of an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
With reference to the drawings, preferred embodiments of a vehicle regenerative braking apparatus in accordance with the present invention will be described hereinafter.
FIG. 1 is a block diagram showing an electrical system of a vehicle having a vehicle electrical load driving control apparatus according to one embodiment of the present invention.
Referring to FIG. 1 , an engine 101 is linked to a generator 102 by a belt 100 . The generator 102 is connected to a battery 103 and to load control means 110 a to 110 e via power supply line 108 . The load control means 110 a executes power supply control of loads 111 a 1 to 111 a 3 , the load control means 110 b executes power supply control of loads 111 b 1 to 111 b 3 , and so forth in the same manner, and the load control means 110 e executes power supply control of loads 111 e 1 to 111 e 3 . The load control means 110 a to 110 e has operating switches (not shown) and various sensors (not shown) required for carrying out power supply control. Each of the load control means 110 a to 110 e either performs output control of their respective loads or performs interruption or continuation thereof according to such factors as externally input signals and output signals from the sensors.
The engine control means 104 is connected to the power supply control means 105 to control the engine 101 . The engine control means 104 sends to the power supply control means 105 the engine speed and other information detected by the sensors (not shown) that detect the various states of the engine 101 , and then increases or decreases the output of the engine 101 in response to a command from the power supply control means 105 .
The power supply control means 105 monitors the states of various components including the generator 102 , the battery 103 , and the power supply line 108 , and controls the generator 102 via generator control means 112 . The power supply control means 105 is connected to the generator control means 112 , and the amount of electrical power output by the generator 102 is controlled by a command from the power supply control means 105 .
The generator control means 112 sends to the power supply control means 105 generator information such as the revolution speed and the present amount of electrical power being output by the generator 102 . The power supply control means 105 is connected to a battery current sensor 107 , a load current sensor 109 , a battery temperature sensor 113 , and a battery volt sensor (not shown), and receives information on input and output current of the battery, the load current, the battery temperature, and battery voltage. The power supply control means 105 is connected to the load control means 110 a to 110 e via a multiplex transmission line 106 , such that information is sent and received bi-directionally with the load control means 110 a to 110 e via multiplex communication.
The generator control means 112 receives vehicle braking information from a vehicle controller (not shown) and controls the amount of power output from the generator 102 to a value equivalent to the amount of vehicle braking acknowledged from the vehicle braking information. The field current for the generator 102 is then increased to execute regenerative braking, and generates the necessary amount of braking (regenerative braking). Further, the vehicle controller, for example, calculates a vehicle braking amount equivalent to the degree or amount of operation of the brake operation means such as a brake depression sensor (not shown), and sends a command to a control portion of a hydraulic brake apparatus (not shown) to generate a braking amount which is the total vehicle braking amount minus the regenerative braking amount. Further, the generator control means 112 determines the increased amount of generated power from regenerative braking so that it is within the range of the maximum amount of power that can be produced by the generator 102 and sets it to be within the range of the maximum chargeable amount of the battery 103 (maximum charge amount).
(Regenerative Power Control)
An example of regenerative power control when a driver depresses the brake pedal will be explained with reference to the flow chart of FIG. 2 . First, at step 1000 , an amount by which generated power may increase is obtained through the aforementioned method. More specifically, the increase amount is calculated based on the battery state and the size limit of the charge amount, on the generator state and the size limit of generated power, and on each electrical load state and the size limit of power being consumed. For example, in the instance of a vehicle having a generator with a maximum rated capacity of 2.0 kW, where a present maximum charge amount of the battery is 1.0 kW and electrical load is consuming 0.5 kW, a generated power increase amount (regenerative power) of up to 1.5 kW is possible.
At step 1002 , the routine waits until the brake switch is put into an on state. Once the brake switch is “on,” the brake stroke (brake operation amount) is detected at step 1004 , and the declaration torque (vehicle braking amount) calculated having a positive correlation to the brake operation amount is divided into regenerative braking torque and mechanical braking torque at step 1006 . Here, regenerative braking torque is derived by first finding the numerical value of an increase amount of generated power (regenerative power) divided by the angular velocity of the generator 102 , and then multiplying by the speed ratio of the same torque transmission system. Mechanical braking torque is derived by multiplying the mechanical braking torque gained from the friction brake by the speed ratio of the same torque transmission system.
Next, at step 1008 , the field current of the generator 102 is controlled so as to generate regenerative power derived by the previous calculations, and a value for regenerative braking torque is simultaneously sent to the control portion of a hydraulic brake (not shown), after which a corresponding mechanical braking torque is generated by the hydraulic brake control portion.
(Handling of Excess Power)
Handling of excess power will now be explained. Excess power is generated when some of the electrical loads are suddenly shut off during regeneration. During regeneration, the battery charge is increased to a level close to the maximum charge amount, which is the maximum chargeable amount, to increase regeneration efficiency. Accordingly, due to sudden shutting-off of electrical loads, there occurs a state where regenerative power exceeds the maximum charge amount of the battery. This excess amount of electrical power will be referred to as “excess power.”
For example, given the preceding example where regenerative power is 1.5 kW and 0.5 kW is being consumed by electrical load and there is a present battery maximum charge amount of 1.0 kW, charge to the battery matches and there is no problem. However, if the power being consumed by the electrical loads changes from 0.5 kW to 0.2 kW, 0.3 kW of excess power is generated and the battery 103 is affected.
Handling of excess power will now be explained with reference to the electrical system of FIG. 3 . This electrical system shows the excess power distribution control function of the power supply control means 105 shown in FIG. 1 . The electrical system has a commanded consumption calculation means 201 , function power distribution means 202 , an individual load power distribution means 203 a to 203 f , and a consumable power calculation means 204 a 1 to 204 f 2 . Each of the individual load power distribution means 203 a to 203 f controls several of the consumable power calculation means 204 a 1 to 204 f 2 as a subordinate group belonging to the means. As shown in FIG. 3 , each group is classified in accordance with the function of an electrical load corresponding to each of the consumable power calculation means 204 a 1 to 204 f 2 .
The commanded consumption calculation means 201 receives the total of power which can be consumed beyond the present point by each electrical load (consumable power) from the function power distribution means 202 . When excess power has been generated, the commanded consumption calculation means 201 calculates a power consumption load, which is electrical power to be further consumed by the electrical loads, and sends this to the function power distribution means 202 as a commanded power consumption. If the total of consumable power is smaller than the calculated load power consumption, the load power consumption is regulated to below the total of the consumable power.
The function power distribution means 202 calculates the total of the consumable power based on the consumable power of each group (group consumable power) received from the individual load power distribution means 203 a to 203 f , and sends this to the commanded consumption calculation means 201 . The function power distribution means 202 also distributes the commanded power consumption received from the commanded consumption calculation means 201 to each of the individual load power distribution means 203 a to 203 f by a predetermined distribution method.
The individual load power distribution means 203 a to 203 f respectively control the consumable power calculation means 204 a 1 to 204 f 2 as a subordinate group belonging to the means. Each of the consumable power calculation means 204 a 1 to 204 f 2 is formed with another into groups to which electrical loads of similar functions belong as previously discussed, and each of individual load power distribution means 203 a to 203 f controls a differing group of the power calculation means.
Each of the individual load power distribution means 203 a to 203 f receives a consumable power load, which is power that can be further consumed, from each of the consumable power calculation means 204 a 1 to 204 f 2 , which individually correspond to an electrical load belonging to a group represented thereby. Each of the individual load power distribution means 203 a to 203 f then outputs a total of each load consumable power as a group consumable power to the function power distribution means 202 . Each of the individual load power distribution means 203 a to 203 f determines the commanded power consumption (commanded power consumption load) to each electrical load by a predetermined distribution method. Each predetermined distribution method operates according to the commanded power consumption (group commanded power consumption) of each subordinate group sent from the function power distribution means 202 , as well as according to the consumable power (load consumable power) of the electrical loads belonging to each group, and individually sends each determined commanded power consumption load to each of the consumable power calculation means 204 a 1 to 204 f 2 of each load.
The consumable power calculation means 204 a 1 to 204 f 2 are established for respective electrical loads in this embodiment. Each of the consumable power calculation means 204 a 1 to 204 f 2 determines further consumable power as a load consumable power based on the present power consumption of loads regulated thereby, on the state of the loads, and on other factors. Each of the consumable power calculation means 204 a 1 to 204 f 2 then outputs this to one of the individual load power distribution means 203 a to 203 f controlling the group to which each belongs. Each of the consumable power calculation means 204 a 1 to 204 f 2 receives a commanded power consumption load from each of the corresponding load power distribution means 203 a to 203 f , and also acts in sending this via a multiplex transmission line 106 to each of the load control means 110 a to 110 e shown in FIG. 1 that control respective loads.
Each of the load control means 110 a to 110 e , supplies a total of electrical power which includes the added commanded power consumption load to respective electrical loads controlled thereby, based on the received commanded power consumption load. Normal requirements indicated here are discussed in more detail in the publication of Japanese Patent Application No. 2002-311466.
As has been explained, according to this embodiment, the excess power and the total of the present consumable power of groups of electrical loads are derived, and based on these values a commanded power consumption is set, after which the commanded power consumption is distributed to each group and then to each electrical load via a predetermined distribution method.
Further, according to this embodiment, the calculation of excess power was performed according to the excess power actually generated. It is also possible to perform load supply control where the commanded power consumption load to be sent to each electrical load is calculated at regular intervals by the same method for each calculated value of excess power before excess power is generated. Once excess power has actually been generated, the power to be consumed by each electrical load is increased only by the amount of each commanded power consumption load based on the calculated result.
(Control Process)
Next, referring to the flow chart of FIG. 4 , the control process of the power supply control means 105 for excess power consumption control will be discussed. First, the routine is started by the commencement of power supply or with generation of excess power at step 2100 . At step 2102 , which comprises the consumable power calculation means 204 a 1 to 204 f 2 , power that is further consumable by each load, i.e., consumable power load, is calculated based on each electrical load switched on by the vehicle passengers, on operational states of such components as speaker volume, and on load state. The load consumable power is then sent to the individual load power distribution means 203 a to 203 f at step 2102 .
At step 2104 , which comprises the individual power load distribution means 203 a to 203 f , the total for each consumable power load is calculated. The totals are sent to the function power distribution means 202 which acts in performing higher level distribution control at step 2104 .
Next, an anticipated charge amount and a predetermined allowable charge amount (maximum charge amount) for the battery 103 are compared at step 2106 , after which the routine finishes at step 2122 if the anticipated charge amount is less than the allowable charge amount. The anticipated charge amount is derived from the difference between a commanded generation amount (commanded regeneration amount) and the present load power requirement. The sum of power for consumption that is required by all the electrical loads is being referred to, however, the sum of power being consumed by all the loads at the present point may also be used. Load power requirement is discussed in more detail in the publication of Japanese Patent Application No. 2002-311466.
If at step 2106 the anticipated charge amount is found to be greater than the allowable charge amount, then surplus power (excess power), which is the difference between the anticipated charge amount and the allowable charge amount, is compared with the consumable power at step 2108 . When the consumable power is smaller, the routine proceeds to step 2110 and the difference between the surplus power and consumable power is calculated, and the commanded power consumption is set to the value for consumable power at step 2112 , and the routine proceeds to step 2116 .
When the consumable power is larger at step 2108 , the commanded power consumption is set to the value for surplus power (excess power) at step 2114 . Next, the commanded power consumption to be sent to each function group (individual load power distribution means 203 a to 203 f ) is calculated, and is sent to each appropriate function group of individual load power distribution means 203 a to 203 f at step 2116 .
The commanded power consumption to be sent to each function group is determined based on the consumable power of each group, and is determined by a predetermined distribution method for allotting within a range that doesn't exceed the consumable power of each function group. This determination also gives precedence in allotment to groups which include regular loads such as the amenities load group and pumps. Each of the individual load power distribution means 203 a to 203 f receives its share of commanded power consumption, and calculates the commanded power consumption values for each load belonging thereto by a predetermined distribution method, and the values are sent individually to appropriate loads at step 2118 . The commanded power consumption of each load is determined based on the consumable power of each load, however, precedence in allotment is given to loads such as the heater which has a short electrical time constant and to the motor which has a large power consumption during startup. This allotment is carried out within a range that does not exceed the consumable power of each load.
The commanded power consumption is next sent to each of the load control means 110 a to 110 e at step 2120 appropriately, and the routine finishes at step 2122 . After a fixed interval of time, the routine returns to step 2100 and starts again. Thus, each of the load control means 110 a to 110 e adds a commanded power consumption to either the present power being consumed or to the normally required power and drives a corresponding load. It is also possible to complete the determination of excess power-consuming loads for an anticipated amount of excess power or per each calculated value of excess power before the actual generation thereof.
When generation of excess power has been either calculated, detected, or anticipated, an optimal combination of excess power-consuming loads for the size of the excess power can be realized. From among the total vehicle electrical loads, groups of electrical loads which are selectable as excess power-consuming loads are stored in memory as selectable loads. A single excess power-consuming load or a combination thereof is then selected from among the selectable loads. Determination of the excess power-consuming loads can then be carried out from among the selectable loads. Thus, undesirable increases of power to be consumed from distribution of excess power to electrical loads can be prevented.
Once it has been detected that a passenger intends to manually shut off an electrical load which has had its power consumption increased by commanded power consumption, the consumable power or commanded power consumption to the electrical load can be set to zero for the next distribution of excess power. Thus, a lack of smoothness in driving felt by a driver as a result of power consumption of electrical loads automatically increasing can be prevented. A method for detecting driver operation in such an instance is discussed in the publication of Japanese Patent Application No. 2002-300337.
With the embodiment which has been explained, individual electrical loads are formed into groups per similar function, and these groups are further grouped and controlled in a multi-level hierarchy, however, structuring as a single level is possible.
(Modification)
A modification of the embodiment will be now discussed with reference to FIG. 5 . When excess power is being generated when an electrical load switch is put into the off state, the routine shown in FIG. 5 is initiated as an interrupt routine at step 3100 and a battery anticipated charge amount due to the off state of the electrical load is calculated at step 3102 . Whether the calculated battery anticipated charge amount exceeds a battery allowable charge amount is checked at step 3104 . If the calculated value exceeds the allowable value then the routine proceeds to step 3106 and shut off of the electrical load is not permitted; otherwise, the routine proceeds to step 3110 and returns to the main routine. At step 3108 , a signal not to switch off the load, that is, the previous commanded power consumption load, is sent to load control means 110 a to 110 e , and the routine finishes by proceeding to step 3110 . In this manner, generation of excess power can be easily prevented.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A vehicle regenerative braking apparatus of simple structure is provided, which prevents adverse effects on a battery while handling excess power appropriately. In a vehicle regenerative braking, when excess power which exceeds a preferable charge amount of a battery has been generated as a result of regeneration, the excess power is consumed by increased power consumption of a plurality of electrical loads selected from among several electrical loads.
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BACKGROUND OF THE INVENTION
Many applications exist today for lamps powered by rechargeable batteries in combination with automatic battery charger circuits adapted to operate from AC power lines. One particular application where such circuits are used is in emergency lights which provide emergency illumination upon failure of AC power. Generally, such emergency illumination is only required for a short period following the failure of AC power to permit safe exit from dangerous, darkened areas, such as stairways, and to provide time for procuring other means of temporary illumination. However, most emergency lights available today continue to provide illumination for as long as the power failure continues, until the battery is fully discharged. Since most rechargeable batteries suffer damage and/or have their useful lives shortened when discharged beyond a certain point, such operation requires that batteries be frequently checked and replaced following each power outage. While low-charge cut-off circuits are known, the addition of such circuitry to the power failure detection circuitry and full-charge monitor circuitry already required for proper rechargeable emergency light operation entails even more complication and expense. Additionally, in many solid-state emergency light circuits, the loss of AC power is detected by the circuitry which requires direct connection to the power line voltage, creating potential safety habits.
SUMMARY OF THE INVENTION
Briefly, the present invention includes an emergency light circuit which maintains a battery in a fully-charged condition during periods when AC power is present, and detects a failure of the AC power, providing current to an emergency lamp in response to such failure. The circuit further includes means for monitoring the voltage of the battery and for interrupting the discharge current when the charge state of the battery reaches a predetermined level. Economy of circuitry design is effected by the dual use of a solid-state switch both as the relay for applying current to the emergency lamp upon loss of AC power and as the low-voltage disconnect circuitry for monitoring the charge state of the battery. Additionally, the novel solid-state relay circuitry of the present invention is connected in the secondary of the charger transformer, eliminating safety hazards of conventional emergency lights having such circuitry directly connected to the AC lines. By means of a simple circuit modification, the present circuit may be also used in a rechargeable portable lantern configuration.
DESCRIPTION OF THE DRAWINGS
The FIGURE shows a schematic diagram of a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the FIGURE, one preferred implementation of the emergency light battery charger of the present invention is shown in detail. This implementation provides the above-described advantages, including a low-charge cut-off of discharge current from the battery, AC power sensing in the secondary for safety, and the dual use of solid-state circuitry for both voltage sensing and low voltage disconnect functions. The preferred embodiment described herein may be easily modified for use as a portable rechargeable light merely by the addition of a single-pole switch. It should be appreciated that the circuit described in the following detailed explanation is only exemplary of the present invention and should not be construed as implying any limitation thereon.
Referring to the FIGURE, AC power from the power lines is applied to the primary of a transformer 10. If desired, an optional pilot light assembly 12 may be connected between the AC lines as shown to provide an indication of the presence or absence of AC power. The pilot light assembly 12 shown is a conventional, commercially-available module composed of a current-limiting resistor 14 and a neon indicator 16. Transformer 10 is a step-down transformer which converts the high voltage present at the input to a lower voltage suitable for charging the lamp battery and for powering the solid-state electronics associated therewith and described in detail below.
The output from transformer 10 is applied to a full-wave rectifier 18 including diodes 20 through 23. These diodes are connected in a conventional bridge circuit with the junction of diodes 21 and 23 providing a negative output terminal 26 and the junction of diodes 20 and 22 providing a positive output terminal 28. The positive output from the rectifier circuit is applied via current-limiting resistor 30 and silicon-controlled-rectifier (SCR) 32 to the positive terminals of a battery 34. The negative terminal of battery 34 is returned to the negative terminal 26 of rectifier circuit 18. The gate terminal of SCR 32 is returned to the negative terminal 26 via diode 36, zener diode 38, and diode 40. The junction of zener diode 38 and diode 36 is connected to the positive terminal through resistors 42 and 30, and thus, this junction is maintained at a requested voltage, denoted as V, equal to the zener voltage plus the forward voltage drop across diode 40. Diode 40 is provided in series with zener diode 38 to provide protection in the event that battery 34 is improperly installed with reverse polarity.
The charging circuit operates in the following manner. When the voltage of battery 34 falls below the voltage V, current will flow through diode 36 into the gate terminal of SCR 32, turning on the SCR and causing a charging current to flow through the SCR, charging battery 34. This charging current will continue to flow until battery 34 is sufficiently charged so that its output voltage equals the voltage V. At this point, gate current to SCR 32 will no longer flow through diode 36, and SCR 32 turns off, interrupting the charging current to battery 34. Diode 36 prevents battery 34 from being discharged by any reverse leakage current from the cathode to the gate of SCR 32.
An optional charging current indicator 44 may be provided if desired. As shown in the FIGURE, this charging indicator may include a light-emitting diode 46 in series with resistor 48, which series combination is connected in parallel with resistor 30. During periods when charging current is flowing through SCR 32, the voltage drop developed across resistor 30, due to this flow of current, is applied to indicator 44, illuminating it. Once battery 34 has been fully charged, significant current no longer flows through resistor 30 and indicator 44 is extinguished.
The present circuit may be used either to sense the loss of AC power and to provide emergency illumination in response thereto, or as a rechargeable lantern circuit which provides illumination upon actuation of a switch. To provide the emergency illumination function, a jumper wire 50 is connected across or in place of a switch 52 between the negative terminal 26 and the junction of resistors 54, 56, 58 and the emitter of transistor 60. To select portable lantern operation, jumper wire 50 is cut or otherwise disconnected, and switch 52 turns the lantern on and off, as described below.
Upon loss of AC power, the circuit provides emergency illumination in the following manner. An emergency lamp 62, typically a sealed beam lamp, is connected in series with a transistor 64 across battery 34. When AC power is present, a capacitor 66 charges up to the positive potential through diode 68 connected to the positive terminal 28 of full-wave rectifier circuit 18. This positive voltage is applied to the base of a transistor 70 through a resistive voltage divider made up of resistors 72 and 56. The emitter of transistor 70 is connected to the base of transistor 64, and transistor 70 controls the base current to transistor 64. Normally, an SCR 74 is turned off and transistor 70 will be held in an off state by the positive voltage applied to its base by the resistive dividers 72 and 56. The voltage to which capacitor 66 charges is proportional to the AC line voltage; and the values of resistors 56 and 72 determine at what threshold voltage on capacitor 66, and hence at what line voltage, transistor 70 will turn on. When the AC voltage falls to a value less than this threshold, base current flows from the base of transistor 70 through 56 to the negative terminal 26, turning on transistor 70. The emitter current of transistor 70 provides a base current for transistor 64 and transistor 64 switches into a conducting state, providing current from battery 34 to lamp 62. Load resistor 58 in the collector circuit of transistor 70 provides current limiting for the collector current of transistor 70.
When the present circuit is used in a rechargeable, portable lantern, jumper wire 50 is removed and the connection of resistors 54, 56, 58 and the emitter of transistor 60 to ground is controlled by switch 52. When the rechargeable lantern is disconnected from AC power and switch 52 is closed, current is applied to lamp 62 in the manner described above. When switch 52 is opened, collector current through transistor 70 is interrupted, causing the base current to transistor 64 to be removed, and transistor 64 goes to the off state, turning off lamp 62.
When battery 34 is providing current to lamp 62 in either the emergency light configuration or the rechargeable, portable lantern configuration, as described above, the voltage of battery 34 is monitored by the present circuit; and when the voltage of battery 34 falls below a predetermined limit, the discharge current from battery 34 is interrupted. This prevents battery 34 from being damaged or from having its life reduced by being completely discharged.
The voltage of battery 34 appears across a voltage divider, including resistor 76, zener diode 78, and resistor 54 connected in series across battery 34. The voltage across resistor 54 is applied to the base to emitter junction of transistor 60. The resulting base current of transistor 60 is given by: ##EQU1## where I B is the base current of transistor 60, V BAT is the battery voltage, V ZEN is the zener voltage of zener diode 78, V BE is the base to emitter voltage of transistor 60, and R 76 and R 54 are the values of resistors 76 and 54. Equation (1) is valid for non-negative values of I B . When the voltage on battery 34 is sufficient to turn on transistor 60, the voltage drop across load resistor 80 applied via a diode 82 to the gate terminal of SCR 74 holds SCR 74 in the off state. When the battery voltage drops to a value which causes the base current I B to go to zero, as determined by equation (1), transistor 60 turns off, the voltage drop across 80 drops to a very small value, and the positive potential from battery 34 is applied via resistor 80 and diode 82 to the gate terminal of SCR 74, turning on SCR 74. With SCR 74 in the on state, the base of transistor 70 rises to a voltage equal to the voltage of battery 34 less the forward conduction drop across SCR 74, and this causes transistor 70 to turn off, removing the base current from transistor 64.
The base of transistor 64 is connected to the emitter of transistor 70 via series-connected diodes 84 and 86. The emitter of transistor 64 is connected to the emitter of transistor 70 via SCR 74 and a diode 88. The voltage drops across diodes 84 and 86 compensate for the voltage drops across SCR 74 and diode 88, causing the base and emitter of transistor 64 to be effectively shorted when SCR 74 is on. This reduces the collector leakage current in transistor 64 when it is in the off state, due to the fact that I CES is less than I CEO , which otherwise would contribute to the discharge of battery 34.
Capacitor 90 connected between the base and emitter of transistor 60 acts to suppress spurious transients which might otherwise fire SCR 74 prematurely. Capacitor 90 also serves to decrease the turn-on time of transistor 60 when the circuit is being used in a portable, rechargeable lantern and switch 52 is closed. The presence of capacitor 90 between the base and emitter of transistor 60 also prevents the entire voltage from battery 34 from being applied across the base to collector junction of transistor 60 which switch 52 is closed.
There has been described a unique circuit which advantageously provides for the charging of a battery and monitoring of the discharge of the battery in a rechargeable emergency light or portable lantern. It should be appreciated that modifications of the preferred embodiment described may be made by those of ordinary skill in the art in utilizing the teaching of the present application in various applications. Therefore, the description herein of a preferred embodiment is not to be taken as a limitation to the present invention, and the scope of the present invention is to be determined entirely in accordance with the appended claims.
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A battery charger circuit for providing a charging current to a rechargeable battery from AC line voltage. The charger circuit is especially adapted for use in an emergency light and includes circuitry to provide automatic charging current shut-off when the battery is fully charged. Failure of AC power is detected by the charger circuit, and current is applied to an emergency lamp in response to such failure. Circuitry is included for monitoring the charge state of the battery and for interrupting discharge current to the lamp from the battery when the charge state falls below a predetermined limit. Provision is included for use of the battery charger circuit in a portable lantern configuration.
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BACKGROUND
[0001] The present invention relates to hoists and the connection between a hoist and a machine, track, arm or other structure.
SUMMARY
[0002] In one embodiment, the invention provides a hoist assembly for overhead lifting. The hoist assembly including an upwardly extending attachment member, a downwardly depending shank coupled to the attachment member and having a polygonal cross sectional shape and a hoist body coupled to the downwardly depending shank. The hoist assembly further includes a plate, positioned between the upwardly extending attachment member and the hoist body, that defines a first circular aperture that matingly receives the polygonal shank and a second polygonal aperture laterally spaced from the first circular aperture. The plate is moveable between a first position, in which the polygonal shank extends into the first circular aperture, and a second position, in which the polygonal shank extends into the second polygonal aperture. Rotation of the attachment member with respect to the plate is permitted when the plate is in the first position, and rotation of the attachment member with respect to the plate is inhibited when the plate is in the second position.
[0003] In another embodiment the invention provides a method of coupling an attachment member to a hoist body. The method includes positioning a plate between the attachment member and the hoist body in a first plate position; the plate has a first aperture and a second aperture. The method further includes inserting a shank of the attachment member through the first aperture into a mating recess in the hoist body to couple the attachment member to the hoist body, rotating the hoist body with respect to the attachment member and extracting the shank from the hoist body. The method further includes moving the plate from the first plate position to a second plate position, inserting the shank through the second aperture into the mating recess in the hoist body to couple the attachment member to the hoist body, and inhibiting rotation of the hoist body with respect to the attachment member.
[0004] In another embodiment, the invention provides an attachment assembly for coupling a hoist body to a support structure to selectively permit and inhibit rotation of the hoist body with respect to the support structure. The attachment assembly includes an attachment member having a first end and a second end, the first end is connectable to the support structure, and the second end defines a shank having a polygonal cross sectional shape. The attachment assembly further includes a receiving member that defines a through hole sized to receive the shank and permit rotation of the shank with respect to the receiving member, and a key member defining a first circular aperture and a second polygonal aperture spaced from the first aperture. In a first position, the shank extends into the first circular aperture to permit rotation of the attachment member with respect to the receiving member, and in a second position, the shank extends into the second polygonal aperture to inhibit rotation of the attachment member with respect to the receiving member.
[0005] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a hoist assembly according to one embodiment of the present invention.
[0007] FIG. 2 is a close up perspective view of a first portion of the hoist assembly with a portion of a hoist body removed to show an attachment assembly.
[0008] FIG. 3 is a close up perspective view of a second portion of the hoist assembly with a portion of the hoist body removed to show the attachment assembly.
[0009] FIG. 4 is a cross-sectional view taken along line 4 - 4 of FIG. 1 with a plate in a first position.
[0010] FIG. 5 is an exploded view of a portion of the hoist assembly of FIG. 1 .
[0011] FIG. 6 is an exploded view of a hook sub-assembly of FIG. 1 including a plate in the first position.
[0012] FIG. 7 is an exploded view of a hook sub-assembly of FIG. 1 including the plate in a second position.
[0013] FIG. 8 is a bottom perspective view of the hook sub-assembly of FIG. 7 .
[0014] FIG. 9 is a perspective view of the hook sub assembly of FIGS. 7 and 8 with a portion removed for clarity.
DETAILED DESCRIPTION
[0015] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
[0016] FIG. 1 illustrates a hoist assembly 10 that includes a hoist body 12 , a first attachment member, such as the illustrated top hook 14 , coupled to the hoist body 12 , a second attachment member, such as the illustrated bottom hook 16 , coupled to the hoist body 12 via a chain 18 , and a plurality of cables 20 coupled to the hoist body 12 . The cables are operable to move the chain 18 with respect to the hoist body 12 in response to user actuation. Movement of the chain 18 with respect to the hoist body 12 thereby alters the distance between the bottom hook 16 and the hoist body 12 . A chain bag 22 is utilized to store excess length of chain 18 as the bottom hook 16 is moved toward the hoist body 12 .
[0017] FIG. 2 is a close up view of FIG. 1 with a portion of the hoist body 12 removed to show an attachment assembly 24 . The attachment assembly 24 includes the hop hook 14 , a first block 26 , a second block 28 , a plate 30 , a pair of fasteners 32 , and a fastener 52 (see FIG. 5 ). The pair of fasteners 32 extend through the hoist body 12 , the first block 26 and the second block 28 to secure the top hook 14 to the hoist body 12 . The hoist body 12 defines a blind hole 34 , such as a recess, that receives at least a portion of the first and second blocks 26 , 28 and the plate 30 . The first and second blocks 26 , 28 are not rotatable about a vertical axis 33 within the hole 34 , and are consequently fixed for rotation about the vertical axis 33 with the hoist body 12 . Although first and second blocks 26 , 28 are illustrated, other quantities, shapes and constructions of parts can be utilized. Although the illustrated fasteners 32 include shoulder bolts with respective washers and nuts, other fasteners can be utilized to couple the attachment assembly 24 to the hoist body 12 .
[0018] FIG. 3 further illustrates the hoist assembly 10 with the second block 28 and a different portion of the hoist body 12 removed to further illustrate the blind hole 34 and the plate 30 . The plate 30 , or key member, defines a first aperture 40 having a substantially circular cross-section and a second aperture 42 having a polygonal cross-section. The top hook 14 includes a shank 44 connected to the hook at one end and includes an opposite polygonal end 45 . The shank 44 is at least partially received in the first and second blocks 26 , 28 and in the first aperture 40 in the plate 30 .
[0019] FIG. 4 shows the shank 44 extending through the second block 28 and into the first aperture 40 of the plate 30 . The first and second blocks 26 , 28 each define a depression 46 a, 46 b, respectively (see FIG. 5 ), that together form an opening 46 sized to receive the shank 44 . The shank 44 includes an annular recess 48 that is sized to receive an annular rib 50 in the opening 46 formed between the first and second blocks 26 , 28 . The engagement of the annular rib 50 in the annular recess 48 retains the shank 44 of the top hook 14 in the first and second blocks 26 , 28 . The shank 44 is permitted to rotate within the opening 46 relative to the blocks 26 , 28 .
[0020] FIGS. 2-6 show the attachment assembly 24 with the plate 30 in a first orientation with respect to the shank 44 . In the first orientation, the shank 44 extends through the opening 46 and the polygonal end 45 is at least partially received in the first aperture 40 . Consequently, the hoist body 12 , first block 26 , second block 28 and plate 30 freely rotate about the vertical axis 33 with respect to the top hook 14 when the attachment assembly 24 is in the first orientation. The first aperture 40 is sized to receive the polygonal end 45 of the shank 44 and permit rotation of the polygonal end 45 within the first aperture 40 .
[0021] As shown in FIGS. 4-6 , the fastener 52 is inserted through an aperture in the second block 28 and threaded into an aperture in the first block 26 to couple the first block 26 to the second block 28 , and thereby retain the shank 44 within the opening 46 formed between the first and second blocks 26 , 28 . Other fasteners, or methods of fastening can be utilized to removably couple the first and second blocks 26 , 28 together.
[0022] FIG. 6 shows that the plate 30 defines a first bevel 54 around the first aperture 40 and a second bevel 56 around the second aperture 42 . The first and second bevels 54 and 56 , guide the polygonal end 45 of the shank 44 into the respective aperture 40 , 42 . The illustrated bevels 54 and 56 are shown by way of example only and are not intended to limit the scope of the present invention. Other configurations and arrangements of the plate and the apertures are possible and can be utilized in addition to or in lieu of the illustrated structure.
[0023] FIGS. 7-9 show the attachment assembly 24 with the plate 30 in a second orientation with respect to the shank 44 . In the second orientation, the polygonal end 45 of the shank 44 is at least partially inserted into the second aperture 42 . The second aperture 42 is sized to receive the polygonal end 45 of the shank 44 and limit or inhibit rotation of the shank 44 with respect to the plate 30 , which thereby limits or inhibits rotation of the hoist body 12 with respect to the top hook 14 . The second aperture 42 is slightly larger than the polygonal end 45 to form a slip fit in the second aperture 42 . Consequently, slight rotational movement of the polygonal end 45 within the second aperture 42 is permitted, but substantial rotation of the polygonal end 45 within the second aperture 42 is inhibited.
[0024] In the illustrated embodiment, the polygonal end 45 and the second aperture 42 are square in shape. Thus, the hoist body 12 can be positioned at four distinct orientations, spaced-apart in ninety degree increments, namely 0°, 90°, 180° or 270°, with respect to the top hook 14 . In other embodiments, other polygonal shapes, such as a triangle, a pentagon, a hexagon, an octagon, and the like, can be utilized. In still other embodiments, non-polygonal shapes, such as a five point star, a six point star, and the like, can be utilized.
[0025] The quantity and angle of the orientations for a specific embodiment depend primarily upon the geometry of the polygonal end 45 and the second aperture 42 . In some embodiments, the polygonal end 45 and the second aperture 42 have the same shape, whereas in other embodiments, the polygonal end 45 and the second aperture 42 can have different shapes that are compatible with one another (a triangle shank in a six-sided star aperture, for example).
[0026] In order to rotate the plate 30 from the first orientation to the second orientation and vice versa, a user removes the fasteners 32 from the hoist body 12 and the first and second blocks 26 , 28 . The hoist body 12 is removed from the first and second blocks 26 and 28 and top hook 14 . The plate 30 is removed from the blind hole 34 in the hoist body 12 and rotated about the vertical axis 33 . The plate 30 is re-inserted into the blind hole 34 and the first and second blocks 26 , 28 are inserted into the blind hole 34 . The polygonal end 45 of the shank 44 is inserted into the other of the apertures in the plate 30 . The fasteners 32 are re-inserted into the hoist body 12 and first and second blocks 26 , 28 and are tightened to couple the top hook 14 to the hoist body 12 . This process is repeated whenever it is desired to alter the relationship between the hoist body 12 and the top hook 14 , for example, to permit or resist rotation of the hoist body 12 with respect to the top hook 14 . If free rotation of the hoist body 12 with respect to the top hook 14 is desired, the plate 30 can optionally be omitted.
[0027] The illustrated top hook 14 includes a substantially c-shaped hook that defines an opening and includes a clasp that is moveable to substantially cover the opening. In other embodiments, the attachment member is a trolley mount or other similar mounting device.
[0028] The illustrated arrangement selectively permits or inhibits rotation of the hoist body 12 with respect to the top hook 14 without adding or removing different parts. The same plate 30 is used to both inhibit and permit rotation of the hoist body 12 with respect to the top hook 14 . This is advantageous because the same structure is utilized for both functions, i.e. no extra parts, fasteners, pins, screws, clamps or the like are needed. Furthermore, it permits the same top hook 14 to be utilized with a hoist body 12 in which the user can determine the rotational relationship between the hoist body 12 and the top hook 14 without requiring additional components or separate top hook assemblies.
[0029] Various features and advantages of the invention are set forth in the following claims.
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A hoist assembly for overhead lifting including an upwardly extending attachment member, a downwardly depending shank coupled to the attachment member and having a polygonal cross sectional shape, a hoist body coupled to the downwardly depending shank, and a plate positioned between the upwardly extending attachment member and the hoist body, that defines a first circular aperture that matingly receives the polygonal shank and a second polygonal aperture laterally spaced from the first circular aperture. The plate is moveable between a first position, in which the polygonal shank extends into the first circular aperture, and a second position, in which the polygonal shank extends into the second polygonal aperture. Rotation of the attachment member with respect to the plate is permitted when the plate is in the first position, and rotation of the attachment member with respect to the plate is inhibited when the plate is in the second position.
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FIELD AND BACKGROUND OF THE INVENTION
This invention relates, in general, to control devices and, more particularly, to a new and useful control device for an underground mining advancing support unit arrangement, for example, of hydraulic props and the like for underpinning a mine rod, in which a hydraulic working medium is supplied to several load points, having control valves, a combination of hydraulic control conduits and fittings associated with each support unit which connect or transmit the loads to the control valves, the control conduits being of the type having a normal diameter which permits direct control of the loads.
For safety reasons, the loads accommodated by the hydraulic working medium are controlled as a rule from a neighboring or adjacent support unit arrangement. The individual control valves are associated with a control block and are connected over control lines or conduits with the loads in the working support. Since each individual load point is connected through a feed and return line to the control valves, and since each support unit arrangement accommodates a plurality of load points, the space requirement for the hose lines is quite considerable and represents not only a great material consumption, but hinders at the same time the descent and increases the risk of damage by falling rocks or improper driving of the support unit arrangements. In this type of laying the the control lines it is advisable if the loads can be controlled directly from the control valves, because of the hose lines with a great nominal diameter.
In order to reduce the space required by the control lines laid between the support unit arrangement, it has been suggested (see West German Offenlegunschrift No. 27 00 829) to use control lines having small diameters which are connected to a multiple hose line. Multiple hose lines used in a so-called pilot control, characteristically, are additionally protected by sheathing the multiple hose. A disadvantage however, is that pilot valves are required, in addition to the main valves, which complicates the control and leads to higher material and maintenance costs. Pilot valves are necessary because direct control over multiple lines with a small cross section is not possible.
Based on the finding that the individual loads have a different consumption of working medium, it has been suggested (see West German Auslegesschrift No. 28 07 431) to indirectly actuate the load portions with a relatively great media consumption per unit of time, from the adjacent support unit, that is, over control hoses with a small cross section and pilot valves, and to directly actuate the load points, with a low media consumption per unit of time, from the main control valve in the adjacent support unit arrangement.
However, the great number of pilot valves required is still a disadvantage resulting in increased material and maintenance costs.
SUMMARY OF THE INVENTION
An object of the invention is to provide a control device which permits the use of multiple hose lines, even with direct control, without additional requirements and expenditures for pilot valves and control lines.
The problem is solved, according to the invention, by providing an arrangement in which several load points can be successively connected to the control valves, of the adjacent support unit arrangement, by the same control lines over reversing valves associated with the working support unit arrangement.
The invention advantageously utilizes the fact that all load points of a support unit arrangement are not simultaneously supplied with the hydraulic working medium. The various control lines for different load points, therefore, can be used over the reversing valves so that the required number of control lines is considerably reduced.
Due to the greatly reduced need for control lines, it is possible to use multiple hose lines for direct control, even with the use of control lines with a greater nominal diameter, with the advantageous results of reduced space requirement and greater safety for the control lines. Particularly advantageous is the fact that sensitive pilot valves are not required anymore and, beyond that, the number of control valves can be reduced, since these can autoamtically be used for several loads.
Proper handling of the entire control device is ensured, since the reversing valves are actuated, according to the invention, from the control valve block of the adjacent support unit arrangement over a control valve. The control valve required for the reversing valves is thus integrated into the control system so that accessibility and handling safety are ensured.
In expedient embodiment of the invention, the control line for the reversing valves has the same nominal diameter as the control lines for the working valves and it is a part of the multiple hose line. Any commercial multiple hose line can be used that has individual pipes which can be randomly assigned to the individual control valves.
The sequence of operations in the support units is substantially the same and is repeated in a certain rhythm. In addition, there are load points which are admitted continuously with hydraulic working medium. A uniform balancing of the various control lines can be achieved with particular advantage if the load points to be actuated simultaneously are combined to group, as suggested by the invention, and are assigned to corresponding reversing valves. Furthermore, the reversing valves to expediently connect the load points having a high media consumption per unit of time with the control valves, since these are, as a rule, also the load points that are important for the operation of the support unit arrangement. This can be achieved in a particularly advantageous manner by designing the control actuating the reversing valves, according to the invention, as a self-closing valve. When the control valve is released, it immediately locks so that the load points with a high media consumption per unit of time are reconnected with the control lines over the reversing valves.
Adaptation to the local conditions, by increasing or changing the groups of load points to be actuated simultaneously, is readily possible since the control valves assigned to the control valve block are interchangeable, according to the invention. Since all control lines have the same nominal diameter, the number of control valves assigned to the load points, or the reversing valves or their position inside the control block can be readily changed.
The invention is particularly characterized by the elimination of control valves, sensitive pilot valves and hose lines, as well as by a reduced space requirement. In addition, the inventive arrangement can be adapted to the given local conditions without great costs.
Accordingly, it is a further object of the invention to provide an improved control device for an underground mining working support unit arrangement having hydraulic supports for supporting several load points, means for admitting a hydraulic working medium to the hydraulic supports, the admitting means including an adjacent support unit arrangement hydraulically connected to the working support unit arrangement, a control block having control valves and control conduits connected to the adjacent support unit arrangement for connecting the hydraulic supports for supporting the load points with the control valves, and each of the conduits having a nominal diameter which permits direct control of the hydraulic supports for supporting the load points, the improved control which is provided includes means for connecting the hydraulic supports for supporting the several load points excessively over the same control conduits to the control valves of the adjacent support unit arrangement, the connecting means includes reversing valves connected to the hydraulic support of the working unit arrangement and the conduits and over which the hydraulic supports for supporting the load points are connectable.
It is a further object of the invention to provide an improved control for an underground mining working support unit arrangement of the type having an adjacent support unit arrangement hydraulically connectable to the working support unit arrangement, a plurality of hydraulic supports composed of piston cylinder units having a cylinder with a bore and a piston member slidably mounted in the bore of the cylinder for displacement responsive to a hydraulic working medium admitted in first and second compartments in the cylinder on opposite sides of the piston member, means for admitting the hydraulic working medium to the bore, the admitting means having control conduits connected to each of the compartments of each piston cylinder unit and control valve means interposed in the conduits for controlling the admission of the hydraulic working medium, the admitting means being hydraulically connected to the adjacent support unit arrangement, the hydraulic support supporting a plurality of load points, and each of the conduits having nominal diameter which permits the direct control of the hydraulic supports, the improvement, which is provided, comprises means for successively connecting selective hydraulic supports for supporting several of the load points to the control valve means, and the connecting means including at least one reversing valve operable to alternately connect control valves to selected hydraulic supports.
It is a further object of the invention to provide an improved control for an underground mining working support unit arrangement which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawing and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates a schematic hydraulic transmission diagram of a control device according to the invention.
DETAILED DESCRIPTION
Portions of a working support unit arrangement 1 and an adjacent support unit arrangement 2 are indicated in the drawing by the separate reference numbers to clarify which parts of the control device are assigned to one or the other support unit arrangement. Each support unit arrangement 1 or 2 receives again from the adjacent support unit corresponding to the other part of the control device. The illustrated control device is intended for mine shield units, but can also be readily used for shoring or blocks with some modifications.
The adjacent support unit arrangement 2 has the so-called adjacent control with control valves 4,5,6,7. The control valves 4,5,6,7 are connected jointly over a hydraulic conduit or line 8 with a pump 9, and over hydraulic conduit or line 10 with a reservoir of a hydraulic working medium in a tank 11. The control valves 4,5,6,7 are mounted in a control valve block 12.
A multiple hose line 15, including control line pairs 16,17,18, 19 serves to connect valves 4,5,6,7 to the load points. The multiple hose line has, at both ends, a special fitting or coupling 13,14, over which a quick connection and disconnection are ensured for the assembly and for repairs.
At the receiving end 20 of the working support arrangement 2, in the represented embodiment, there is found props 21,22, line cylinders 23,24,25,26 and corner cylinders 28,28' as well as an advancing cylinder 29 which, as illustrated, are normally designed in the form of piston cylinder units having a cylinder with a bore and piston member slidably mounted in the bore of the cylinder for displacement responsive to a hydraulic working medium admitted in first and second compartments in the cylinder on opposite sides of the piston member.
In the normal operating position, props 21,22 are controlled by control valve 4. When the operating lever of control valve 4 is actuated and a first switching position 31 is set, the pistons of props 21,22 are extended by pressurization over a line 32, a reversing valve 34, and a clearing and setting valve 35. By switching the control valve 4 into a second switching position 36, and reversing valve 34 over line 33, clearing and setting valve 35 is unlocked so that the pistons of props 21,22 are relieved to the reservoir of tank 11 over line 32 and control valve 4.
When control valve 5 is switched into a switching position 38, the piston of line cylinder 25 is extended directly, over line 39, and line cylinders 23 and 24 over an open reversing valve 41. In a switching position 42 of control valve 5, the pistons of line cylinders 23,24 and 25 are retracted over line 40.
Through control valve 6, the piston of advancing cylinder 29 is extended in switching position 44 over a line 45, and in a switching position 47, it is retracted again over line 46.
The above described control functions are selected directly over control valves 4,5,6. When control valve 7 is brought into switching position 49, reversing valve 34 is brought into switching position 52, reversing valve 41 into closing position and reversing valve 53 into transient position. By actuating reversing valves 34,41,53, control line pairs 16,17 which have been used heretofore for props 21,22 and line cylinders 23,24, are now used for corner cylinders 28,28' and line cylinders 25,26. When control valve 4 is brought into the second switching position 36, the pistons of corner cylinders 28,28' are extended over line 33, reversing valve 34, line 45 and valve 57. When switching position 31 is selected, reversing valve 34 is unlocked over line 32 and valve 57 over line 56, and at the same time the ring surface of corner cylinders 28,28' is admitted so that the pistons of the latter retract.
The pistons of line cylinders 25,26 are extended by bringing control valve 5 into switching position 42, so that hydraulic working medium is conducted over line 39 and the open shut-off valve 53 to line cylinders 25,26. In switching position 38, line cylinder 25,26 retract again via line 40.
In the represented embodiment, control valve 6, and thus also control line pair 18 are not double-occupied. Rather advancing cylinder 29 is supplied continuously with hydraulic working medium over this line and the control position.
If switching position 59 of valve 7 is selected during the clearance of the pistons of the props 21,22, the latter are retracted over line 51.
Control valve 7, just like control valve 6, is designed as a self-closing valve, that is, as a deadmans valve. When the operating lever of control valve 7 is released, reversing valves 34,41,53 therefore move back automatically into their normal position, so that direct control with control valves 4,5,6 is possible again. Control line pairs 16,17 are thus switched again to props 21,22 and line cylinders 23,24,25 respectively, while control line pair 18 is still being switched to advancing cylinder 29. Control line pair 19 is reserved exclusively for control valve 7 and reversing valves 34,41,53.
Thus, in accordance with the invention, a control device is provided for a support unit arrangement having several load points that can be admitted with a hydraulic working medium in underground mining with control valves and control lines associated with the adjacent support unit arrangement, which connects the load points with the control valves and whose nominal diameter permits direct control of the load points, characterized in that several load points have hydraulic supports 21,22,23,24,25,28,29 can be connected successively over the same control lines 16,17 to the control valves 4,5 arranged in the adjacent support unit arrangement 2 over reversing valves 34,41,53 associated with the working support unit arrangement 1. The inventive arrangement is preferably characterized in that the reversing valves 34,41,53 are actuated from the control valve block 12 on the adjacent support unit arrangement 2 over a control valve 7.
In accordance with a preferred embodiment, the inventive arrangement is further characterized in that the control line 19 for the reversing valves 34,41,53 has the same nominal diameter as the control lines 16,17,18 for the working valves 36,57 and is a part of the multiple hose line 15.
The load point hydraulic supports 21,22,23,24,25,26,28,29 are preferably combined into groups which are to be actuated simultaneously and are assigned to corresponding reversing valves 34,41,53. The reversing valves 34,41,53 preferably connect the load point hydraulic supports 21,22,23,24,25,29, having a large media consumption per unit of time, with the control valves 4,5,6.
The control valve 7, actuating the reversing valves 34,41,53 is preferably designed as a self-closing valve, and the control valves 4,5,6,7 associated with the control block 12 are interchangeable.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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An improved control for an underground mining working support unit arrangement of the type having an adjacent support unit arrangement hydraulically connectable to the working support unit arrangement in which a plurality of hydraulic supports support load points, it is disclosed wherein the hydraulic supports are successively connectable to several of the load points with a reversing valve operable to alternately connect control valves to selected hydraulic supports.
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BACKGROUND
[0001] The present invention pertains to the relationship between virtual capacity in a data container holding data objects stored by a storage application, and real capacity of a storage container supporting the capacity of the virtual data container. More specifically, the invention relates to providing a view of usage of real space in the storage container as reflected in usage of virtual space in a corresponding data container, and avoiding the consequences of running out of real space caused by an incorrectly perceived availability of virtual space.
[0002] Storage controllers that support thin-provisioning and compression offer storage efficiency capabilities. In one embodiment, the data container is a file system instance, and a data object is a file in the file system instance. Similarly, in one embodiment, the storage application is file system software. A common aspect of the storage efficiency capabilities is that a storage application that stores data in a data container is offered a limited amount of virtual capacity, and the real capacity backing the virtual capacity is smaller. For example, a one terabyte data container might be limited to 500 gigabytes of real capacity. In one embodiment, real capacity is a set of hard disks. To support the relationship between the virtual capacity and the real capacity, the storage controller may in one embodiment employ compression for stored data, or in another embodiment, the storage controller may limit allocation of storage blocks for data that is actually written by the storage application.
[0003] Thin-provisioning storage controllers are known for presenting a larger virtual capacity than that which is supported by real capacity. The storage application may operate as if the large virtual capacity exists, but when the real space in the storage container nears capacity, data access may be interrupted if the storage application continues to write data to the data container. At the same time, storage efficiencies, such as thin provisioning, enable the storage controller to provide capacity at lower cost. However, an entity such as a storage administrator must predict how much real space will be used, and use the prediction to establish a ratio of virtual space in the data container to real space in the storage container in configuring the real space. An inaccurate prediction may result in running out of real space while the storage application is unaware that insufficient real space exists.
BRIEF SUMMARY
[0004] The invention comprises a method, computer program product, and system for managing capacity overflow conditions in storage controllers through application of a virtual space filling data object.
[0005] A method, computer program product, and system are provided for importing knowledge of an associated storage container and data container to an agent. Virtual space in a data container allocated by a storage application is monitored. Similarly, real space allocated in the associated storage container is monitored. The real space holds data written by the storage application. Usage of the virtual space is compared to usage of the real space. An agent is employed to balance usage of space in the data container with real space usage in the storage container, the act of balancing including the agent adjusting an amount of a reserved portion of free capacity in the virtual space.
[0006] Other features and advantages of this invention will become apparent from the following detailed description of the presently preferred embodiment(s) of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] The drawings referenced herein form a part of the specification. Features shown in the drawings are meant as illustrative of only some embodiments of the invention, and not of all embodiments of the invention unless otherwise explicitly indicated.
[0008] FIG. 1 depicts a block diagram illustrating tools embedded in a computer system to support monitoring virtual and real space used, and allocating and de-allocating data container space controlled by a storage application.
[0009] FIG. 2 depicts a flow chart illustrating one aspect of the agent consuming space in the data container in a periodic adjustment mode.
[0010] FIG. 3 depicts a flow chart illustrating an alternate function mode of the agent, also referred to herein as an emergency mode.
[0011] FIG. 4 depicts a block diagram of a computing environment according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0012] It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the apparatus, system, and method of the present invention, as presented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention.
[0013] Reference throughout this specification to “a select embodiment,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “a select embodiment,” “in one embodiment,” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment.
[0014] The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the invention as claimed herein.
[0015] Reference is made to real space and a storage container, and virtual space and a data container. Real space and the storage container refer to actual, physical storage capacity of a nonvolatile storage system, such as a hard disk drive or a pool of hard disk drives. Virtual space and the data container refer to an addressable space in which a storage application may operate. Capacity of the data container may not directly correspond to the capacity of the storage container. An agent is provided to balance the reported available space between the storage container and the data container.
[0016] The functionality of the agent monitors capacity of both the data container and the storage container, and through its operation supports the storage application's ability to create, write, truncate, and delete data objects without disruption. More specifically, the agent creates a data object to occupy virtual space in the data container so that an appropriate amount of virtual space is consumed while consuming little or no real space, and adjusts the size of the data object over time to cause the amount of real capacity available in the storage container to be reflected in the amount of virtual capacity available in the data container. As used virtual space reaches full capacity due to the size adjustment of the agent-controlled data object, the storage application that stores data in a data container is inhibited from allocating more space for other data objects. To create more space in the associated storage container, more real storage capacity may be added, or if possible, data objects may be migrated to another storage container, or real space still allocated to deleted data objects may be freed. Accordingly, the agent functions to bring the knowledge of the new available space state of the storage container to the data container.
[0017] FIG. 1 is a block diagram ( 100 ) illustrating tools embedded in a computer system to support monitoring of virtual and real space used, and allocating and de-allocating data container space in a storage application. There are five primary components shown herein, including an application server ( 110 ), a storage application ( 160 ), a data container ( 130 ), a storage controller ( 140 ), a storage container ( 146 ) and a monitoring agent ( 150 ).
[0018] The application server ( 110 ) is provided with a processing unit ( 112 ) operatively coupled to memory ( 114 ) across a bus ( 116 ). The application server is shown with an operating system ( 118 ) in communication with application software ( 120 ) and computer hardware, e.g. the processing unit ( 112 ) and memory ( 114 ). The application software ( 120 ), also referred to herein as a user application, reads and writes data to the data container ( 130 ), via requests to the storage application ( 160 ). The storage controller ( 140 ) is in communication with the storage application ( 160 ). As shown, the storage controller ( 140 ) includes a processing unit ( 142 ) in communication with memory ( 144 ) and is embodied with a storage container ( 146 ). In one embodiment, the storage container ( 146 ) includes multiple physical storage devices. In one embodiment, the storage controller ( 140 ) is in local communication with the application server ( 110 ) and functions to store data generated by application software ( 120 ) operating in the application server ( 110 ). In one embodiment, the storage controller ( 140 ) may be in remote communication with the application server ( 110 ), and may also be in communication with one or more additional storage containers in a shared pool of resources. Regardless of the local or remote communication between the application server ( 110 ) and the storage controller ( 140 ), the data container ( 130 ) reflects the virtual capacity and the storage container ( 146 ) reflects the real capacity.
[0019] The monitoring agent ( 150 ), also referred to herein as the agent, is in communication with both the data container ( 130 ) and the storage container ( 146 ). The agent ( 150 ) may be in the form of an application, or in one embodiment an independent process in the operating system ( 118 ). The agent ( 150 ) functions to learn from the data container ( 130 ) how much of its virtual space is available, and to learn from the associated storage container ( 146 ) how much real space is available The agent ( 150 ) monitors virtual space allocated in the data container ( 130 ) and monitors real space allocated in the storage container ( 146 ).
[0020] In addition to the monitoring function, the agent ( 150 ) compares usage of the virtual space to usage of the real space. The agent ( 150 ) functions to provide a balance between the spaces. In one mode, the agent ( 150 ) operates in a passive mode in which it reserves a portion of free capacity in the virtual space. The agent ( 150 ) adjusts the size of this reserved portion in order to bring balance to the real and virtual spaces. The adjustment set forth by the agent ( 150 ) includes expanding the size of the reserved virtual space when the available real space in the storage container is below a threshold. In one embodiment, the agent ( 150 ) operates in a continuous mode to monitor available capacity in the real space. The continuous mode of operation includes reducing the size of the reserved virtual space when the available real space in the associated storage container is greater than a threshold. As noted above, in one embodiment, the virtual space reservation is accomplished via a data object created or embedded in the data container ( 130 ).
[0021] In another mode, the agent ( 150 ) operates in an aggressive mode in which the agent reacts to usage of the real space in the storage container ( 146 ) exceeding a capacity utilization threshold. Once this threshold is attained, the agent ( 150 ) inhibits writing of new data in the real space by increasing the size of the reserved virtual space such that there is very little or no virtual space available. With respect to both the passive mode and the aggressive mode, the function of the agent ( 150 ) is to enable the storage application to maintain full operability while occupancy in the storage container ( 146 ) is balanced with the data container ( 130 ).
[0022] As identified above, the agent ( 150 ) is shown residing local to the application server ( 110 ). In one embodiment, the agent ( 150 ) may reside as an application in memory ( 114 ) or as a hardware tool or an application external to the memory ( 114 ). In another embodiment, the agent ( 150 ) may be implemented as a combination of hardware and software. In the case of the storage container representing a shared pool of resources, the agent ( 150 ) may be collectively or individually distributed across the shared pool of computer resources and function as a unit to support maintaining the occupancy of the storage space in alignment with the virtual space. Accordingly, agent ( 150 ) may be implemented as a software tool, hardware tool, or a combination of software and hardware.
[0023] To further illustrate and as shown herein, FIG. 2 is a flow chart ( 200 ) illustrating one aspect of the agent consuming virtual space in the data container in a periodic adjustment mode. The agent periodically monitors a real capacity utilization of the storage container, compares this against the virtual capacity utilization of the data container, and adjusts the size of a virtual space filling data object in order to align virtual space used with real space used. More specifically, the agent aligns virtual capacity utilization of the data container with the real capacity utilization of the storage container. In one embodiment, the alignment includes making the percentage of used space the same in both the data and storage containers. A data object whose size can be adjusted is created in the data container ( 202 ). The size of the data object is adjustable and can be expanded or contracted. The data object is created to consume an appropriate amount of virtual space while consuming little or no real space. In one embodiment, the data object is a file that has file system data blocks allocated to it without writing data to the storage controller. In another embodiment, the data object has zeros written to all of the bytes in the data object given that for storage controllers with compression or thin provisioning capability, a zero filled file will cause minimal or no real space to be consumed. In one embodiment, the agent is configured in a Linux based system and the file allocate command, e.g. fallocate, is used to pre-allocate blocks to the file, where blocks are allocated and marked as uninitialized, requiring no I/O to the data blocks. Accordingly, the size-adjustable data object is created in the virtual space and occupies a minimal amount of space therein.
[0024] The size-adjustable data object in the virtual space balances availability of the virtual space with the real space. Virtual space in the data container is measured ( 204 ), and the real space in the storage container is measured ( 206 ). As shown, it is determined if the real space occupancy is greater than expected ( 208 ). In one embodiment, the occupancy determination may be with respect to a threshold. The determination at step ( 208 ) ascertains if the available capacity of the storage container is reflected by the available capacity in the data container. In one embodiment, the determination at step ( 208 ) ascertains if the capacity of the storage container is being consumed faster than expected. If the real space occupancy is greater than expected, the virtual size of the size-adjustable data object in the virtual space is expanded ( 210 ). Accordingly, the capacity of the real space is monitored and the size-adjustable data object is expanded in the virtual space in response to the occupancy of the real space being greater than expected.
[0025] If the determination at step ( 208 ) is negative, it is then determined if the real space occupancy is less than expected ( 212 ). This determination ascertains if the virtual size of the size-adjustable data object needs to be contracted. In the periodic adjustment mode, the data object is present in the data container, and it is adjusted in response to the monitoring of the occupancy of the storage container. If the storage container occupancy is less than expected, the virtual size of the size-adjustable data object is contracted ( 214 ). The contraction of the data object provides more space for applications to write data to the data container. At the same time, the contraction of the data object brings knowledge to the data container that there is more space available in the storage container. The continuity of the monitoring is demonstrated with an interval associated with monitoring. As shown, following the expansion of the virtual size of the file at step ( 210 ), a negative response to the determination at step ( 212 ), or following contracting the virtual size of the file at step ( 214 ), the agent pauses for a set interval ( 216 ) prior to returning to the measurements at steps ( 204 ) and ( 206 ). In one embodiment, the interval at step ( 216 ) may be adjusted. Accordingly, the virtual size of the size-adjustable data object in the data container is adjusted such that the virtual occupancy of the data container reflects occupancy in the associated storage container.
[0026] The determinations illustrated at steps ( 208 ) and ( 212 ) are an example of the assessments in the storage container that may be employed for adjustment of the virtual data object in the data container. In one embodiment, an agent is provided to monitor the occupancy of the real space. The determinations shown at step ( 208 ) and ( 212 ) exemplify how the agent may employ periodic monitoring to the occupancy of the storage container, and implement expansion or contraction of the virtual data object. Furthermore, the order of the determinations at steps ( 208 ) and ( 212 ) should not be considered limiting, and in one embodiment the order in which they are implemented may be reversed. Accordingly, the expansion and contraction of the virtual data object ensures that virtual capacity utilization of the data container generally reflects the real capacity utilization of the storage container.
[0027] As shown in FIG. 2 , the agent monitors virtual space in a data container allocated by a storage application and real space allocated in a storage container. In one embodiment, the agent functions by comparing a ratio of virtual space usage to real space usage with an expected value for the ratio. The ratio reflects a balance between the containers. As noted above, when the occupancy of the storage container reaches its limit, this affects the functionality of the data container. If the ratio meets the expected value, the agent may keep the size of the data container to be the same, and if the ratio exceeds the expected value, the agent may activate or otherwise adjust the size of the virtual data object in the data container. Accordingly, the agent may operate in a comparison mode between the containers and their associated occupancy.
[0028] As shown in FIG. 2 , the virtual data object is present in the data container and the size of the virtual data object is adjusted on a periodic basis to balance usage of space in the data container with usage of space in the storage container. In one embodiment, balancing of available virtual space in the data container ensures availability of real space in an associated storage container. FIG. 3 is a flow chart ( 300 ) depicting an alternate function mode of the agent, also referred to herein as an emergency mode. In this mode, the virtual data object is activated based on detection that the real space is close to attaining full capacity. As shown, a capacity utilization threshold is established in the real space ( 302 ). In one embodiment, the capacity utilization threshold reflects a maximum or near maximum quantity of consumed blocks in the real space. Real space in the storage container is periodically measured ( 304 ), and it is determined if the threshold has been reached ( 306 ). In one embodiment, the determination at step ( 306 ) ascertains if the threshold has been met or exceeded. At such time as this threshold is attained ( 306 ), the virtual data object is activated and the size of the virtual data object is expanded ( 308 ). In one embodiment, the virtual data object is always present or available in the virtual space. When expanded, the virtual file effectively reserves almost all the virtual space in the data container based upon meeting the threshold in the storage container. At the same time, the occupation of expanded virtual space by the virtual data object inhibits further allocation of virtual space in the data container, which inhibits writing of new data into the real space. If at step ( 306 ) it is determined that the threshold has not been met, then the agent pauses for a set interval ( 310 ) prior to returning to the periodic measurement at step ( 304 ). In one embodiment, the interval at step ( 310 ) may be adjusted.
[0029] Expansion of the size of the virtual data object in the virtual space at step ( 308 ) reserves virtual space to inhibit further virtual space allocation. Either during or following the expansion of the virtual file at step ( 308 ), the capacity utilization threshold in the real space of the storage container is periodically measured ( 312 ), and it is determined if the amount of free space in the storage container is great than a threshold ( 314 ). Once the free space in the storage container is greater than the threshold, the virtual data object is contracted ( 316 ) or deactivated. In one embodiment, the size of the virtual data object may be contracted to a lower percentage of free capacity once the amount of allocated real space in the storage container goes under the threshold. The monitoring of the real space in the storage container continues. As shown, following a negative response to the determination at step ( 314 ), the agent pauses for a set interval ( 318 ) prior to returning to the periodic measurement at step ( 312 ). In one embodiment, the interval at step ( 318 ) may be adjusted. Following the contraction of the file at step ( 316 ), the process returns to step ( 310 ) to pause for the set interval. Accordingly, continuity of the monitoring is demonstrated with an interval associated with monitoring.
[0030] With respect to the embodiments shown and described in both FIG. 2 and FIG. 3 , some storage applications' data containers are configured to store data in multiple storage controller storage containers. In this embodiment, the virtual data object may be configured for the entire data container. Similarly, the virtual data object may be configured on a storage container basis that can individually balance the virtual space with the real space separately for each storage controller storage container. Accordingly, the virtual data object may be employed on either an individual basis or a multiple storage container basis.
[0031] The agent is employed to manage the virtual data object. There are two modes of operation for the data object, one mode operating on a periodic basis, FIG. 2 , and another mode operating on an emergency basis, FIG. 3 . These two modes are not mutually exclusive. Regardless of the mode or combination of modes, the use of the virtual data object brings knowledge to the storage application of how much space is available in the storage container. Without the virtual data object and the expansion and contraction thereof, knowledge of the data container and available space is limited to the virtual space. Expansion of the data object brings knowledge to the data container about space limitations in the storage container. Conversely, contraction of the virtual data object brings knowledge to the data container about space availability in the storage container. Accordingly, by activating the virtual data object for expansion or contraction, knowledge about space availability or space restrictions is made available to the storage application by adjusting the apparent amount of virtual space available in the data container.
[0032] The server described above in FIG. 1 has been labeled with a tool in the form of an agent. The tool may be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices, or the like. The tool may also be implemented in software for execution by various types of processors. An identified functional unit of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, function, or other construct. Nevertheless, the executable of the tool need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the tool and achieve the stated purpose of the tool.
[0033] Indeed, executable code could be a single instruction, or many instructions, and may even be distributed over several different code segments, among different applications, and across several memory devices. Similarly, operational data may be identified and illustrated herein within the tool, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, as electronic signals on a system or network.
[0034] Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of agents, to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0035] Referring now to the block diagram of FIG. 4 , additional details are now described with respect to implementing an embodiment of the present invention. The computer system includes one or more processors, such as a processor ( 402 ). The processor ( 402 ) is connected to a communication infrastructure ( 404 ) (e.g., a communications bus, cross-over bar, or network).
[0036] The computer system can include a display interface ( 406 ) that forwards graphics, text, and other data from the communication infrastructure ( 404 ) (or from a frame buffer not shown) for display on a display unit ( 408 ). The computer system also includes a main memory ( 410 ), preferably random access memory (RAM), and may also include a secondary memory ( 412 ). The secondary memory ( 412 ) may include, for example, a hard disk drive ( 414 ) and/or a removable storage drive ( 416 ), representing, for example, a floppy disk drive, a magnetic tape drive, or an optical disk drive. The removable storage drive ( 416 ) reads from and/or writes to a removable storage unit ( 418 ) in a manner well known to those having ordinary skill in the art. Removable storage unit ( 418 ) represents, for example, a floppy disk, a compact disc, a magnetic tape, or an optical disk, etc., which is read by and written to by removable storage drive ( 416 ). As will be appreciated, the removable storage unit ( 418 ) includes a computer readable medium having stored therein computer software and/or data.
[0037] In alternative embodiments, the secondary memory ( 412 ) may include other similar means for allowing computer programs or other instructions to be loaded into the computer system. Such means may include, for example, a removable storage unit ( 420 ) and an interface ( 422 ). Examples of such means may include a program package and package interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units ( 420 ) and interfaces ( 422 ) which allow software and data to be transferred from the removable storage unit ( 420 ) to the computer system.
[0038] The computer system may also include a communications interface ( 424 ). Communications interface ( 424 ) allows software and data to be transferred between the computer system and external devices. Examples of communications interface ( 424 ) may include a modem, a network interface (such as an Ethernet card), a communications port, or a PCMCIA slot and card, etc. Software and data transferred via communications interface ( 424 ) is in the form of signals which may be, for example, electronic, electromagnetic, optical, or other signals capable of being received by communications interface ( 424 ). These signals are provided to communications interface ( 424 ) via a communications path (i.e., channel) ( 426 ). This communications path ( 426 ) carries signals and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, a radio frequency (RF) link, and/or other communication channels.
[0039] In this document, the terms “computer program medium,” “computer usable medium,” and “computer readable medium” are used to generally refer to media such as main memory ( 410 ) and secondary memory ( 412 ), removable storage drive ( 416 ), and a hard disk installed in hard disk drive ( 414 ).
[0040] Computer programs (also called computer control logic) are stored in main memory ( 410 ) and/or secondary memory ( 412 ). Computer programs may also be received via a communication interface ( 424 ). Such computer programs, when run, enable the computer system to perform the features of the present invention as discussed herein. In particular, the computer programs, when run, enable the processor ( 402 ) to perform the features of the computer system. Accordingly, such computer programs represent controllers of the computer system.
[0041] As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
[0042] Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
[0043] A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
[0044] Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
[0045] Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0046] Aspects of the present invention are described above with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0047] These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0048] The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0049] The flowcharts and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowcharts or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
[0050] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0051] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. Accordingly, the code stream compression supports flexibility with respect to decompression, including, decompression of the code stream from an arbitrary position therein, with the decompression being a recursive process to the underlying literal of a referenced phrase.
Alternative Embodiment
[0052] It will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. In particular, a capability may be introduced in the storage application to coordinate with the agent monitoring occupancy in the storage container to have virtual space filling data objects per storage container that can individually balance the virtual with the real sizes separately for each storage controller storage container. Accordingly, the scope of protection of this invention is limited only by the following claims and their equivalents.
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Embodiments of the invention relates to avoiding out-of-space conditions in storage controllers operating with efficiency capabilities between virtual space in a data container and real space in a storage container. Both the real space and the virtual space are monitored and their respective usage is compared to provide information about occupancy of the real space to the virtual space. Usage of the containers is balanced by employing a virtual file associated with a reserved portion of free capacity in the virtual space.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an evaporator, and in particular to a portable evaporator for use in the mining industry.
Specifically, the invention relates to an evaporator for use in the mining industry to reduce the volume of water in tailings ponds during reclamation. In order to keep the volume of water in tailings ponds to a minimum, it is necessary to supplement natural evaporation using a mechanical spraying device or evaporator. The evaporator jets fine streams of liquid from a tailings pond into a stream of air under pressure to effect evaporation of large volumes of liquid. It will be appreciated that the evaporator can be used for other purposes, i.e. for evaporating water other than that taken from tailings ponds.
2. Discussion of the Prior Art
Spraying devices or evaporators of the types disclosed herein are by no means new. Examples of such apparatus are disclosed by U.S. Pat. No. 3,069,091, issued to R. C. Giesse et al on Dec. 18, 1962; U.S. Pat. No. 3,269,657, issued to V. P. M. Ballu on Aug. 30, 1966; U.S. Pat. No. 3,319,890, issued to D. E. Wolford on May 16, 1967; U.S. Pat. No. 3,883,073, issued to V. P. M. Ballu on May 13, 1975; U.S. Pat. No. 5,269,461, issued to J. F. Davis on Dec. 14, 1993 and U.S. Pat. No. 5,299,737, issued to C. D. McGinnis et al on Apr. 5, 1994.
In general, while existing devices perform the desired function in varying degrees of efficiency, it has been found that a need still exists for an evaporator which can be used on virtually any terrain for quickly evaporating large volumes of liquid.
GENERAL DESCRIPTION OF THE INVENTION
The object of the present invention is to meet the above defined need by providing a relatively simple, efficient, portable evaporator, which can be used on uneven terrain.
Accordingly, the present invention relates to an evaporator for quickly evaporating large volumes of liquid comprising:
(a) a stand for supporting the evaporator in a fixed position;
(b) a frame rotatable on said stand for rotation around a vertical axis;
(c) a tubular horizontal housing on said frame, said housing having first and second open ends;
(d) a fan in said housing;
(e) a motor on said frame at the first open end of said housing for driving said fan to move air through said housing from said first open end to the second open end thereof;
(f) an elongated tubular nozzle extending upwardly and outwardly from said second open end of said housing for discharging a stream of air from the evaporator;
(g) a manifold around an upper outlet end of said nozzle for receiving liquid from a source thereof; and
(h) a plurality of jets in said manifold for discharging atomized liquid into the stream of air exiting said nozzle, whereby evaporation of the liquid is facilitated.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described below in greater detail with reference to the accompanying drawings, which illustrate a preferred embodiment of the invention, and wherein:
FIG. 1 is a perspective view of an evaporator in accordance with the present invention;
FIG. 2 is a side view of the evaporator of FIG. 1;
FIG. 3 is a schematic front view of the evaporator of FIGS. 1 and 2;
FIG. 4 is a top view of a stand and frame used in the evaporator of FIGS. 1 to 3 ;
FIG. 5 is a partly exploded, cross-sectional view of the stand and the frame of FIG. 4;
FIG. 6 is a longitudinal sectional view of a housing and nozzle used in the evaporator of FIGS. 1 to 3 ;
FIG. 7 is an exploded view of a turbine assembly used in the evaporator of FIGS. 1 to 3 ;
FIG. 8 is a top view of a louver used in the nozzle of FIG. 6; and
FIG. 9 is a cross section of the louver taken generally along line 9 — 9 of FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2, the basic elements of the evaporator include a stand generally indicated at 1 , a frame 2 rotatably mounted on the stand 1 carrying a motor 3 and a housing horizontal 4 , and a discharge nozzle 6 for discharging a stream of air and fine water droplets from the evaporator.
The stand 1 is defined by four extensible legs 7 supporting a pair of crossbars 8 at their upper ends. Each leg 7 includes a tubular top section 9 with a smaller diameter, tubular bottom section 10 telescopically mounted in the top section 9 . The sections 9 and 10 are releasably locked in one position by pins 11 extending through diametrically opposed holes 12 (FIGS. 3 and 5) in the top and bottom sections 9 and 10 , respectively. As shown in FIG. 5, a plurality of spaced apart, opposed holes 12 in the bottom section 10 permit individual adjustment of the length of the legs 7 so that the evaporator can be stabilized on uneven terrain. Stops defined by rectangular projections 13 are provided near the bottom end of each leg 7 for limiting movement of the bottom section 10 into the top section 9 . Rectangular feet 14 are welded to the bottom ends of the legs 7 at an angle of 45° to the longitudinal axes of the legs for penetrating the ground, thus providing additional stability.
The crossbars 8 are defined by rectangular cross section, steel tubes. Square cross section tubes 15 (FIGS. 2 to 5 ) are welded to the crossbars 8 to define a support for a rectangular top plate 16 . A cylindrical tubular post 17 (FIGS. 2, 3 and 5 ) is welded to the two crossbars 8 at the center of the stand 1 . The post 17 extends upwardly beyond the top of the stand 1 for rotatably supporting the frame 2 for rotation around a vertical axis. A reinforcing plate 19 with a semicircular notch (not shown) in one side thereof for receiving the post 17 is welded to the bottom of the crossbars 8 and to the post 17 for added strength. The post 17 extends upwardly through a turntable defined by a circular plate 20 on the bottom of the frame 2 and a sleeve 21 carried by the plate 20 . The frame 2 is secured in position by a tubular cap 23 (FIGS. 4 and 5) on the top end of the tube 17 , and a pin (not shown) which extends through diametrically opposed, aligned holes 25 and 26 in the post 17 and the sleeve 21 , respectively.
With reference to FIGS. 4 and 5, the skeletal frame 2 includes a pair of parallel, spaced apart sides 28 interconnected at the center by a bottom crossbar 29 , which is welded to the turntable 20 and receives the sleeve 21 , and a top crossbar 30 . Additional crossbars 32 and 33 are provided at the top of the rear end of the frame 2 , and at the rear end of the frame, respectively. The crossbars 32 are large angle irons for supporting the motor 3 . A pair of inverted L-shaped ledges 35 (FIGS. 4 and 5) are welded to the interior of the sides 28 at the front end of the frame 2 for supporting a cradle 36 (FIG. 1) carrying the fan housing 4 . The motor 3 is held in position by triangular braces 38 (FIGS. 1 and 2 ), and is protected from the elements by an arcuate cover 39 cantilevered from a generally triangular stand 40 mounted on the sides 28 of the frame 2 . Side shields 41 are mounted on the stand 40 limiting access to the moving parts at the air inlet end of the machine.
The flared rear or inlet end 42 of the horizontal fan housing 4 is protected by a cage 43 , the bottom ends of which are bolted to the sides 28 of the frame 2 . Referring to FIGS. 2 and 6, a generally C-shaped handle 44 is provided on the top of the housing 4 to facilitate lifting of the evaporator. The nozzle 6 includes a cylindrical, horizontal bottom arm 46 , which is rotatably connected to the front or outlet end 47 of the housing 4 , and an upwardly tapering top arm 48 inclined 45° to the horizontal through which a stream of air is discharged from the evaporator. Rings 50 and 51 (FIG. 6) of generally U-shaped cross section are welded to the outlet end 47 of the housing 4 and to the inlet end 52 of the nozzle 6 , respectively. The sides of a split ring 53 with a cross section which is the reverse of that of rings 50 and 51 embraces the abutting outer sides of the rings 50 and 51 . Outwardly extending flanges 55 (FIG. 1) on the free ends of the ring 53 are releasably interconnected by a T-shaped bolt 56 . When the bolt 56 is manually rotated to loosen the ring 53 , the nozzle 6 can be rotated using a handle 57 (FIG. 2) on the bottom of the horizontal arm 46 of the nozzle 6 . The bolt 56 is tightened to lock the nozzle 6 in the desired position.
A turbine 58 (FIGS. 6 and 7) is fixedly mounted in the inlet end 42 of the housing 4 . The turbine 58 includes a hollow, cylindrical hub 59 with closed ends, and blades 60 extending radially outwardly from the hub 59 to the housing 4 . The outer ends of the blades 60 are connected to the interior of the housing 4 . Thus, the turbine acts as a stator for cutting and directing air entering the inlet end 42 of the housing 4 .
A pair of bearings 62 in the ends of the turbine hub 59 rotatably support a shaft 63 , which is connected to the shaft 64 of the motor 3 by a flexible coupler 65 (FIG. 7) available from T. B. Woods, Chambersburg, Pa. A fan 67 and a generally hemispherical nose cone 68 are mounted on the outer end of the shaft 63 for rotation therewith. Actuation of the motor 3 results in the drawing of air into the rear end 42 of the housing 4 for discharge through the nozzle 6 .
With reference to FIGS. 6, 8 and 9 , a plurality of parallel louvers 70 extend across the nozzle 6 at the elbow 72 between the horizontal and inclined arms 46 and 48 , respectively of the nozzle 6 . Each louver 70 includes a horizontal lower section 73 , an intermediate section 74 bent 22.5° with respect to the lower section 73 , and an upper section 75 bent 22.5° with respect to the intermediate section, i.e. 45° from the horizontal. The louvers 70 redirect air entering the inlet end 52 of the nozzle 4 upwardly through the inclined arm 48 to the outlet end 77 thereof.
An annular manifold 80 is mounted on the upper, outlet end 77 of the nozzle 6 using brackets 81 . An inlet tube 83 in the bottom of the manifold 80 introduces water pumped from a tailings pond through a hose 84 (FIG. 2) connected to the inlet tube. The water is discharged through a plurality of atomizing jets or nozzles 85 into the stream of air exiting the nozzle 6 . The jets 85 extend radially upwardly and inwardly for providing a fine mist of water particles, which are picked up by the air under pressure to accelerate evaporation. The nozzle 6 can readily be rotated to a plurality of positions (FIG. 5) so that residual spray does not land in the same place each time and cause erosion.
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A relatively simple portable evaporator for quickly evaporating large volumes of water includes a stand with adjustable legs, a frame carrying a tubular housing and a motor rotatably mounted on the stand for rotation around a vertical axis, a fan in the housing driven by the motor, a nozzle rotatably mounted on one end of the housing for directing air from the fan upwardly and outwardly from the housing, and a manifold carrying a plurality of jets for receiving water from a tailings pond or other source and spraying the water into a stream of air exiting the nozzle for expediting evaporation.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention is generally directed to outdoor animal kennels.
BACKGROUND ART OF THE INVENTION
[0002] Kennels for outdoor animals, such as pet dogs, are typically large enclosures constructed with materials similar to a chain link fence. The enclosures are preferably large enough to give a dog room to run around within the kennel. As a result, the kennels are heavy and bulky. In many situations, it would be advantageous to be able to move the kennel—either temporarily, such as for mowing a yard, or permanently to a new location. Prior art kennels are very difficult to move, often requiring disassembly or a large number of persons. What is needed is an outdoor dog kennel that may be easily moved when desired, yet remains stable and stationary at other times.
SUMMARY
[0003] The present invention solves problems with the prior art by providing rollers, attached to a kennel, and configurable in first and second positions. In the first position, the rollers contact the ground and the kennel walls are elevated above the ground. In the second position, the kennel walls rest on the ground while the rollers are elevated. In one embodiment, a kit provides rollers which are attachable to existing kennels. The kit allows rollers to be easily attached to each corner of the kennel. The rollers remain attached and are movable from a mobile position, with wheels in contact with the ground, to a stationary position with wheels off the ground. In another embodiment, the kit includes two or more brackets which secure a shaft to the kennel. A device, such as a cotter pin, secures the shaft in two or more selectable positions relative to the brackets. The wheels are lowered by 1) lifting a portion of the kennel, 2) removing a cotter pin from a first position, 3) lowering the wheel, and 4) inserting the cotter pin in a second position. The kit may also include a handle for easily lifting the kennel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] For a more complete understanding of the present invention and for further advantages thereof, reference is now made to the following Description of the Preferred Embodiments taken in conjunction with the accompanying Drawings in which:
[0005] FIG. 1 is a perspective view of a typical outdoor kennel.
[0006] FIG. 2A is a perspective view of a mobile kennel with wheels in a raised position.
[0007] FIG. 2B is a perspective view of a mobile kennel with wheels in a lowered position.
[0008] FIG. 3A is a closer view of a roller assembly for a mobile kennel, with wheel in a raised position.
[0009] FIG. 3B is a closer view of a roller assembly for a mobile kennel, with wheel in a lowered position.
[0010] FIG. 4 is a closer view of a mounting bracket for a mobile kennel.
[0011] FIG. 5 is a closer view of a portion of a roller shaft for a mobile kennel.
[0012] FIG. 6A is a closer view of a shaft engaged in a mounting bracket in a raised position.
[0013] FIG. 6B is a closer view of a shaft engaged in a mounting bracket in a lowered position.
[0014] FIG. 7 shows a handle for a dog kennel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] FIG. 1 shows a kennel 10 for a large dog. Kennel 10 shown in FIG. 1 comprises four walls 102 . One of the walls 102 comprises a door 104 . Walls 102 and door 104 are preferably constructed of a galvanized steel frame supporting a chain-link mesh (not shown). Walls 102 are connected at corner poles 106 to form a square enclosure. Kennel 10 does not include a floor or roof.
[0016] FIGS. 2A and 2B show a kennel embodying features of the present invention. A roller assembly 20 is preferably connected to a corner pole 106 at each corner of kennel 10 . In FIG. 2A roller assembly 20 is shown with rollers in a raised position. In this position, walls 102 rest on the ground. In FIG. 2B roller assembly 20 is shown with rollers in a lowered position. In this position, walls 102 are elevated above the ground.
[0017] FIG. 3A shows a closer view of roller assembly 20 . Roller assembly 20 includes a shaft 302 which is attached to corner poles 106 by brackets 304 . Shaft 302 is preferably 13 gauge tube constructed from powder coated cold-rolled steel with an outer diameter of about 11/16″ and in inner diameter of about 0.520″. A roller 308 is attached to the bottom of shaft 302 . Roller 308 is preferably a swivel caster with a steel body and rubber wheels about 4″ in diameter, however, many other rollers, including many types of wheels, are known and may be used. Roller 308 preferably comprises a 1 1/4″ long steel prong (not shown) with an outer diameter of about 7/16″ and a ring clip (not shown). Roller 308 is preferably held in shaft 302 by the ring clip and a nylon bushing (not shown) with an inner diameter of 7/16″ and an outer diameter of ½″. Other dimensions for the steel prong, nylon bushing, and shaft 302 may be used, however, the listed dimensions have been found to securely attach roller 308 to shaft 302 without the need for gluing. Alternatively, roller 302 may be attached to shaft 308 by gluing, welding, or other methods.
[0018] Roller assembly 20 preferably comprises at least two brackets 304 which are attached to higher and lower positions on corner pole 106 , such as at about 10″ and 30″ from the bottom of corner pole 106 . Using multiple brackets 304 is helpful to keep shaft 302 aligned with corner pole 106 . Alternatively, shaft 302 could be maintained in alignment with corner pole 106 by other means, such as providing a tube (not shown) attached to bracket 304 and positioning shaft 302 within the tube. In FIG. 3A , roller assembly 20 is shown with roller 308 in the raised position. FIG. 3B shows roller assembly 20 with roller 308 in the lowered position.
[0019] FIG. 4 is a closer view of bracket 304 . Bracket 304 comprises two mounting panels 404 , a front panel 406 , and a positioning panel 408 . Mounting panels 404 , front panel 406 , and positioning panels 408 are preferably constructed from a single piece of metal, preferably powder coated steel. Mounting holes 412 are defined in each mounting panel 404 . Bracket 304 is preferably mounted to corner pole 106 by positioning corner pole 106 between the two mounting panels 404 and securing bracket 304 in place using screws 414 (seen in FIGS. 6A and 6B ) through mounting holes 412 and corner pole 106 . Screws 414 are preferably self tapping screws, however, bolts or other types of screws may be used. To facilitate securing bracket 304 to corner pole 106 , bracket holes (not shown) are preferably pre-drilled in corner pole 106 . A positioning hole 402 is defined in positioning panel 408 . In operation, shaft 302 is retained in positioning hole 402 but is able to slide up and down within positioning hole 402 . As discussed above, alternatively to positioning hole 402 , bracket 304 may comprise an outer tube (not shown) configured to align and retain shaft 302 with the ability to slide within the tube.
[0020] FIG. 5 is a view of an upper section of shaft 302 . Preferably, three sets of holes are defined in shaft 302 : upper retaining holes 502 , support holes 504 , and lower retaining holes 506 . Each set of holes comprises a pair of holes defined at equal heights on opposite sides of shaft 302 . Upper retaining holes 502 are preferably defined near an upper end of shaft 302 . Support holes 504 are defined slightly below upper retaining holes. Lower retaining holes 506 are preferably defined several inches below support holes 504 . Lower retaining holes 506 are configured so that, when shaft 302 is in positioning hole 402 and a support pin 604 (shown in FIGS. 6A and 6B ) is placed in lower retaining holes 506 , shaft 302 is held in an elevated position with rollers 308 above the ground. Support holes 504 are configured so that, when shaft 302 is in positioning hole 402 and support pin 604 (shown in FIGS. 6A and 6B ) is placed through support holes 504 , support pin 604 will support walls 102 of kennel 10 above the ground on rollers 308 . In one embodiment, upper retaining holes 502 , support holes 504 , and lower retaining holes 506 are about ⅝″, 1″ and 7″, respectively, below the top of shaft 302 and are about 3/16″ in diameter. Support pin 604 and retaining pin 602 are preferably steel.
[0021] Upper retaining holes 502 are configured so that when retaining pin 602 (shown in FIGS. 6A and 6B ) is place through the retaining holes 502 , shaft 302 going through positioning hole 402 will not disengage with bracket 304 . This configuration helps prevent accidental disassembly. Other configurations, such as an enlarged upper cap (not shown) which does not fit through positioning hole 402 would provide similar benefit. As described above, the upper retaining holes 502 , support holes 504 and lower retaining holes 506 are preferably configured to interact with an upper bracket 304 . Where multiple brackets 304 are used, the holes may be configured to interact with any of the brackets 304 , however, using the topmost bracket 304 will generally be more convenient to the user. Shaft 302 is preferably provided with an end cap (not shown) configured to protect the interior of shaft 302 from the elements and from entry of foreign objects. The end cap is preferably plastic.
[0022] FIGS. 6A and 6B show a closer view of a bracket 304 engaging a shaft 302 . In FIG. 6A , shaft 302 is shown in a raised position, in which walls 102 will contact the ground and rollers 308 will be elevated. A retaining pin 602 placed through lower retaining holes 506 supports the weight of shaft 302 and rollers 308 in an elevated position off the ground. In FIG. 6B , shaft 302 is show in its lower position. In this position, support pin 604 is placed through support holes 504 defined in shaft 302 . Positioning panel 408 rests on support pin 604 and a portion of the weight of kennel 10 is transferred to shaft 302 through support pin 604 . Retaining pin 602 is positioned in upper retaining holes 502 . Alternatively to using pins extending completely through shaft 302 , a shorter pin (not shown) could potentially be used and held in position by, for example, being attached to bracket 304 and biased toward shaft 302 by a spring (not shown) or similar device. Further alternatively, shaft 302 could be positioned using a clamp or other friction means.
[0023] To transform kennel 10 from its stationary position (with walls 102 resting on the ground and rollers 308 elevated), to its mobile position (with walls 102 elevated and rollers 308 on the ground) the user lifts a portion of kennel 10 , preferably near a corner pole 106 . While lifting kennel 10 , the user removes support pin 604 from lower retaining holes 506 and allows shaft 302 to slide down until retaining pin 602 contacts positioning panel 408 . The user then inserts support pin 604 into support holes 504 and lowers kennel 10 until positioning panel 408 rests on support pin 604 . To transform kennel from its mobile position to its stationary position, the user lifts kennel 10 , removes support pin 604 , and lowers kennel 10 until walls 102 rest on the ground. The user then lifts shaft 302 until lower retaining holes 506 are above positioning panel 408 . Next the user places support pin 604 through lower retaining holes 506 and releases shaft 302 .
[0024] Because it can be painful to lift kennel 10 using only the chain link, a lifter 30 may be provided as shown in FIG. 7 . Lifter 30 preferably comprises a wooden handle 702 attached to a metal engaging hook 704 . The user may lift kennel 10 using handle 702 by engaging hook 704 with the chain link. Many other handles designs are know and may be used.
[0025] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions, will be apparent to persons skilled in the art upon reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.
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A mobile pet kennel comprising: a plurality of kennel walls connected to form an enclosure; rollers; and a roller positioner, wherein the roller positioner is configured to retain the rollers in a selectable first or second position relative to the kennel walls. In the first position the rollers contact the ground and in the second position the rollers are elevated above the ground.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a full-wave rectifying device. More specifically this invention relates to a transistor full-wave rectifying device.
[0003] 2. Description of Related Art
[0004] Radio-Frequency Identification (RFID) System is an automatic identification method that involves affixing a small electronic tag to a product which may be checked and monitored by a device known as “reader” which in turn transmits the data stored in the electronic tag back to the system via a wireless RF means, thus achieving remote authentication, tracking, control, management and handling.
[0005] The electronic tags are categorized into two general varieties, passive and active. In particular, passive RFID tags have no internal power supply. The minute electrical current induced in the antenna by the incoming radio-frequency (RF) signal provides just enough power for the CMOS integrated circuit in the tag to power up and transmit a response.
[0006] Generally, the amplitude of the RF signal is approximately 200 mV or lower, and it is not easy to power up passive RFID tags with such a weak signal. Moreover, current leakage or parasitic effect often occurs in electrical circuits, thereby causing the RF signal energy to be further dissipated.
[0007] Consequently, a rectifier is designed such that, upon receiving the RF signal by the antenna of passive RFID tags, the capacitors are charged repeatedly, thereby converting the RF signal to a sufficient dc voltage level for the next stage of circuit operation.
[0008] Referring to FIG. 1 , the first conventional full-wave rectifying circuit structure is shown. The full-wave rectifying circuit has eight transistors, P 1 -P 6 , N 1 and N 2 . Such a circuit structure lowers the transistor body effect, thus improving the efficiency of converting the RF signal to a dc voltage.
[0009] However, such a circuit structure is only a single-stage rectifying circuit, which produces the dc voltage output that is approximately the amplitude of the RF signal only. Even under the circumstance of 100% conversion efficiency, such a circuit structure usually fails to provide a sufficient dc voltage level.
[0010] Referring to FIG. 2 , another conventional full wave rectifying circuit structure is illustrated. Diode-connected transistor instead of Schottky diode is used in the cascade of a multistage rectifying circuit, thereby deriving a sufficient dc voltage level given a specified input power.
[0011] However, the chip manufacturing process of such a circuit structure does not take into account the importance of separate bulk connection which suppresses the body effect. Hence, such a circuit may be affected by the body effect, thus causing a significant difference in the threshold voltage of the transistor at each stage. Consequently, the output voltage level is lowered and the circuit fails to output a dc voltage level that matches the designed value.
[0012] In summary, it has become an urgent issue to designers of the RF circuit design field to propose a multistage full-wave rectifying circuit that not only provides a sufficient dc voltage level, but also avoids or lowers the body effect such that the difference in the threshold voltage of the transistor at each stage is reduced to minimum, in order for the circuit successfully to output a dc voltage level that matches the designed value.
SUMMARY OF THE INVENTION
[0013] In view of the above disadvantages of the conventional techniques, it is a primary objective of the present invention to provide a full-wave rectifying device that supplies a sufficient dc voltage level and avoids or lowers the body effect such that the difference in the threshold voltage of the transistor at each stage is reduced to minimum, in order for the circuit successfully to output a dc voltage level that matches the designed value.
[0014] In order to achieve the above-mentioned objective, the present invention provides a full-wave rectifying device that has a first rectification unit having a first transistor and a second transistor, a second rectification unit having a third transistor and a fourth transistor, and a plurality of capacitors. In particular, the source of each transistor is connected to the substrate and the drain is connected to the gate; by connecting the source of the transistor to the substrate, the body effect in the rectifying circuit is effectively lowered.
[0015] In addition, the first transistor is connected in series with the second transistor, between which a capacitor is connected. The third transistor is connected in series with the fourth transistor, between which a capacitor is connected. Furthermore, the first rectification unit is connected to the second rectification unit to form a symmetrical full-wave rectifying circuit.
[0016] Finally, the symmetrical full-wave rectifying circuit is connected to a signal input unit, a ground terminal and a load, thereby allowing the signal input unit to receive the RF signal fed from the external environment. The first rectification unit and the second rectification unit in turn convert the RF signal to a rectified dc voltage level.
[0017] In order to achieve the aforementioned objective, the present invention provides another full-wave rectification device, which has a first rectification module, a second rectification module and a plurality of capacitors. In particular, the first rectification module includes two first rectification units, and each of the first rectification unit further includes a first transistor and a second transistor. As well, the second rectification module has two second rectification units, and each of the second rectification units further includes a third transistor and a fourth transistor. In addition, the source of each of the transistors is connected to the substrate, and the drain is connected to the gate. Hence, the body effect in the rectifying circuit is effectively lowered by employing the method of connecting the source of the transistor to its substrate.
[0018] Also, the first transistor of each of the first rectification units is cascaded with the second transistor between which a capacitor is connected. As well, the third transistor of each of the second rectification units is cascaded with the fourth transistor between which a capacitor is connected.
[0019] Subsequently, the first first rectification unit is connected to the second first rectification unit to form a first rectification module; similarly, the first second rectification unit is connected to the second second rectification unit to form a second rectification module. Furthermore, the first rectification module is connected to the second rectification module to form a symmetrical two-stage full-wave rectifying circuit.
[0020] Finally, the symmetrical two-stage full wave rectifying circuit is connected to a signal input unit, a ground terminal and a load, thereby allowing the signal input unit to receive the RF signal fed from the external environment. The first rectification module and the second rectification module in turn convert the RF signal to a rectified dc voltage level.
[0021] In order to achieve the above-mentioned objective, the present invention also provides another full-wave rectifier, which includes a first rectification module, a second rectification module and a plurality of capacitors. In particular, the first rectification module has a plurality of first rectification units, and each of the first rectification unit further includes a first transistor and a second transistor. As well, the second rectification module has a plurality of second rectification units, and each of the second rectification units further includes a third transistor and a fourth transistor. In addition, the source of each of the transistors is connected to the substrate and the drain is connected to the gate. The body effect in the rectifying circuit is effectively lowered by employing the method of connecting the source of the transistor to its substrate.
[0022] Also, the first transistor of each of the first rectification units is cascaded with the second transistor between which a capacitor is connected. As well, the third transistor of each of the second rectification units is cascaded with the fourth transistor between which a capacitor is connected.
[0023] Subsequently, the (N-1) st first rectification unit is connected to the N th first rectification unit to form a first rectification module; similarly, the (N-1) st second rectification unit is connected to the N th second rectification unit to form a second rectification module. Furthermore, the first rectification module is connected to the second rectification module to form a symmetrical N-stage full-wave rectifying circuit.
[0024] Finally, the symmetrical N-stage full-wave rectifying circuit is connected to a signal input unit, a ground terminal and a load, thereby allowing the signal input unit to receive the RF signal fed from the external environment. The first rectification module and the second rectification module in turn convert the RF signal to a rectified dc voltage level.
[0025] In summary, the full-wave rectifying device of the present invention employs the method of connecting the source of each transistor to the substrate in order to effectively lower the body effect in the rectifying circuit. Next, a plurality of capacitors are used to generate a rectified dc voltage level. Besides the present invention also discloses a multistage rectifying circuit design that employs a plurality of first rectification units and a plurality of second rectification units, so as to increase the rectified dc voltage level to a sufficient level.
[0026] As a result, the above-mentioned multistage full-wave rectifying circuit designed using transistors not only lowers the body effect of transistors in the conventional rectifier, but also significantly increases the rectified dc voltage level to a level that matches the designed value.
BRIEF DESCRIPTION OF DRAWINGS
[0027] FIG. 1 illustrates a first conventional full-wave rectifying circuit structure;
[0028] FIG. 2 illustrates a second conventional full-wave rectifying circuit structure;
[0029] FIG. 3 a is a circuit schematic according to a first embodiment of the present invention;
[0030] FIG. 3 b is a diagram showing a connection of the source of a transistor and the substrate;
[0031] FIG. 4 is a circuit schematic according to a second embodiment of the present invention;
[0032] FIG. 5 is a circuit schematic according to a third embodiment of the present invention; and
[0033] FIG. 6 is a circuit schematic of a symmetrical N-stage full-wave rectifying device according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] The following illustrative embodiments are provided to illustrate the disclosure of the present invention, these and other advantages and effects can be apparently understood by those in the art after reading the disclosure of this specification. The present invention can also be performed or applied by other different embodiments. The details of the specification may be on the basis of different points and applications, and numerous modifications and variations can be devised without departing from the spirit of the present invention.
[0035] The following embodiments further illustrate the points of the present invention in detail, however the scope of the invention is not limited to any points.
First Embodiment
[0036] FIG. 3 a illustrates a circuit according to a first embodiment of the present invention. As shown in the diagram, a full-wave rectifying device 10 of the present invention includes a first rectification unit 11 and a second rectification unit 12 .
[0037] In particular, the first rectification unit 11 further has a first transistor 111 having a first drain 1111 , a first source 1112 , a first gate 1113 , and a first substrate 1114 ; a second transistor 112 having a second drain 1121 , a second source 1122 , a second gate 1123 and a second substrate 1124 ; the first source 1112 is connected to the first substrate 1114 to form a first connection node 191 ; the second drain 1121 is connected to the second gate 1123 to form a second connection node 192 ; the first drain 1111 , the first gate 1113 , the second source 1122 and the second substrate 1124 are connected to one another to form a third connection node 193 .
[0038] The second rectification unit 12 further includes a third transistor 121 having a third drain 1211 , a third source 1212 , a third gate 1213 , and a third substrate 1214 ; a fourth transistor 122 having a fourth drain 1221 , a fourth source 1222 , a fourth gate 1223 and a fourth substrate 1224 ; the third source 1212 is connected to the third substrate 1214 to form a fourth connection node 194 ; the fourth drain 1221 is connected to the fourth gate 1223 to form a fifth connection node 195 ; the third drain 1211 , the third gate 1213 , the fourth source 1222 and the fourth substrate 1224 are connected to one another to form a sixth connection node 196 .
[0039] It is to be noted that the present invention adopts the transistor symbol of source-to-substrate connection in the TSMC twin-well process as shown in FIG. 3 b.
[0040] The first rectification unit 11 further includes a first capacitor 113 having a first capacitor terminal 1131 and a second capacitor terminal 1132 , and a second capacitor 114 having a third capacitor terminal 1141 and a fourth capacitor terminal 1142 ; the second rectification unit 12 further includes a third capacitor 123 having a fifth capacitor terminal 1231 and a sixth capacitor terminal 1232 , and a fourth capacitor 124 having a seventh capacitor terminal 1241 and an eighth capacitor terminal 1242 . The second capacitor terminal 1132 is connected to the third connection node 193 ; the third capacitor terminal 1141 is connected to the first connection node 191 ; the sixth capacitor terminal 1232 is connected to the sixth connection node 196 ; the seventh capacitor terminal 1241 is connected to the fifth connection node 195 .
[0041] The full-wave rectifying device 10 also includes a signal input unit 13 , a load 14 , and a ground terminal 15 . In particular, the signal input unit 13 is connected to the first capacitor terminal 1131 and the fifth capacitor terminal 1231 . The load 14 is connected in series between the first connection node 191 and the fifth connection node 195 . In addition, the second connection node 192 , the fourth connection node 194 , the fourth capacitor terminal 1142 and the eighth capacitor terminal 1242 are connected to the ground terminal 15 .
[0042] Such an arrangement allows the signal input unit 13 to receive the RF signal, wherein a stable rectified dc voltage level is generated by the first rectification unit 11 and the second rectification unit 12 . The rectified dc voltage is then presented between the first connection node 191 and the fifth connection node 195 as an output signal.
Second Embodiment
[0043] FIG. 4 illustrates a circuit schematic according to a second embodiment of the present invention. The present embodiment and the first embodiment have the same basic rectifying circuit concept. The only difference is that a rectification module composed of two rectification units is employed in the present embodiment in place of a single rectification unit.
[0044] As shown in the diagram, the full-wave rectifying device 20 of the present invention includes a first rectification module 21 , a second rectification module 22 , a signal input unit 23 , a load 24 and a ground terminal 25 , wherein the first rectification module 21 further includes a first first rectification unit 211 and a second first rectification unit 212 ; the second rectification module 22 has a first second rectification unit 221 and a second second rectification unit 222 .
[0045] In particular, each of the first rectification units and each of the second rectification units according to the present invention have the same circuit structure as the first rectification unit 11 and the second rectification unit 12 , respectively, described in the first embodiment. Besides, in the present embodiment, the first first rectification unit 211 has a first connection node 2111 and a second connection node 2112 . The second first rectification unit 212 includes a first connection node 2121 and a second connection node 2122 . Also the first second rectification unit 221 includes a fourth connection node 2211 and a fifth connection node 2212 . The second second rectification unit 222 has a fourth connection node 2221 and a fifth connection node 2222 .
[0046] In the present embodiment, the first first rectification unit 211 has a first capacitor terminal 2113 and a fourth capacitor terminal 2114 ; the second first rectification unit 212 includes a first capacitor terminal 2123 and a fourth capacitor terminal 2124 . Also, the first second rectification unit 221 has a fifth capacitor terminal 2213 and an eighth capacitor terminal 2214 ; the second second rectification unit 222 includes a fifth capacitor terminal 2223 and an eighth capacitor terminal 2224 .
[0047] In terms of the circuit structure, the second connection node 2122 of the second first rectification unit 212 is connected to the first connection node 2111 of the first first rectification unit 211 . The fourth connection node 2221 of the second second rectification unit 222 is connected to the fifth connection node 2212 of the first second rectification unit 221 . Subsequently, the second connection node 2112 of the first first rectification unit 211 and the fourth connection node 2211 of the first second rectification unit 221 are grounded.
[0048] Next, the first capacitor terminal 2113 , the first capacitor terminal 2123 , the fifth capacitor terminal 2213 , and the fifth capacitor terminal 2223 are connected to the signal input unit 23 ; the fourth capacitor terminal 2114 , the fourth capacitor terminal 2124 , the eighth capacitor terminal 2214 and the eighth capacitor 2224 are connected to the ground terminal 25 .
[0049] Finally, the first connection node 2121 of the second first rectification unit 212 and the fifth connection node 2222 of the second second rectification unit 222 are connected to the load 24 , thereby forming a two-stage rectifying circuit structure.
[0050] Such an arrangement allows the signal input unit 23 to receive the RF signal, wherein a stable, rectified dc voltage level is generated by the first rectification module 21 and the second rectification module 22 . The rectified dc voltage is increased to a sufficient level and then presented at the first connection node 2121 of the second first rectification unit 212 and the fifth connection node 2222 of the second second rectification unit 222 as an output signal.
Third Embodiment
[0051] FIG. 5 illustrates a circuit schematic according to a third embodiment of the present invention. The present embodiment has the same basic rectifying circuit concept as that of the first and the second embodiments. The only difference is that the present embodiment discloses a full-wave rectifying device that is allowed to be expanded arbitrarily, thereby forming an N-stage rectification module composed of N rectification units. In the present embodiment, N is a whole number that is greater than 2.
[0052] However, it is too complicated to list all N rectification units of the rectification module, thus the present embodiment describes the concept of the rectification module composed of N rectification units using the rectification module made up of 4 rectification units as an example. In situations where N is greater than 4, the rectification structure is expanded accordingly.
[0053] As shown in FIG. 5 , the full-wave rectifying device 30 of the present invention includes a first rectification module 31 , a second rectification module 32 , a signal input unit 33 , a load 34 and a ground terminal 35 , wherein the first rectification module 31 further includes a first first rectification unit 311 , a second first rectification unit 312 , a third first rectification unit 313 , and a fourth first rectification unit 314 ; the second rectification module 32 includes a first second rectification unit 321 , a second second rectification unit 322 , a third second rectification unit 323 and a fourth second rectification unit 324 .
[0054] In particular, each of the first rectification units and each of the second rectification units according to the present invention have the same circuit structure as the first rectification unit 11 and the second rectification unit 12 described in the first embodiment. Besides, in the present embodiment, the first first rectification unit 311 has a first connection node 3111 and a second connection node 3112 . The second first rectification unit 312 includes a first connection node 3121 and a second connection node 3122 . The third first rectification unit 313 has a first connection node 3131 and a second connection node 3132 . The fourth first rectification unit 314 includes a first connection node 3141 and a second connection node 3142 .
[0055] The first first rectification unit 311 has a first capacitor terminal 3113 and a fourth capacitor 3114 ; the second first rectification unit 312 includes a first capacitor terminal 3123 and a fourth capacitor terminal 3124 ; the third first rectification unit 313 has a first capacitor terminal 3133 and a fourth capacitor terminal 3134 ; the fourth first rectification unit 314 includes a first capacitor terminal 3143 and a fourth capacitor terminal 3144 .
[0056] The first second rectification unit 321 has a fourth connection node 3211 and a fifth connection node 3212 ; the second second rectification unit 322 includes a fourth connection node 3221 and a fifth connection node 3222 ; the third second rectification unit 323 has a fourth connection node 3231 and a fifth connection node 3232 ; the fourth second rectification unit 324 has a fourth connection node 3241 and a fifth connection node 3242
[0057] The first second rectification unit 321 has a fifth capacitor terminal 3213 and an eighth capacitor terminal 3214 ; the second second rectification unit 322 includes a fifth capacitor terminal 3223 and an eighth capacitor terminal 3224 . Also, the third second rectification unit 323 has a fifth capacitor terminal 3233 and an eighth capacitor terminal 3234 ; the fourth second rectification unit 324 includes a fifth capacitor terminal 3243 and an eighth capacitor terminal 3244 .
[0058] In terms of the circuit structure, the second connection node 3122 of the second first rectification unit 312 is connected to the first connection node 3111 of the first first rectification unit 311 . The second connection node 3132 of the third first rectification unit 313 is connected to the first connection node 3121 of the second first rectification unit 312 . The second connection node 3142 of the fourth first rectification unit 314 is connected to the first connection node 3131 of the third first rectification unit 313 .
[0059] The fourth connection node 3221 of the second second rectification unit 322 is connected to the fifth connection node 3212 of the first second rectification unit 321 . The fourth connection node 3231 of the third second rectification unit 323 is connected to the fifth connection node 3222 of the second second rectification unit 322 . The fourth connection node 3241 of the fourth second rectification unit 324 is connected to the fifth connection node 3232 of the third second rectification unit 323 .
[0060] Finally, the second connection node 3112 of the first first rectification unit 311 and the fourth connection node 3211 of the first second rectification unit 321 are grounded to form a symmetrical four-stage full-wave rectifying circuit structure.
[0061] Based on the same concept and in the event that N rectification units are employed, it is concluded that the basic concept of such circuit connection involves connecting the second node of N th first rectification unit to the first node of the (N-1) st first rectification unit. In addition, the fourth connection node of the N th second rectification unit is connected to the fifth connection node of the (N-1) st second rectification unit. Finally, the second connection node of the first first rectification unit and the fourth connection node of the first second rectification unit are grounded, thereby forming a symmetrical N-stage full-wave rectifying circuit structure.
[0062] Next, the first capacitor terminal 3113 , the first capacitor terminal 3123 , the first capacitor terminal 3133 , and the first capacitor terminal 3143 as well as the fifth capacitor terminal 3213 , the fifth capacitor terminal 3223 , the fifth capacitor terminal 3233 and the fifth capacitor terminal 3243 are connected to the signal input unit 33 . Subsequently, the fourth capacitor terminal 3114 , the fourth capacitor terminal 3124 , the fourth capacitor terminal 3134 , and the fourth capacitor terminal 3144 as well as the eighth capacitor terminal 3214 , the eighth capacitor terminal 3224 , the eighth capacitor terminal 3234 and the eighth capacitor terminal 3244 are connected to the ground terminal 35 . Finally, the first connection node 3141 of the fourth first rectification unit 314 and the fifth connection node 3242 of the fourth second rectification unit 324 are connected to the load 34 .
[0063] Such an arrangement allows the signal input unit 33 to receive the RF signal, wherein a stable, rectified dc voltage level is generated by the four-stage full-wave rectifying circuit composed of the first rectification module 31 and the second rectification module 32 . The rectified dc voltage is increased to a sufficient level and then presented between the first connection node 3141 of the fourth first rectification unit 314 and the fifth connection node 3242 of the fourth second rectification unit 324 as an output signal.
[0064] Hence, based on the same concept and in the event that N rectification units are employed, the basic concept of such circuit connection is concluded as follows. The RF signal, after received by the signal input unit, is converted to a stable, rectified dc voltage by the N-stage full-wave rectifying circuit composed of the first rectification module and the second rectification module. The voltage is also increased to a sufficient level and then presented between the first connection node of the N th first rectification unit and the fifth connection node of the N th second rectification unit as an output signal.
[0065] In summary, the full-wave rectifying device of the present invention employs the method of connecting the source of each transistor to the substrate in order to effectively lower the body effect in the rectifying circuit. Next, a plurality of capacitors are used to generate a rectified dc voltage. Besides, the full-wave rectifying device of the present invention also discloses a multistage rectifying circuit design that employs a plurality of first rectification units and a plurality of second rectification units, so as to increase the rectified dc voltage to a sufficient level.
[0066] While the invention has been particularly shown and described with reference to preferred embodiments for purposes of illustration, it will be understood that variations and modifications can be effected thereto by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
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A full-wave rectifying device includes a first rectification module and a second rectification module. The first rectification module includes one or a plurality of first rectification units. The second rectification module includes one or a plurality of second rectification units. In each of a plurality of transistors, the substrate is connected to the source so as to reduce the body effect of the rectifying circuit efficiently and enable generation of a dc voltage signal through rectification by a plurality of capacitors. A multistage rectifying circuit architecture including a plurality of first rectification units and second rectification units is provided, so as to reduce the body effect of transistors of a conventional rectifier and significantly stabilize the voltage output level, thereby allowing the rectifying circuit to generate a dc voltage level of designed value.
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This invention relates to a high pressure liquid rotary swivel nozzle assembly device intended to be supported by a small diameter cable spanning interior walls of a chamber, or extending along a spacial area in which may be located a variety of objects, to be cleaned by high pressure liquid jet streams issuing in continuously varying directions from multiple jet nozzle elements of the device as the device is propelled along the cable support. The device is particularly useful for cleaning the interior of large cylindrical chambers where the cable support extends coaxially of the chamber between its opposite end walls with the device moving from one end wall to the other during a cleaning operation.
BACKGROUND OF THE INVENTION
It is frequently necessary to remove layers of particulates or other coatings which have collected on surfaces of an extended array of objects or on the interior walls of industrial chambers, transportation vessels or other large containers by means of high pressure liquid jet streams moved to scan and scrub with high pressure liquid jet streams all exposed and interior surfaces of the various structures. Often it is inconvenient or impossible to position and move bulky spray cleaning equipment along or within such objects or structures because of the nature of access around an array of objects, or access through openings, or around interior interfering beams, posts or other structural obstructions so that cable carried spraying devices become practical for cleaning. Also a cable carried movable multi-jet cleaning tool with rotating jets angled in forward and backward directions may provide optimum cleaning of opposite sides of and behind such obstructions.
DESCRIPTION OF PRIOR ART
Rotary spray devices for cleaning large chamber interiors are disclosed in U.S. Pat. No. 4,690,159 and references cited or discussed therein. This patent discloses an air-motor driven rotary high pressure fluid nozzle device carried by a cable support.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a compact cable carried rotary nozzle assembly that lends itself to use of a variety of spray nozzle elements of lengths without interference of spray patterns therefrom by any structural portions of the nozzle assembly or by portions of objects being cleaned.
Another object of this invention is to provide a compact cable carried rotary nozzle assembly that can be self-propelled along the cable by jet stream reaction and lends itself to use of a variety of oppositely balanced spray nozzle elements of maximum length without interference of spray patterns therefrom by any structural portions of the nozzle assembly. Another object of this invention is to provide a compact cable carried rotary nozzle assembly that can be self-rotating by jet stream reaction while being propelled along the cable.
Another object of the invention is to provide in a compact cable carried rotary nozzle assembly an improved low friction rotary bearing support between a relatively stationary high pressure liquid input body member and a rotatable multi-nozzle spray head member.
Another object of the invention is to provide in a compact cable carried rotary nozzle assembly an improved long wearing low drag high pressure liquid sealing structure between a relatively stationary high pressure liquid input body member and a rotatable multi-nozzle spray head member.
Another object of the invention is to provide an improved compact cable carried rotary nozzle assembly that is readily and easily disassembled for inspection, cleaning or replacement of parts and reassembled with minimum tools.
Another object of the invention is to provide an improved shaft structure in a cable carried rotary nozzle assembly having a rotary nozzle carrying shaft with separate axially extending liquid-carrying and cable-accommodating bored passages.
Another object of the invention relates to an improved shaft structure for a cable mounted spray assembly structure utilizing multiple elongated bores in a unitary shaft member as the fluid passage conduits through the shaft.
Another object of the invention is to provide an improved shaft structure for a cable mounted spray assembly having a central cable passage surrounded by a plurality of uniformly angularly spaced and symmetrically spaced individual liquid passage bores for conducting high pressure liquid between an input body member and a rotatable spray head member.
Another object of the invention is to provide an improved liquid sealing structure in the nozzle carrying shaft of a cable carried rotary nozzle assembly having a rotary nozzle carrying shaft with separate axially extending liquid-carrying and cable-accommodating shaft passages.
Another object of the invention is to provide an improved shaft-supported pulling eye assembly for a cable carried rotary nozzle assembly having a rotary nozzle carrying shaft with separate axially extending liquid-carrying and cable-accommodating passages.
Another object of the invention is to provide an improved cable carried rotary nozzle assembly which lends itself to fast setup along an array of objects to be cleaned or within an enclosed area having limited access in the vicinity of surfaces to be cleaned.
The present invention provides a high pressure liquid swivel nozzle assembly adapted for sliding movement along a small diameter cable support, or similar elongated support, and for spraying multiple high pressure liquid streams outwardly in continuously changing directions relative to the cable support. An elongated main shaft of the nozzle assembly, rotatably carried by the cable and having a longitudinal axis, carries a relatively stationary liquid input body member and an output liquid spray head member rotatable with the shaft. The cable passes through a central axial passage in the shaft. The shaft has multiple internal liquid passage means extending longitudinally within the shaft in isolated relationship to a central axial passage for the cable.
Each of the input body member and the nozzle carrying spray head member encircles the shaft and includes means sealed with respect to the shaft for defining with the shaft a respective annular plenum chamber around the shaft with each plenum chamber communicating with the liquid passage means in the shaft to enable flow of high pressure liquid from the body member to the nozzle carrying spray head member.
At one plenum chamber between the rotary shaft and a relatively rotatable member encircling the shaft the sealing structure comprises symmetrical opposed stacks of sealing elements including abutting but relatively movable flat radially extending surfaces forming a set of axially engaged face seals and radially engaged cylindrical seals at opposite ends of the plenum chamber.
The invention provides the arrangement of face seals and cylindrical seals at opposite ends of the plenum chamber at an interface between two relatively movable members for sealing of high pressure liquid within the plenum chamber and for helping to provide low drag during relative rotation of the two members.
Sealed radial ball bearing means support the input body member relative to the shaft enabling the shaft to rotate within the body member while the latter is held against rotation by liquid input hoses attached to the input body member and by non-rotating portions of an air motor assembly which rotates the shaft. The output liquid spray head member is secured to the rotatable shaft.
Hose means couple a high pressure liquid source to the input body member. Multiple hoses are preferably used to assure high volume liquid supply to the spray nozzle assembly. Liquid supply hoses are preferably connected to a lower portion of the spray nozzle assembly to improve stability of the assembly and minimize rotation of the assembly relative to its supporting cable during a cleaning operation. Multiple nozzle elements are carried by the spray head member for creating multiple high velocity jet streams when high pressure liquid is supplied to the body member, The ball bearing means facilitate rotating the spray head member relative to the body member to continuously change the directions of the high velocity jet streams during operation of the nozzle assembly.
Mechanical connection means between the non-rotating housing of the air motor and the liquid input body member help to prevent rotation of the liquid input body member relative to the support cable during operational movement of the swivel assembly along the cable.
A dynamic sealing means is provided at each end of the plenum chamber at the liquid input member forming a high pressure liquid seal between the shaft and the input body member to prevent escape of high pressure liquid.
Each such sealing means comprises spaced sealing rings at opposite sides of the plenum chamber at the liquid input member, annular wear resistant sealing disks engaging the sealing rings, and annular plastic sealing elements in axial facial sealing engagement with the disks and in radial sealing engagement with an inwardly facing cylindrical surface of the liquid input member.
The sealing rings are located between the ball bearing means which support the shaft in the input body member and are sealed with respect to the shaft. The sealing rings have opposed parallel flat annular faces closely encircling the shaft. The input body member has a pair of inner annular surfaces opposite the flat annular faces of the sealing rings. These sets of opposed faces define a pair of annular spaces for retaining the sealing disks and the plastic sealing elements in stacked pairs with the wear resistant disks abutting the flat annular faces of the rings.
The air motor has an air driven vane rotor connected to a worm gear which drives an annular output gear member which is keyed to an extension portion of the main shaft of the nozzle assembly.
In lieu of a speed controlled air motor drive for the nozzle assembly, speed controlled hydraulic or electric motors may be substituted.
In lieu of an externally powered separate motor drive with an appropriate speed control mechanism for rotating the shaft , the shaft may be rotated by reaction forces of jet streams from the sets of spray nozzles appropriately oriented. Damping or retarding means may be connected between the shaft an a relatively stationary structure to limit rotating speed of the shaft to an efficient speed.
DESCRIPTION OF DRAWINGS
FIG. 1 is a top view of a cable carried rotary nozzle assembly using a speed controlled air motor for nozzle rotation.
FIG. 2 is a side view of t he cable carried rotary nozzle assembly of FIG. 1.
FIG. 3 is a section of a subassembly of FIG. 1 showing a shaft with longitudinal cable and high pressure liquid passages, a liquid input member rotatably carrying the shaft, a spray nozzle carrying head member carried by the shaft, and details of bearings and liquid seals between the input and head members and the shaft.
FIG. 4 is an exploded view of the components of the assembly of FIG. 3.
FIG. 5 is an exploded view of a pulling eye subassembly forming part of the assembly of FIGS. 1 and 2 for attachment of a pulling lanyard at the left end of the assembly.
FIG. 6 is a side view similar to FIG. 1 of an alternative embodiment of a cable carried rotary nozzle assembly using a speed controlled hydraulic motor for nozzle rotation.
FIG. 7 is a side view similar to FIG. 6 of an alternative embodiment of a cable carried rotary nozzle assembly using a speed controlled electric motor for nozzle rotation.
FIG. 8 is a side view similar to FIG. 1 of an alternative embodiment of a cable carried rotary nozzle assembly in which nozzle rotation is achieved by reaction of liquid jet streams from the nozzles and which includes in the assembly a speed controlling retarding mechanism to limit nozzle rotation speed.
FIG. 9 is a section of an alternative shaft configuration with eccentric cable passage.
FIG. 10 is a section of another shaft configuration with eccentric cable passage.
DESCRIPTION OF PREFERRED EMBODIMENT
The present invention provides a high pressure liquid swivel nozzle assembly 10 adapted for sliding movement along a small diameter support cable 14, or similar elongated support, and having multiple sets of two or more nozzle element pairs, such as A--A, B--B and C--C, on a rotatable spray head member 12 for spraying multiple high velocity liquid streams outwardly in continuously changing directions relative to the cable support. FIGS. 3-4 show an elongated main shaft 22 of a nozzle subassembly 11 (FIG. 3), to be rotatably carried by the cable 14 and having a longitudinal axis. The shaft 22 is encircled and rotatably carried by a relatively stationary liquid input body member 16. The output liquid spray head member 12 is rotatable with the shaft 22. The shaft 22 is rotated relative to the body member 16 by means of an air motor 18. The air motor 18 has a conventional air driven vane rotor connected to a worm gear which drives an annular output member 25 which is keyed to an extension portion 24 of the main shaft 22 of the nozzle subassembly 11 seen in FIG. 3.
The cable 14 passes through a central axial longitudinal passage 23 in the shaft. The shaft 22 has internal liquid passage means formed by six bores 30 extending longitudinally within the shaft in isolated relationship to the central axial passage 23 for the cable.
Each of the input body member 16 and the spray head member 12 encircles the shaft 22 and includes means sealed with respect to the shaft 22 for defining with the shaft respective annular plenum chambers 19 and 20 around the shaft with each plenum chamber communicating with the six axially extending uniformly angularly spaced liquid passage bores 30 in the shaft to enable flow of high pressure liquid from the body member 16 to the heat member 12. The bores 30 in the shaft 22 are sealed at their outer ends by means of plugs 31 having O-rings 32 in annular grooves in their outer surfaces. The outer ends of these plugs 31 may be internally threaded to facilitate removal with a threaded tool. The plugs 31 are secured in place by set screws 33 recessed in outer threaded ends of the bores 30 at one end of the shaft 22. Radial or lateral passages 35 provide means for connecting opposite ends of the bores 30 with the respective plenum chambers 19 and 20.
It will be seen from FIG. 3 that each of the bore passages 23 and 30 has an outer wall structure extending essentially the length of the shaft portion between the plenum chambers 19 and 20. These walls are part of the monolithic structure of the shaft and the walls of each passage are connected to other passage walls along their lengths between the plenum chambers.
Throughout the axial extent of the shaft 22 within the input member 16 and output member 12 and all along the flow passages within the shaft from plenum chamber 19 to plenum chamber 20, and along the extent of the wall of the central axial passage 23 the shaft 22 is a monolithic shaft structure produced by simple precise machining of a round bar stock. There are no high pressure liquid seals along the internal high pressure liquid flow passages. The only seals used in the shaft structure are the small O-rings seals 32 around the plugs 31 and these O-ring seals 32 are in the static plugs 31 backed up by the set screws 33 and not subject to being blown out by high pressure liquid in the bores 30.
Sealed radial ball bearing means 40 support the shaft 22 relative to the stationary input body member 16. During assembly and disassembly of the structure of FIG. 3, the outer races of bearings 40 are retained in annular recesses at opposite ends of the input body member 16 by means of removable spring retaining rings 41 snapped into grooves at outer ends of the respective annular recesses. The bearings 40 enable the shaft 22 to be rotated within the body member 16 while the latter is held against rotation by means including one or more liquid input hoses 17 attached to the input body member 16 in respective threaded sockets 37 and by non-rotating portions of an air motor assembly 18 which rotates the shaft 22. The output liquid spray head member 12 is secured to the shaft in a clamped assembly between collars 26 threaded on opposite ends of the shaft 22. Each collar 26 has a radial slit with an internal clamping screw 27 (FIG. 2) spanning the split to tighten the collar 26 securely after it is threaded onto the shaft 22.
Mechanical connection means comprising the ring 27 clamped to the end of the input body member adjacent the air motor 18 pin 28 extending radially outward from ring 27 and plate 29 between the non-rotating housing of the air motor 18 and the liquid input member help to preventing rotation of the liquid input body member 16 relative to the support cable during operational movement of the swivel nozzle assembly 10 along the cable. The air motor is supplied with pressurized air via an input hose 43. Air is exhausted from the motor 18 at an exhaust muffler 44 attached to the motor. Speed of the air motor 18 is controllable by suitable conventional adjustable valve means (not shown) to control the volume of air supplied to the air motor.
Hose means couple a high pressure liquid source to the input body member 16. Each liquid supply hose 17 is connected to a threaded input connection 36 in body member 16. Multiple hoses 17 are preferably used to assure high volume liquid supply to the input body 16 of the spray assembly 10 . When only one supply hose 17 is used, remaining connections 36 in the input body member 16 are sealed with suitable plugs 36P. The multiple pairs of nozzle elements A--A, B--B and C--C are carried by the head member 12 in respective pairs of threaded sockets 37 for creating multiple high velocity jet streams when high pressure liquid is supplied to the body member 16. The ball bearing means 40 facilitate rotation of the head member 12 and the shaft 22 relative to the body member 16 to continuously change the directions of the nozzle streams during operation of the nozzle assembly.
A dynamic sealing means is provided at each end of the plenum chamber 19 at the liquid input member 16 forming a high pressure liquid seal between the rotating shaft 22 and the stationary input body member 16 to prevent escape of high pressure liquid.
At each end of the plenum chamber 19, and at each side of the set or ring of radial passages 35 supplying liquid from the shaft to plenum chamber 19, there is a high pressure rotary liquid sealing means between the relatively rotating shaft and the body member 16. Each sealing means is formed by a stack of sealing components comprising a sealing ring 50, a flat washer-like annular wear resistant carbide sealing seat disk 52 and a strong tough durable flat washer-like deformable plastic annular sealing element 54. The sealing rings 50 each have a central cylindrical opening closely fitting around and sealed with the shaft 22. The rings 50 have flat parallel annular faces orientated toward the plenum chamber 19. The carbide disks 52 each have flat parallel opposite faces, one of which disk faces abuts the flat face of the respective sealing ring 50. The sealing elements 54 each have flat parallel opposite faces, one of which element faces abuts the flat face of the respective carbide disk 52. The disks 52 and the sealing elements 54 have central cylindrical openings which, during assembly, fit closely around the outer cylindrical surface of the shaft 22 and outer cylindrical peripheral surfaces which are radially confined by respective opposing inwardly facing annular cylindrical wall surfaces of the body member 16. Also, during assembly, the disks 52 and sealing elements are axially confined between respective flat faces of the sealing rings 50 and flat radially extending annular wall surfaces of the body member 16. These confining cylindrical wall surfaces and radially extending wall surfaces of the body member 16 meet at the corners 56, identified in FIG. 3, and together with the flat faces of the respective sealing rings 50 define recesses or spaces around the shaft in which the stacked sets or pairs of a carbide disk 52 and a sealing element 54 are located.
The sealing means structures at each end of the plenum chamber 19 are located between the ball bearing means 40 which support the shaft 22 in the input body member 16. The bearings 40 are individually sealed to protect their internal elements from environmental liquids or other contaminants in the vicinity of the shaft.
During operation of the nozzle assembly 10, high pressure liquid in plenum chamber 19 presses the sealing elements 54 axially away from the center of the plenum chamber 19 and against the disks 52 which are in turn pressed axially against the respective sealing rings 50. The deformable sealing elements 54 not only form a facial seals against the respective sealing seat disks 52 , but also are forced outwardly to form a peripheral cylindrical seals against the inwardly facing annular cylindrical surfaces of the body member near the corners 56 as seen in FIG. 3. The sealing elements 54 are held by the liquid pressure relatively stationary against the cylindrical inner surfaces of the body 16 near the corners 56 whereas the abutting sealing faces of the disks 52 and sealing elements 54 have relative sliding movement while the sealing seat disks 52 and the face rings 50 rotate together in abutting relationship during rotation of the shaft 22.
Weep passages 57 in the input body 16 permit escape to the exterior of the spray assembly of liquid seeping past the dynamic sealing means.
The collars 26 at opposite ends of the subassembly of FIG. 2, are threaded on the shaft 22 to clamp therebetween the spray head member 12, a spacing ring 58, and the bearing and sealing components held with the input body member 16 by the spring retaining rings 41. These components include the bearings 40 and the sealing components 50, 52 and 54.
At each end of the plenum chamber 19 the face rings 50 have inner cylindrical surfaces closely fitting around the shaft. These surfaces have grooves of sufficient axial extent to each accommodate O-ring sets comprising a primary O-ring seal 61 and a backup O-ring seal 62 to prevent escape along the shaft of high pressure liquid in the plenum chamber 19. Similarly, at each end of the plenum chamber 20 the head 12 has inner cylindrical surfaces closely fitting around the shaft and provided with like sets of primary and backup O-ring seals 60 and 61. The primary seals of each set are nearest the respective plenum chamber.
A swivel pulling eye subassembly 68, with a bail member 69 for attachment of a suitable pull cable and a pull cable attaching ring, for pulling the nozzle assembly 10 along the cable 14 is shown attached to the nozzle assembly 10 in FIGS. 1 and 2. The components of this swivel subassembly 68 are shown in the exploded view of FIG. 5.
The bail 69 is swingably mounted on an annular housing member 72 by means of shouldered bolts 73 threaded in holes 74 in the housing 72. An outer race 75 of a sealed radial ball bearing 76 is retained against an internal shoulder 77 in housing 72 by means of a spring retaining ring 78 snapped into an annular groove 79 in housing 72.
A shouldered cylindrical spacer 80 has an end face (hidden in FIG. 5) for engaging the end of shaft 22 and/or collar 26 at the end of the shaft 22 containing the bores 30. A reduced diameter portion of the spacer 80 fits closely within the inner race 81 of bearing 76 and race 81 is held against spacer shoulder 82 by a washer 84. The washer 84, inner race 81 and spacer 80 are secured to the shaft 22 by means of three bolts 86 which pass through uniformly angularly spaced holes 87 and 88 in washer 84 and spacer 80, respectively. The bolts 86 are threaded into the outer ends of three alternate bores 30 after the set screws 33 are threaded into and recessed in respective bores 30 as seen in FIG. 3.
In lieu of the fluid operated air motor 18, a hydraulic liquid operated fluid motor may be used with suitable hydraulic fluid lines providing supply and exhaust connections to the motor. Such an arrangement has an advantage of enabling recirculation of the operating fluid without exhausting the motor operating fluid into the chamber where cleaning is taking place. FIG. 6 shows a rotary high pressure spray nozzle assembly having essentially the same components as the assembly of FIG. 1 except for the use of a hydraulic motor 90 for rotating the shaft 22 of the subassembly of FIG. 3. The hydraulic motor has supply and discharge lines 91 and 92 for supplying appropriate hydraulic fluid pressure and volume to achieve a desired motor speed for rotating the shaft 22 at a desired speed.in a manner well known in the art.
Similarly, in lieu of air or hydraulic motors, the shaft may be rotated by an electric motor 93 as seen in FIG. 7. Suitable electric cables 94 and 95 supply controlled power to the motor to rotate the shaft 22 at a desired speed.in a manner well known in the art.
In lieu of an externally powered separate motor drive with an appropriate speed control mechanism for rotating the shaft 22, the shaft may be rotated by reaction forces of jet streams from the sets of spray nozzles appropriately oriented. Damping or retarding means may be connected between the shaft an a relatively stationary structure to limit rotating speed of the shaft to an acceptable speed . Preferable speeds may be in the range of 5 to 200 rpm dependent on the geometry and size of the spray assembly. Well known retarders for such purpose include viscous damping devices, eddy current devices, permanent magnet retarders, rotatably driven hydraulic retarders with adjustable speed regulating orifices and speed regulating friction devices.
FIG. 8 shows an embodiment of the invention using a retarder mechanism 96 having a central rotatable shaft 97 encircling the cable 14 and keyed to the shaft 22 of the subassembly of FIG. 3, A housing 98 of the retarder mechanism 96 is kept stationary relative to the input body member 16 by means of a projection 99 having an aperture through which the pin 28 on ring 27 projects to limit the speed of rotation of the nozzles on the output member when the nozzles are self-rotating in response to reaction forces produced by jet streams from the nozzles.
In the embodiment of FIG. 8, at least some of the pairs of spray nozzles are offset relative to the shaft axis to provide a self-rotating torque to the head 12. Also, at least some of the pairs of spray nozzles may be similarly angled relative to a transverse plane to create a jet reaction force to move the nozzle assembly along the cable support.
The low drag forces achieved with the bearing structure and seals shown in FIG. 3 lend the invention to practical use where the air motor 18 may be eliminated and the output nozzles driven by self rotation forces achieved by appropriate angular orientation of the jet streams flowing from the nozzle tip elements at the ends of the nozzles A--A B--B and C--C.
When the output head 12 is self rotated, the respective mounting, bearing and sealing arrangements of head 12 and input body 16 vis-a-vis the shaft 22 may be reversed so the only the head 12 rotates and the input body 16 is secured to the shaft with the shaft 22 and body 16 remaining non-rotating while the nozzle assemble moves along the cable 14. This can be achieved by connecting input supply hoses to threaded sockets corresponding to sockets 37 and nozzle elements into threaded sockets corresponding to sockets 36.In either case the spray assembly 10 may be moved along the cable 14 by self propulsion due to jet force reaction or by being pulled by the pulling eye assembly of FIG. 5.
All of the components of the jet spray assembly 10 may be readily disassembled for inspection or replacement merely by removing the plate 29, separating the keyed connection between the output member 25 of air motor 18 and shaft 22, loosening and unscrewing one or both of the collars 26 and removing the snap rings 41. The pulling eye assembly can be easily disassembled by unscrewing bolts 73 and 86 and removing the snap ring 78.
Nipples for the pairs of nozzle elements A--A, B--B and C--C may vary in length depending upon the spray cleaning job being performed. The nipples for each nozzle element of a respective pair of elements are of like lengths and angular orientation and the nipples may vary from a few inches to several feet in length. The nozzle elements provide spray jet diameters of the order of one eighth inch. The high pressure liquid is supplied to the nozzle elements at a pressure of 10,000 psi or higher. The flow rate is of the order of 50 gallons per minute per jet stream from each nozzle element. Preferable nozzle rotation speeds may be in the range of 5 to 200 rpm dependent on the geometry and size of the spray assembly.
The cable 14 is of sufficient length to support a spray nozzle assembly weighing about 40 pounds in addition to portions of the cleaning liquid hoses and power hoses or electrical cables necessary to supply cleaning liquid to the jet nozzles and power to any motor being used. Cable length will vary with various applications and may be as long as 200 or so feet with hoses and cables also carried by appropriate hangers carried by the support cable 14. Prior to anchoring the ends of the cable where the spray cleaning is to take place, one end of the cable is threaded through the shaft 22 and the central passage of whatever drive motor or nozzle speed retarder is being used.
Whether the invention is used as in FIG. 3 with a rotating shaft or with a non-rotating shaft, as when the spray head may be self-rotating, the passage which carries the cable support may be eccentrically located toward one side of the shaft, but still isolated from the liquid flow path through one or more other liquid passages between the two plenum chambers.
FIG. 9 illustrates a modification of the invention which can be used with any of the other described embodiments. In FIG. 9 the shaft, now designated as shaft 22A, has an eccentric bore passage 23A to pass the cable support 14 and a relatively larger passage 30A to provide a flow path between the plenum chambers 19 and 20. Appropriate lateral port means like radial passages 35 connect passage 30A with the respective plenum chambers.
FIG. 10 illustrates a modification of the invention which can be used with any of the other described embodiments. In FIG. 10 the shaft, now designated as shaft 22B, has an eccentric bore passage 23B to pass the cable support 14 and multiple other different sized passages 30B and 30C to provide a flow path between the plenum chambers 19 and 20. Appropriate lateral port means like radial passages 35 connect passage 30B and 30C with the respective plenum chambers.
Use of the eccentric cable passages as shown allows the total crosssectional area of the fluid passages to be maximized for high volume fluid flow.
Other variations within the scope of this invention will be apparent from the above described embodiment and it is intended that the present descriptions be merely illustrative of the inventive features encompassed by the appended claims.
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A multiple nozzle swivel assembly for mounting on a cable support stretched across the interior of a chamber to be scrubbed with high velocity jet streams or stretched along an array of objects to be cleaned as the swivel assembly traverses the cable from one end to the other. The cable passes through a coaxial bore in an elongated shaft carrying both a relatively stationary an input member for supply of high pressure liquid to the assembly and a rotatable output nozzle-carrying spray head member. The shaft is monolithic with multiple angularly spaced bores around the central bore and parallel thereto and sealed from the central bore carry high pressure liquid from the input member to the output spray head member with very low drag bearings and liquid seals being provided between relatively rotating liquid carrying components. The assembly includes multi-directioned nozzle elements on a rotatable spray head. Positive drive to rotate the spray head is achieved with a rotational speed controlling motor. With the aid of low drag forces at bearings and rotating liquid seals, the spray head may be self rotated by reaction forces of jet streams from the head. The assembly may be pulled along the cable by an auxiliary device or it may be self-propelled along the cable by reaction of jet streams. For pulling the assembly along the cable a swivelled pulling bail is attached to the shaft.
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RELATED APPLICATIONS
[0001] The application claims priority to German Application No. 10 2005 008 080.4, which was filed on Feb. 22, 2005.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a window regulator rail, in particular for a motor vehicle, and to a mounting of the window regulator rail on the motor vehicle.
[0003] A carriage is mounted on the window regulator rail. An adjustable window or other components of a window regulator are accommodated in the carriage. For a vehicle manufacturer who will mount the window regulator in a vehicle, the window regulator rail is supplied to an assembly line preassembled as much as possible, so that minimal effort can be used to mount the window regulator in the vehicle.
[0004] A commonly used way of mounting a window regulator rail includes screwing the window regulator rail to a mounting lug that is provided on the vehicle for mounting the window regulator rail. For this purpose, a bore is provided in the window regulator rail and the mounting lug, which bore constitutes an elongated hole in one of the window regulator rail and mounting lug. This provides for a precise alignment of the window regulator rail during installation.
[0005] One disadvantage with this mounting method is that the window regulator rail must be aligned during assembly and a separate screw must be supplied to an assembly line.
SUMMARY OF THE INVENTION
[0006] It is the object of the invention to create a window regulator rail, as well as an assembly including a window regulator rail and mounting lug, which considerably simplifies the assembly.
[0007] For this purpose, a window regulator rail for a motor vehicle includes a mounting portion and a fastening bolt. The fastening bolt includes an attachment collar and first and second fastening portions that are arranged on opposite sides of the attachment collar from each other. The fastening bolt is releasably and adjustably attached to the mounting portion of the window regulator rail in a predefined position by the first fastening portion. On the second fastening portion, a fastening member is arranged in a mounting position.
[0008] With the subject window regulator rail, all requirements can be satisfied at once. On the one hand, the position and alignment, in which the window regulator rail is mounted in the vehicle, can be specified precisely because the fastening bolt can be attached to the mounting portion of the window regulator rail in a nominal position. This nominal position corresponds to a constructionally specified position, which the fastening bolt must assume theoretically, to ensure that the window regulator rail is mounted in the vehicle in the desired position and alignment. Since the inevitable manufacturing tolerances are distributed around the nominal position in the manner of a Gaussian curve, it can be expected for the majority of the window regulator rails that the fastening bolt is “correctly” arranged in the nominal position. In the few cases in which a readjustment is required, the readjustment can be made, as the fastening bolt is releasably and adjustably attached to the mounting portion. On the other hand, it is not necessary to provide a separate component at the assembly line for the window regulator rail, as the necessary fastening member for mounting on the mounting lug is already part of the second fastening portion.
[0009] Preferably, the mounting portion includes an elongated hole that receives the first fastening portion. This provides for shifting the fastening bolt within limits provided by the elongated hole, so that the fastening bolt can take either the nominal position or, in the case of a readjustment, an individually determined position.
[0010] In accordance with the preferred embodiment, it is provided that the first fastening portion is a threaded bolt with a first nut screwed onto the threaded bolt. This provides a low manufacturing and mounting effort.
[0011] Preferably, the first nut is non-rotatably held at the mounting portion. For instance, an outside surface of the first nut rests against a contact surface of the mounting portion. In this case, no additional measures must be taken to prevent the first nut from rotating when the fastening bolt is mounted at the mounting portion. The first nut could be a square nut, which rests against a bent tab of the mounting portion at the outside surface. A square nut provides a low piece cost.
[0012] In accordance with the preferred embodiment, the second fastening portion is also a threaded bolt with a second nut screwed onto the threaded bolt. This provides for adjustably mounting the window regulator rail and the fastening bolt at the mounting lug in the vehicle with little effort.
[0013] Preferably, the second nut is a self-locking nut. The advantage is that the second nut captively remains in the mounting position, i.e. in that position in which the second fastening portion of the fastening bolt can loosely be inserted into the mounting lug. In other words, the second nut is screwed onto the second fastening portion just so far such that an associated locking ring will bite, and the second nut cannot be released from the second fastening portion during the transport of the preassembled window regulator rail. Only during the assembly of the window regulator rail in the vehicle will the second nut then be screwed further onto the second fastening portion, until the second nut fixes the window regulator rail at the mounting lug. The term “self-locking nut” is also meant to include an assembly including a nut and a separate locking member that prevents the nut from being released due to vibrations, etc.
[0014] In accordance with the preferred embodiment of the invention, the second fastening portion is provided with an engagement portion for a tool at an end facing away from the attachment collar. The engagement portion constitutes a square or hexagon, for example. On the one hand, this provides for retaining the fastening bolt to prevent the fastening bolt from rotating when the second nut on the second fastening portion is tightened. On the other hand, the engagement portion provides for rotating the fastening bolt. As a result, the first fastening portion can be screwed into the first nut when the fastening bolt is mounted for instance in the nominal position, or can slightly be screwed out of the first nut, in order to bring the fastening bolt from the nominal position into an individually determined position, and can then be re-tightened in the first nut.
[0015] The above-mentioned object is also solved by an assembly including a window regulator rail, as mentioned above, and a mounting lug that is mounted on the vehicle. The mounting lug includes a positioning configuration, preferably formed by an indentation, in which the attachment collar is at least partly received. As a positioning configuration, the indentation provides for an automatic positioning of the fastening bolt at the mounting lug and hence for the correct alignment of the window regulator rail in the vehicle. The actual adjustment of the correct position has already been accomplished before the assembly because the fastening bolt was mounted on the mounting portion of the window regulator rail in the nominal position. During the actual assembly of the window regulator rail, no further steps must be taken. Apart from the positioning of the window regulator rail during the assembly, the positioning configuration also has another function. The positioning configuration ensures that the correct position of the window regulator rail is maintained even if the second nut should loosen in operation. Even if the second nut is not completely tightened, the attachment collar cannot leave the indentation. This is only possible after the second nut has been screwed down very far from the second fastening portion.
[0016] Preferably, both the indentation and the attachment collar are circular. This ensures that the attachment collar can be received in the indentation independent of an associated rotary position.
[0017] Preferably, the attachment collar is bevelled towards the second fastening portion. This facilitates the positioning of the attachment collar of the fastening bolt in the indentation, and the attachment collar acts in the manner of an inlet bevel.
[0018] In accordance with the preferred embodiment, the mounting lug has a slot that ends in a middle of the indentation. The fastening bolt is simply laterally inserted into the mounting lug until the attachment collar lies in the indentation. Then, it is only necessary to tighten the second nut, and the window regulator rail is mounted precisely and reliably.
[0019] The above-mentioned object is also solved by a method for mounting a component, in particular for mounting a window regulator rail in a vehicle, which includes the following steps: A fastening bolt is releasably mounted to the component in a nominal position. Then, the component together with the fastening bolt, is mounted in the vehicle, the fastening bolt automatically defining the mounting position of the component. Subsequently, the fastening bolt is attached to the vehicle. Thereupon, it is checked whether the nominal position of the component complies with a geometry of the vehicle. If the position of the component does not comply with the geometry of the vehicle, the fastening bolt is released from the component, the component is adjusted, and the fastening bolt is firmly re-mounted to the component. The particular advantage of this method is, for a majority of the mounted components, such as window regulator rails, the position of the component in the vehicle can already be precisely defined before the actual assembly, while the position nevertheless can newly be adjusted at a later date if necessary. Moreover, reference is made to the advantages mentioned above with respect to the window regulator rail.
[0020] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows a cross-sectional view of a window regulator rail of the invention, which is mounted on a mounting lug in a vehicle.
[0022] FIG. 2 shows the mounted window regulator rail in a first perspective view.
[0023] FIG. 3 shows the mounted window regulator rail in a second perspective view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] In FIGS. 1-3 , a portion of a window regulator rail 5 is shown, which is mounted on a mounting lug 7 . The window regulator rail 5 is shown in a cross-sectional view with one end of the window regulator rail being cut-off. Only a mounting portion 10 of the window regulator rail 5 is relevant for understanding of the invention. The mounting portion 10 is positioned at one end of the window regulator rail 5 . The mounting lug 7 is also shown in a cut-off cross-sectional view; the way in which the mounting lug 7 is mounted in a vehicle, and where the mounting lug 7 is mounted, are not relevant for the understanding of the invention.
[0025] The mounting portion 10 includes an elongated hole 12 , which in the illustrated embodiment extends approximately parallel to a lower edge of the window regulator rail 5 . A first threaded bolt 14 with a first nut 16 screwed onto the first threaded bolt 14 extends through the elongated hole 12 . The first nut 16 is a square nut and rests against a bent edge portion 17 of the mounting portion 10 at one outside surface.
[0026] The first threaded bolt 14 is integrally formed with an attachment collar 18 , which has a circular outer contour. A second threaded bolt 20 is also integrally formed with the attachment collar 18 . The second threaded bolt 20 has a second nut 22 screwed onto the second threaded bolt 20 , which constitutes a self-locking nut. On a side facing the second threaded bolt 20 , the attachment collar 18 has a circumferential bevel 19 .
[0027] The first threaded bolt 14 , the second threaded bolt 20 , and the attachment collar 18 have a rotationally symmetrical design and are arranged coaxially. Together, they form a fastening bolt that includes a first fastening portion, which is associated with the mounting portion 10 , and a second fastening portion, which is associated with the mounting lug 7 .
[0028] At a free end, the second threaded bolt 20 has an engagement portion 24 that constitutes a hexagon shape. The function of the engagement portion 24 will be explained below.
[0029] The mounting lug 7 includes a positioning portion in the form of an indentation 26 , which has a circular contour and is designed as an embossed portion. In the illustrated embodiment, a depth of this embossed portion is approximately equal to a wall thickness of the mounting lug 7 . Proceeding from a bottom of the indentation 26 , an inclined transitional portion extends up to an outside surface of the mounting lug 7 . From an edge of the mounting lug 7 , a slot 28 leads to a middle of the indentation 26 . The width of the slot 28 is slightly larger than a diameter of the second threaded bolt 20 .
[0030] The fastening bolt is mounted at the mounting portion 10 by introducing the first threaded bolt 14 through the elongated hole 12 and screwing the first threaded bolt 14 into the first nut 16 , so that the mounting portion 10 is clamped between the first nut 16 and the attachment collar 18 . The first nut 16 cannot rotate when the first threaded bolt 14 is screwed in, as the first nut 16 is non-rotatably held by the bent edge portion 17 . The required tightening torque is applied by a tool that is placed onto the engagement portion 24 . When the fastening bolt is tightened, it is held in a nominal position which corresponds to that position which it should take in accordance with constructional specifications to ensure that the window regulator rail 5 assumes a required position and alignment in the vehicle. The second nut 22 is loosely screwed onto the second threaded bolt 20 merely to an extent that an associated locking ring will bite and the second nut 22 is captively retained.
[0031] The window regulator rail 5 , preassembled as described below, is mounted in the vehicle by inserting the second threaded bolt 20 into the slot 28 of the mounting lug 7 , until the attachment collar 18 comes to lie in the indentation 26 . The bevel 19 of the attachment collar 18 and the inclined transitional portion of the indentation 26 facilitate the positioning of the attachment collar 18 in the indentation 26 . When the attachment collar 18 is arranged in the indentation 26 , the second nut 22 is tightened until the mounting lug 7 is clamped between the attachment collar 18 and the second nut 22 .
[0032] If it turns out that the window regulator rail 5 is not positioned correctly, although the fastening bolt and hence also the window regulator rail 5 are in the nominal position, the second nut 22 can be released again, the fastening bolt can slightly be screwed out of the first nut 16 , the window regulator rail 5 can be positioned correctly, and then the fastening bolt and the second nut 22 can be re-tightened.
[0033] The cooperation of attachment collar 18 and indentation 26 ensures that the fastening bolt also remains correctly positioned in the indentation 26 when the second nut 22 has not been tightened properly. The attachment collar 18 can only leave the indentation 26 when the second nut 22 has been screwed off very far from the second threaded bolt 20 . This increased constructional safety could possibly eliminate the need for a self-locking nut, and a conventional nut could be used instead.
[0034] The window regulator rail and the mounting thereof as described above are particularly useful for frameless doors of a motor vehicle, in which lowerable windows are not guided in a door frame above a door parapet, but only inside the door parapet. In the case of frameless doors, a particularly high rigidity and precise positioning of the window regulator rails are particularly important, as otherwise the window cannot reliably be urged against an associated seal at a vehicle roof.
[0035] Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
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A window regulator rail, in particular for a motor vehicle, includes a mounting portion and a fastening bolt. The fastening bolt includes an attachment collar and first and second fastening portions that are arranged on opposite sides of the attachment collar. The fastening bolt is releasably and adjustably attached to the mounting portion of the window regulator rail in a predefined position by the first fastening portion. On the second fastening portion, a fastening member is arranged in a mounting position.
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